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This application is a divisional of application No. Ser. 08/678,313 filed Jul. 11, 1996.
BACKGROUND
The present invention is directed generally to radio communication systems and, more particularly, to techniques and structures for presetting transmit power levels in radio communication systems.
Traditionally, radio communication systems have employed either Frequency Division Multiple Access (FDMA) or Time Division Multiple Access (TDMA) to allocate access to available radio spectrum. Both methods attempt to ensure that no two potentially interfering signals occupy the same frequency at the same time. For example, FDMA assigns different signals to different frequencies. TDMA assigns different signals to different timeslots on the same frequencies. TDMA methods reduce adjacent channel interference through the use of synchronization circuitry which gates the reception of information to prescribed time intervals.
In contrast, Code Division Multiple Access (CDMA) systems allow interfering signals to share the same frequency at the same time. More specifically, CDMA systems "spread" signals across a common communication channel by multiplying each signal with a unique spreading code sequence. The signals are then scrambled and transmitted on the common channel in overlapping fashion as a composite signal Each mobile receiver correlates the composite signal with a respective unique despreading code sequence, and thereby extracts the signal addressed to it.
The signals which are not addressed to a mobile receiver in CDMA assume the role of interference. To achieve reliable reception of a signal, the ratio of the signal to the interference should be above a prescribed threshold for each mobile station (referred to as a "required signal-to-interference" level, or SIR req ). For example, as shown in FIG. 1A, consider the case where three mobile stations receive, respectively, three signals from the common CDMA communication band. Each of the signals has a corresponding energy associated therewith--namely energy levels E1, E2 and E3, respectively. Also, present on the communication band is a certain level of noise (N). For the first mobile station to receive its intended signal, the ratio between E1 and the aggregate levels of E2, E3 and N must be above the first mobile's required signal-to-interference ratio.
To improve the signal to interference ratio for a mobile, the energy of the signal is increased to appropriate levels. However, increasing the energy associated with one mobile station increases the interference associated with other nearby mobile stations. As such, the radio communication system must strike a balance between the requirements of all mobile stations sharing the same common channel. A steady state condition is reached when the SIR requirements for all mobile stations within a given radio communication system are satisfied. Generally speaking, the balanced steady state may be achieved by transmitting to each mobile station using power levels which are neither too high nor too low. Transmitting messages at unnecessarily high levels raises interference experienced at each mobile receiver, and limits the number of signals which may be successfully communicated on the common channel (e.g. reduces system capacity).
A steady state condition must be adjusted for various changes within the mobile communication system. For instance, when a new mobile station enters a communication cell, it will create additional interference within the system. For example, as illustrated in FIG. 1B, the introduction of a fourth mobile station to the steady state condition depicted in FIG. 1A imposes a new signal on the common communication channel with energy E4. This new signal energy E4 adds to the aggregate interference experienced by the first through third mobile stations already in the cell. Accordingly, in order to satisfy the required signal-to-interference ratios of the first through third stations, the power associated with the first three mobile stations E1-E3 may have to be adjusted accordingly. The same disruptive effect may be experienced when a mobile station which was previously located within the boundaries of the radio communication cell switches from a passive state to an active state to transmit or receive a message on the common channel. The steady state condition is also disrupted when a mobile station leaves the radio communication cell. For example, if the steady state condition shown in FIG. 1A is disrupted by the third mobile station leaving the radio communication cell, the signal-to-interference ratio of the remaining two mobile stations will be improved by the absence of the energy E3 on the common channel, as shown in FIG. 1C. Accordingly, the power of signals E1-E2 can be decreased to ensure efficient use of the common communication channel. Again, this same effect may be achieved when the third mobile station within the radio communication cell switches from active to passive state (e.g. by terminating its call).
Still another disruption of the steady state may occur when one or more mobile stations within a radio communication cell changes its operating characteristics. For example, as illustrated in FIG. 1D if the third mobile station switches from a low data-rate mode of communication to a high data-rate mode of communication, the remaining two mobile stations within the cell will experience increased levels of interference. To counteract the increased levels of interference in the communication band, the system may have to adjust the power levels E1 and E2. The reverse effect may occur when a mobile station switches from a high data-rate mode to a low data-rate mode.
Prior CDMA-based systems use one or more power control loops to appropriately adjust the power levels of signal transmission within the system to counteract the above described disruptions to the steady state condition. According to one exemplary prior technique, for the downlink the mobile station monitors the strength at which it receives signals from the base site. If the signals are too weak. the mobile station transmits a message to its associated base station informing the base station to increase the power at which it transmits to the mobile station. The base station will respond accordingly. However, over time, the base will "tease" the mobile station by slowly decreasing the power to the mobile station until the base station is informed by the mobile station to once again increase the power of transmission to the mobile station. This ensures that the base station is not communicating with the mobile stations using power levels which are unnecessarily high.
For example, in the case of FIG. 1B where a fourth mobile station enters a cell, the other mobile stations may instruct the base station to increase the level of power to the mobile stations. The base station will respond accordingly by increasing the power by one increment. If still insufficient to satisfy the mobile station's SIR requirements, the mobile stations will repeat their message to the base station, once again requesting the base station to increase the level at which it transmits messages to the mobile stations. This procedure may be repeated through a series of communications between the base and the mobile stations. If the base "overshoots" the power requirements of the mobile stations, it may have to decrease the power levels to the mobile stations.
The iterative nature of this adjustment procedure results in a delay between the time at which a disruption in the interference situation occurs and a time at which the steady state condition is restored. As such, this technique is not well suited for particularly large disruptions to a radio communication system, such as when a high data-rate user suddenly enters a cell comprising only a few mobile users. In this circumstance, as shown in FIG. 1E. the introduction of a new data user at time t=0 will cause a temporary drop in SIR level for user j, which in turn may lead to erroneous signal reception. Such transient peaks in SIR level are particularly common in systems with bursty high data rare users (which are characterized by their discontinuous on-and-off transmission).
It is therefore an exemplary objective of the present invention to adjust the power levels associated with a plurality of mobile stations, in response to the changing needs of the plurality of mobile stations, without resorting to the above described iterative procedure.
SUMMARY
According to exemplary aspects, the present invention achieves the above stated objectives by employing power presetting. More particularly, the present invention detects the introduction or removal of mobile stations to a cell, or the change in operating characteristics of one or more mobile stations already within the cell. In response thereto, the present invention determines the power adjustments in the downlink and the power target adjustments in the uplink necessary to maintain the signal-to-interference ratios required by the mobile stations within the cell.
In the case of downlink power presetting, a change in the number or operating characteristics of mobile stations within a cell triggers a power presetting algorithm which calculates an adjustment in the power levels to each mobile station within the cell to compensate for the change. The algorithm may employ matrix processing to calculate the necessary power adjustments as a function of the SIR requirements of the mobile stations within the cell. Alternatively, the power adjustments can be calculated using an iterative algorithm.
In the uplink, the base station estimates the change in interference which will be caused by a mobile station changing its operating characteristics. In response thereto, the base station computes an updated power target for each mobile station. The base station compares the updated power targets for each mobile station with the actual strength of signals received from each respective mobile station. If the power target and received signal strength differ, the base station transmits a command to the appropriate mobile station instructing it to increase or decrease its transmit power.
In the uplink power presetting, the base station may be apprised of the imminent introduction or removal (or change in operating characteristics) of a mobile station by receiving a control preamble from the mobile station. Alternatively, the base station may detect the change in power requirements from the actual receipt of data from the mobile stations.
In both uplink and downlink cases, power presetting need not be performed for every change in mobile stations using the system. Rather, power presetting can be reserved for only those changes which present significant disruptions to the signal-to-interference ratios of the mobile stations within the cell. For instance, power presetting may be performed when the ratio of the power requirements of a new mobile station to the aggregate power requirements of the other mobile stations within a cell exceeds a prescribed threshold.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing, and other, objects, features and advantages of the present invention will be more readily understood upon reading the following detailed description in conjunction with the drawings in which:
FIG. 1A shows an exemplary distribution of signal energies within a common band in a steady state condition;
FIG. 1B shows an exemplary distribution of signal energies within a common band after the introduction of a new mobile station;
FIG. 1C shows an exemplary distribution of signal energies within a common band after the removal of a mobile station;
FIG. 1D shows an exemplary distribution of signal energies within a common band after a mobile station switches from low to high data-rate mode;
FIG. 1E shows degradation in signal-to-interference ratio caused by the introduction (or removal) of a new mobile station to a radio communication cell according to the prior art;
FIG. 2 is a cell diagram illustrating a base station and several mobile stations;
FIG. 3 is a block diagram of a base station according to an exemplary embodiment of the present invention:
FIG. 4 is a block diagram of a mobile station according to an exemplary embodiment of the present invention:
FIG. 5 is a block diagram modelling power calibration according to an exemplary embodiment of the present invention: and
FIG. 6 shows the performance of an iterative power presetting algorithm according to the present invention.
FIG. 7A shows power presetting in macrodiversity according to a first embodiment.
FIG. 7B shows power presetting in macrodiversity according to a second embodiment.
FIG. 7C shows power presetting in macrodiversity according to a third embodiment.
DETAILED DESCRIPTION
Consider the exemplary situation depicted in FIG. 2. Therein, a base station 100 is currently handling connections with three mobile stations, M1, M2 and M3. For the purposes of this exemplary embodiment, consider that the system depicted in FIG. 2 operates using a CDMA technology with duplexed downlink (i.e. base-to-mobile direction) and uplink (i.e. mobile-to-base direction) channels. In the downlink, base station 100 transmits to each of mobile stations M1, M2 and M3 using a certain power level associated with each of these mobile stations. In the uplink, mobile stations M1, M2 and M2 communicate with base station, each using a certain power level. Although not shown, the base station 100 is in communication with a radio network controller (RNC), which in turn is connected to a public switched telephone network (PSTN).
As illustrated in FIG. 3, the base station 100 is equipped with a plurality of transmitters 16 (only three transmitters 16a, 16b, 16c are illustrated to simplify the figure) for transmitting different data signals to a plurality of mobile stations via a transmitter amplifier 17 and an antenna 18. The relative power level of each transmitted signal is determined by a power control unit 14. As will be described in more detail below, the power control unit 14 according to the present invention estimates the power presetting necessary to counteract the introduction or removal of high data-rate users from a radio communication cell, or the change in operating characteristics of one or more mobile stations already within the cell. The power control unit receives signal-to-interference information via input 101, and receives a power preset trigger signal (to be described below) via input 102. A regional processor 9 controls the overall operation of the base station 100.
According to FIG. 4, an exemplary mobile station 200 (e.g., any one of M1-M4) is equipped with a receiver 22 which operates in a conventional manner to filter, amplify and demodulate a signal from antenna 20. A first decoder 24 is provided for selectively receiving and decoding its intended signal transmitted from the base station 100 and measuring its signal strength. Data signals demodulated in the first decoder are generated as output data signals for subsequent use. Other signals transmitted from the base station 100 intended for other mobiles within its cell are received and decoded in a second decoder 26 where their respective signal strengths are measured. A signal strength calculator 28 receives the signal strength measurements from both of the first and second decoders 24 and 26 and calculates a transmission power for the mobile 200 to use in transmissions to the base station 100. The data input signals to be transmitted from the mobile 200 to the base station 100 are received in a modulator 34. A transmitter 32 receives the modulated signal. Based on the received signal strength power calculated by the signal strength calculator 28, a power level controller 30 varies the power of the transmitter 32 to transmit a mobile output signal.
Any known power control loop technique may be employed to coordinate the activities of the downlink power control and the uplink power control. For instance, the system may use the control loop technique identified in U.S. Pat. No. 5,345,598 to Paul W. Dent, which is incorporated by reference herein, or the dynamic power control discussed hereinabove in the background section of the present application. The power presetting employed by the present invention is preferably used to supplement any conventional power control technique. More particularly, the power presetting algorithm of the present invention preferably comes into play when there are large disruptions in the power requirements of the mobile station, as described below.
Power Presetting in the Downlink
Consider again the situation illustrated in FIG. 2. Assume that at time t the base station 100 is currently connected to mobile stations M1, M2 and M3, but at time t+Δt receives a request to handle a connection with mobile station M4 which has recently moved into its service area. Alternatively, M4 may have been in the service area. At time t+Δt M4 switches from passive to active state (that is, M4 requests and is allocated a traffic channel to handle a call or connection), or switches from a low data rate mode to a high data rate mode.
The introduction of M4 into the pool of active mobile stations, or the change in operating characteristics of M4, imposes a new downlink transmit power level P N+1 at the base station. As illustrated schematically in FIG. 5, the imposition of new power level P N+1 54 alerts the system that the power levels 52 of the connected mobile stations need to be adjusted to prevent increased levels of interference.
Specifically, power P N+1 triggers a power presetting algorithm 50 (through line 102 in FIG. 3) which determines a plurality of power adjustment factors to be applied to each power level 52 (P 1 -P N ) The power presetting algorithm 50 may be implemented by power control unit 14 of FIG. 3. Power control unit 14, in turn, may comprise a central processing unit or other appropriate digital logic circuitry.
The power adjustment factors may be determined as follows for the case of non-orthogonal channels. As a starting point, note that the signal-to-interference ratio (SIR) of a particular mobile station j (denoted MS j ) at time t may be expressed as: ##EQU1## where SIR j | t is the signal-to-noise ratio of a particular mobile station j at time t; I j inter is the intercell interference experienced by MS j , C j is the received power strength at MS j , and N is the number of mobile stations currently transmitting in the system. The equation can be expressed in terms of transmitted power at the base station by noting that P j =L j *C j , where P j is the power at which the base station transmits to MS j and L j is the loss factor between the base station and MS j . The new expression in terms of base station power is: ##EQU2## Taking into account all N mobile stations, the following equation is derived: ##EQU3## where ##EQU4## and ##EQU5## Optimum power levels after a user N+1 has started transmission at time t+Δt are: ##EQU6## The change in power may be expressed as ΔP N such that: ##EQU7## which, using the above equations, may be expressed as: ##EQU8## ΔP N is a vector which provides the power adjustments used according to the present invention to compensate for the introduction of new user P N+1 . Furthermore, equation (9) can be used to account for the removal of a pre-existing user simply be setting P N+1 to a negative value.
The SIR values may be transmitted by each respective mobile station to the base station. Alternatively, the base station may estimate (e.g. approximate) the SIR values by taking into account various factors, such as the characteristics of the channel and the data service associated with each mobile station. The estimation may comprise using some measurement instead of a SIR value, for example frame error rate. In any event, these values should be slowly varying for a given set of mobiles (e.g. the SIR values represent the required SIR or "target SIR" level for each mobile station). Accordingly, the inverse matrix A N -1 can be computed off-line and post multiplied with the vector of ones. Hence when one (or more) new user begins transmitting it is possible to adjust the power levels virtually instantaneously by multiplying the scalar P N+1 with a precomputed remainder of the equation (9). If k users begin transmitting data streams simultaneously then: ##EQU9##
According to another embodiment, presetting can be obtained by resorting to an iterative procedure. More specifically, equation (2) can be reexpressed as follows: ##EQU10## where ##EQU11## Rearranging the above equations for P j | t in terms of SIR j results in:
P.sub.j |.sub.t =SIR.sub.j ·(I.sub.j.sup.inter ·L.sub.j +I.sub.j.sup.intra) (13)
The change in power caused by the introduction of a new user at time t+Δt may be expressed as:
ΔP.sub.j =P.sub.j |.sub.t+Δt -P.sub.j |.sub.t(14)
ΔP.sub.j =SIR.sub.j ·(I.sub.j.sup.intra |.sub.t+Δt -I.sub.j.sup.intra |.sub.t)
Rearranging the above equations to express P j | t+ Δt in terms of P j | t and ΔP results in:
P.sub.j |.sub.t+Δt =P.sub.j |.sub.t +Δt (16)
Equation (16) is employed to calculate a new P j based on the prevailing intracell interference in the cell when a new mobile station enters the cell. This new P j is applied in the downlink causing a change in the intracell interference. In response thereto, a new P j is calculated with the current intracell interference measure. The above procedure can be repeated a plurality of times in iterative fashion (e.g. 5 times). Upon each iteration, the value of P j converges to its ideal value. FIG. 6 illustrates the simulated performance of power presetting in the downlink using the above described technique for different iterations 0-5. The swings in SIR level at 100 (10 ms frames) and 400 (10 ms frames) illustrate the experienced SIR degradation at a mobile station j in response to a high data-rate user's bursty discontinuous transmission (e.g. starting and stopping transmission). Note that the deleterious effects of SIR disruption are virtually removed after only 3 iterations.
In both of the above embodiments, presetting need not automatically occur upon every change in mobile stations entering or leaving a cell. The power control in the base station can be configured such that the power presetting is only performed when the new data user significantly disturbs the preexisting steady state condition within the cell. Whether or not a change is "significant" may depend on one or more of the following factors: the number of mobile stations currently within a cell, the ratio of the power requirement of a new mobile station to the aggregate power requirements of all active mobile station within a cell, and the required signal-to-interference ratio of the new mobile station.
Power Presetting in the Uplink
Power presetting in the uplink may be performed in a manner which is computationally less intensive compared to the downlink. In the uplink, the base station computes a power target for each mobile station. The power target for a mobile station is the product of the SIR target for each mobile station (e.g. the required SIR) and an interference estimate. The base station compares the computed power target for the mobile station with received power from the mobile station. A power control command is then transmitted to the mobile station instructing the mobile station to increase or decrease its power accordingly.
When the base station detects that a new user plans to enter the system (or leave the system) it can preset the interference estimate to take account of the power and SIR requirements of the new user. The base station may be apprised of the introduction of the new user through a control channel preamble message which identifies the new user and his data-rate. Alternatively, the base station may initiate the presetting in response to the actual detection of the start of a new message from the new mobile, and the determination of the characteristics thereof (e.g. its data-rate).
Again, the same analysis is applicable to the case where a data user leaves the radio communication cell (e.g. physically travels beyond the boundaries of the cell, or simply discontinues transmission). Also, power presetting in the uplink can be performed when a pre-existing mobile station switches its operating mode from a high data-rate to a low data-rate, or vice versa.
As was the case with the downlink power presetting, the base station may be configured such that power presetting is only performed when the introduction (or removal) of the new mobile station significantly disturbs the other mobile stations' signal-to-interference ratios.
Power Presetting in the Case of Macrodiversity
For the case of macrodiversity, one or more mobile stations may each actually be communicating with more than one base station. For example, consider mobile station M4 illustrated in FIG. 2. Mobile station M4 is located on the outer bounds of the coverage provided by base station 100. As such, mobile station M4 may receive messages containing substantially the same information transmitted from one or more neighboring base stations (not shown). This technique is used to enhance the received signal quality at a mobile station.
Different downlink power presetting techniques may be appropriate depending on the location of the interferer mobile station within the cells involved in macrodiversity. A first scenario arises, as shown in FIG. 7A, when a high data-rate interferer 704 is in macrodiversity, or in other words, is communicating with both base stations 701 and 705. One technique for power presetting for this interferer is to independently preset the power levels in the downlink for base station 701 and base station 705. More particularly, base station 701 computes the power adjustment values using one of the above described algorithms, treating mobile stations 703 and 704 as members of its cell. Simultaneously, base station 705 computes the power adjustment values, treating mobile stations 704, 706 and 707 as members of its cell. Each base station 701 and 705 will then transmit to the mobile station interferer 704 involved in macrodiversity. The independently computed power adjustment values are used when transmitting to the other mobile stations 703, 706 and 707.
A second scenario is illustrated in FIG. 7B. Here, the high data rate interferer 713 is again in macrodiversity. In addition, there is at least one other mobile station in macrodiversity 711 which suffers interference as a result of interferer 713. In this circumstance, each base station 701 and 705 may again independently perform power presetting, but this time exclude the mobile station 711 from the computations. Such an approximation is acceptable, as the increase in interference suffered by station 711 due to the interferer mobile station 713 is typically small.
Alternatively, the mobile stations 711 involved in macrodiversity may be preset according to the cell that requires the largest power increase. More specifically, base station 701 computes the power adjustment values necessary to compensate for the introduction of the high data rate interferer 713 into the cell, of which mobile stations 712, 713 and 711 are considered members. Similarly, base station 705 computes the power adjustment values necessary to compensate for the introduction of the high data rate interferer 713 into its cell, of which mobile stations 711, 713, 714 and 715 are considered members. Then both base stations 701 and 705 communicate the power adjustment values calculated with respect to mobile station 711 in macrodiversity to the radio network controller 702. The radio network controller chooses the larger of the two values and instructs both base stations to communicate with the mobile station 711 involved in macrodiversity using the larger power adjustment value. Each base station will employ that power adjustment level in transmitting messages to the mobile station 711.
As shown in FIG. 7C, still another scenario may arise when the interferer 721 is not involved in macrodiversity, but affects another mobile station 716 which is involved in macrodiversity. The power presetting for the mobile station 716 may be computed by considering the aggregate effect of interference from the cell associated with base station 701 and the cell associated with base station 705. The radio network controller 702 may perform this computation by, in effect, treating the cells associated with base stations 701 and 705 as a global cell.
For the uplink, presetting of the interference estimate (and consequently the power target) can be done independently in each of the base stations involved in macrodiversity of the new mobile stations.
The above-described exemplary embodiments are intended to be illustrative in all respects, rather than restrictive, of the present invention. Thus the present invention is capable of many variations in detailed implementation that can be derived from the description contained herein by a person skilled in the art. All such variations and modifications are considered to be within the scope and spirit of the present invention as defined by the following claims.
By way of example, power presetting equations were derived for the exemplary case of non-orthogonal channels. However, it will be apparent to one skilled in the art that the principles discussed herein are also applicable to systems employing orthogonal channels.
Furthermore, various power macrodiversity power presetting techniques were associated with different arrangements of mobile stations within two or more base stations in macrodiversity. However, it will be apparent to one skilled in the art that the various techniques disclosed above are not restricted to these specific arrangements of mobile stations. For instance, the power presetting described in connection with FIG. 7C can be used to compute the power levels of the mobile stations in macrodiversity shown in FIGS. 7A and 7B.
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A radio communication method and system employs power level presetting to mitigate the increase in interference caused by the discontinuous transmission of mobile stations. In the downlink, power presetting entails detecting the entry (or removal) of mobile stations to a cell, and in response thereto, calculating a plurality of power adjustment values for each mobile station within the cell. In the uplink, power presetting entails estimating an increase in interference caused by the entry (or removal) of mobile stations to a cell, and using this estimate for calculating an updated power target for each mobile station within the cell. Power presetting is also initiated in response to one or more mobile stations switching from high data-rate mode to low data-rate mode, or vice versa.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 558,376, filed Dec. 5, 1983, now abandoned, which is a continuation-in-part of copending application Ser. No. 490,657, entitled "Metering Feeder", filed May 2, 1983 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains generally to feeders and stokers, and in particular to a feeder for metering and delivering refuse fuel to a furnace, boiler, air heater, kiln, combustion chamber or any device requiring a controlled rate of feed in comparatively homogeneous unit energy per unit weight amounts.
2. Description of the Prior Art
It has been generally recognized that municipal and industrial refuse as well as cellulose waste materials are desired as a fuel to conserve fossil energy. Such use helps to control and greatly reduce the volume of refuse for disposal by alternative methods such as composting or landfill.
One significant problem with refuse as a fuel is that generally refuse is quite heterogeneous, that is, quite nonuniform on a unit energy per unit volume or per unit weight basis. The bulk density or refuse fuel can vary from 3 pounds per cubic foot in a loose state to 40 pounds per cubic foot in a compacted hopper, for example. Refuse fuel intertangles in the compacted state which causes undesirable bridging, clogging or matting within the bin or hopper, and contributes to irregular feeding.
It is often desirable to feed refuse to a boiler, combustion chamber or the like on a volume basis. Preferably the fuel should be supplied at a controlled rate and in a loose density rate in order to promote even burning, to maintain a controlled density and thereby maintain control over the combustion process. Prior art devices have been generally deficient in this regard.
SUMMARY OF THE INVENTION
According to the present invention, a method and apparatus is provided whereby refuse fuel is placed into a feed hopper in a relatively compacted, naturally intertangled state. A predetermined volume of the fuel is segregated, discharged or ejected from the feed hopper by means of a ram type pusher which displaces the lowermost stratum of material through an opening in the hopper. The fuel discharged from the hopper is decompacted by dropping it into a receiving hopper disposed generally beneath the feed hopper. An upwardly inclined conveyor, employing closely spaced extending slats, pans or cleats, removes the fuel from the receiving hopper at a controlled rate. The action of the inclined conveyor also serves to mix and further decompact the fuel by underraking and over tumbling action. The invention is also ideally suited for use with a combustion control system whereby the energy released during combustion can be measured to control the rate at which fuel is removed from the receiving hopper.
Other objects, features, and advantages of the present invention will become apparent from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of the invention;
FIG. 2 is a sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is a sectional view taken along the line 3--3 of FIG. 1;
FIG. 4 is a fragmentary view showing fuel falling from the feed hopper;
FIG. 5 is a side view of the invention showing optical overflow discharge spout;
FIG. 6 is an end view of the invention of FIG. 5 showing overflow discharge spout;
FIG. 7 is a top plan view of a multiple ram embodiment of the present invention;
FIG. 8 is a schematic side view of the multiple ram embodiment of FIG. 7;
FIG. 9 is a sectional view of the multiple ram embodiment taken along the line 9--9 of FIG. 8;
FIG. 10 is a schematic side view of another embodiment of the invention, featuring a conveyor with upwarding inclined cleats; and
FIG. 11 is a detailed view of the inclined cleats of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring principally to FIG. 1, the invention comprises feed hopper 10 having infeed spouts 12 for filling hopper 10 with refuse fuel, or other material denoted generally by reference numeral 14. To permit access to the interior of hopper for inspection or periodic cleaning hinged door 16 is provided. Reciprocating ram pusher or feeder 18, having fixed cylinder 20 and reciprocating plunger or piston rod 22 with stepped pusher or ram 24 attached thereto, is operable to push, force or segregate a volume of refuse 14 out through discharge opening 26. The quantity of refuse discharged through opening 126 is dependent upon the volume displaced by ram 24 and also upon the size of opening 26. To effect positive control over the quantity discharged, ram feeder 18 may be hydraulically operable at a controlled speed or cycle rate and/or with a controlled stroke displacement. Alternatively, ram feeder 18 may be air operated or mechanically operated. In addition, the size of opening 26 may be varied by means of an adjustable bottom plate 28 and plate 30. It will be recognized that plates 28 and 30 may be made manually operable using hand wheels or the like, or they may be motorized for remote control.
The invention further comprises receiving hopper 32 having inwardly sloping plates 33 and 35. Receiving hopper 32 is provided with hinged doors 34 for gaining access to the interior of the hopper in order to clean or inspect. Hopper 32 may include optional overflow discharge spout 17 with adjustable gate 19, as shown in FIGS. 5 and 6, for controlling the level in the receiving hopper 32. One or more level indicators 36 detect the quantity or level of refuse fuel within hopper 32 and provide a signal indicative thereof. The signal may be used, for example, as an input to conventional circuitry 37 for controlling the cycle rate of ram feeder 18 and/or for controlling adjustable plates 28 and 30 thereby controlling the volume or rate of refuse fuel being discharged from hopper 10. In this fashion it can be ensured that hopper 32 will not be overfilled. Alternatively, the signal may be used to control adjustable gate 19. In the presently preferred embodiment, the invention uses three level indicators 36A, 36B, and 36C as shown in FIG. 10. Ram feeder 18 is operable at two speeds, a high speed and a low speed. The proper speed is selected according to which of the three level indicators 36A, 36B, and 36C detects refuse. When only the lowermost level indicator 36A detects refuse, ram feeder 18 operates at the high speed to quickly fill receiving hopper 32. When the level of refuse rises to the intermediate level indicator 36B, the ram feeder speed is decreased to the low speed. At the low speed equilibrium is usually reached whereby the infeed of fuel from the ram feeder 18 is equalled by the outfeed of fuel via conveyor 42. Should equilibrium not be reached such that the infeed outpaces the outfeed, level indicator 36C senses the condition and stops ram feeder 18 before overflow can occur. Once ram feeder 18 is stopped by level indicator 36C, it remains off until the level of fuel within receiving hopper 32 once again reaches level indicator 36B. In the alternative, should outfeed via conveyor 42 exceed the infeed from ram feeder 18, thereby causing the level of fuel in receiving hopper 32 to drop rather than reach equilibrium, level indicator 36A senses the condition and initiates high speed operation.
Alternatively intermediate level indicator 36B may initiate an adjustable timer to result in a delay cycle between strokes of the ram feeder 18. In this mode of operation, the ram feeder 18 travels at a fixed speed. The ram feeder 18 may thus be considered as a means for periodically introducing fuel into hopper 32. Either the frequency of introduction (ram speed) or the period of introduction (time between strokes), or both may be varied in accordance with the level indicators.
As will be explained more fully below, refuse fuel being discharged from hopper 10 is permitted to fall or drop into hopper 32, the drop being of sufficient distance to untangle or decompact the refuse fuel. In FIG. 1 the drop distance is denoted by reference character D as being the verticle distance between discharge opening 26 and the top of the pile of refuse fuel 40 within hopper 32. Clearly the drop distance D can be adjusted by adjusting the level of refuse fuel in the hopper 32. In accordance with the present invention, drop distance D is selected such that the charge of fuel, when dropped from hopper 10, will develop sufficient kinetic energy as it falls to cause the charge to decompact within hopper 32 upon impact with the walls of hopper 32 or with fuel pile 40. In addition, during free fall, wind resistance forces and internal or pent up spring-like forces stored within the charge during original compaction act upon the charge to cause further decompaction. Free fall duration depends upon the drop distance; thus drop distance D can be readily adjusted to control the degree to decompaction.
In the presently preferred embodiment described above, receiving hopper 32 is fed or filled by the action of ram feeder 18. In another embodiment, shown in FIG. 5, receiving hopper 32 is fed or filled from infeed spout 21 which may be coupled to any of a wide variety of material handling devices (not shown). In addition, excess or overflow material from discharge spout 17 may be conveyed back to the prime supply of material or to any desired intermediate supply point.
Disposed within hopper 32 is upwardly inclined conveyor 42 having a plurality of closely spaced cleats or flights 44. Conveyor 42 may take the form of a continuous belt having slats preferably equally spaced about the outer periphery of the belt, or it may take the form of a plurality of equally spaced pans carried on a closed loop chain or chains, both types of conveyors being well known in the art. It will be recognized, however, that generally a wide variety of conveyor mechanisms can be used to practice the invention, and accordingly the scope of the invention is not hereby limited to belt-type or pan-type conveyor mechanisms. For purposes of illustrating the invention a chain conveyor or apron conveyor has been illustrated.
As will be explained more fully below, the action of the conveyor 42 serves to mix or tumble the refuse fuel 40 as by underraking, which also serves to untangle, breakup and otherwise further decompact the refuse fuel. Towards this end, the angle of incline of conveyor 42, measured from the horizontal, is selected so that a portion of the refuse fuel initially picked up by the conveyor will fall or tumble back onto the pile, thereby decompacting or loosening the fuel. It has been found that an angle of incline greater than 20 degrees, preferably between 35 and 75 degrees, gives satisfactory results, although shallower angles are also usable. The particular angle of incline needed for good tumbling action is dependent in part upon the handling characteristics of the material, and its agglomerating and cohesive tendencies. In general, the angle of the conveyor must be greater than the normal angle of repose of the material handled so that the material will fall back, causing rolling or tumbling of any agglomerated material. In addition, sidewall 33 which constitutes the backplate of hopper 32, has an angle of incline with respect to the horizontal, preferably between 60 and 90 degrees. This incline causes refuse material to fall inwardly and downwardly toward conveyor 42, which promotes constant recirculation of the material and a mixing action. The particular backplate angle selected will depend upon the handling characteristics, and the agglomerating and cohesive tendencies of the material, in order to get the desired mixing action. With the correct angle of the conveyor and backplate, the material being handled will be pulled out from the bottom of the pile which results in the material at the back of the hopper 32 continually moving downward. Such action causes mixing in a counter-clockwise direction (viewed from the side as in FIG. 1).
With reference to FIGS. 1, 2, and 3, conveyor 42 comprises drive chains 46 carried between lower sprocket 48 and upper sprocket 50 which are secured for rotation about axles 52. Attached at equally spaced intervals about chains 46 are a plurality of generally horizontal flights or pans 44 for conveying material thereon. To keep drive chains 46 from sagging, outboard rollers 54 are attached through spindles 56 to drive chains 46 for rolling movement along rails 58.
Conveyor 42 is driven by motor 59 which may be under the control of combustion control system 60. Combustion control system 60, which may be based on any of the well known motor control circuit designs, is responsive to sensors 61 such as any of the well known temperature or pressure sensors, located in the combustion area. At the upper end of conveyor 42 is chute 62 through which the refuse fuel may be discharged. Optional magnet 64 disposed near the upper end of conveyor 42 attracts and removes ferrous material from the refuse fuel before discharge thereof through chute 62.
In another preferred embodiment, shown in FIGS. 7, 8 and 9, a plurality of ram feeders 18a and 18b are disposed, side by side, along bottom plates 28. Respective rams 24a and 24b thereof communicate with the interior of hopper 10. Each ram feeder, when actuated, discharges fuel into associated, individual receiving hoppers 32a and 32b respectively, which include respective inclined conveyors 42a and 42b. Although two ram feeders/receiving hoppers are illustrated in FIGS. 8 and 9, in general this multiple ram embodiment may entail a greater number without departing from the scope of the invention. Each ram delivers material to an inclined conveyor feeder and each ram receives its control signal from the sensors within its receiving hopper, so that the receiving hopper material level can be individually maintained, if desired. Each individual conveyor, in turn, delivers an independently controllable rate of material through its outlet chute.
In yet another preferred embodiment, shown in FIGS. 10 and 11, conveyor 42 has a plurality of spaced cleats 44a, preferably equally spaced, which are inclined to define an acute angle 110 with respect to the length of belt or chain drive coupling loop 46a. The drive coupling loop 46a defines a closed course about which cleats 44a travel. A portion of conveyor 42a, designated generally by reference numeral 112, is disposed to contact the fuel within receiving hopper 32. This portion 112 defines an angle of incline with respect to the horizontal as indicated by reference numeral 114. Cleats disposed along portion 112, such as cleats 116, define an acute angle 110 (with respect to portion 112 of drive coupling loop 46a). In the illustrated embodiment, acute angle 110 is generally the complement of the angle of incline 114. In general, however, cleats 44a may be disposed with respect to drive coupling loop 46a at other angles, as well. It will be seen that the angular relationship provides cleats which are generally vertically arranged along portion 116 to allow for complete filling of the cleats with fuel. As the cleats travel the closed course defined by drive coupling loop 46a, they eventually become downwardly directed as at 120 for full and complete discharge through outlet chute 62. It will be understood that the generally vertical orientation of cleats 44a, as described above, is intented to cover a range of orientations about the vertical for achieving the described results.
In operation, refuse fuel is placed in hopper 10 through infeed spouts 12. It will be understood that the refuse fuel in hopper 10 is naturally or becomes relatively compacted and intertangled because hopper 10 is normally kept full. In this compacted state the bulk density of the refuse fuel may be on the order of 40 pounds per cubic foot. By activating ram feeder 18 a preselected volume of refuse fuel is forced out, segregated, displaced or otherwise discharged from hopper 10 through discharge opening 26 as illustrated in FIG. 4. Stepped ram 24 feeds material from different portions or strata within hopper 10 which minimizes compacting and clogging tendencies by promoting a rolling action. By feeding material from different portions of the hopper the ejected material is subjected to lower compression forces than with non-stepped rams. This also minimizes compacting tendencies and clogging. It will be understood that the volume of fuel discharged is dependent upon the size of opening 26 and on the displacement or stroke of ram 24, either of these factors being controllable to control the volume of fuel dischaged. Once ejected from hopper 10, the refuse fuel drops into hopper 32 which serves to break up or decompact the intertangled refuse. It will be understood that the drop distance D, the distance between discharge opening 26 and the top of the pile of refuse fuel in hopper 32, may be controlled by controlling the level of refuse fuel in hopper 32. Automatic level sensors such as sensors 36 are well suited to provide this control function. A precise level in hopper 32 is also maintained to result in an even and full distribution of material on inclined conveyor 42, so that a controlled and consistent amount is discharged at the upper end of the conveyor.
The decompacted refuse fuel in hopper 32 is removed at a controlled rate by conveyor 42. The rate at which conveyor 42 operates may be controlled by a remote sensor or by the combustion control system of a boiler, air heater, or the like in order to maintain the boiler steam pressure at a predetermined level or to control on demand the energy output of the boiler, air heater, kiln, or the like. While the invention finds utility as a feeder for combustion devices, in general it may be used to provide a controlled discharge of materials for a wide variety of processes or to a mechanical handling device.
In addition to removing refuse fuel from hopper 32, inclined conveyor 42 also serves to further decompact the refuse fuel in hopper 32 through underraking action and tumbling, whereby refuse fuel is carried up from the bottom of hopper 32 on flights 44 en route to the upper regions of the conveyor. Due to the angle of incline some of the refuse falls or rolls back onto the pile leaving conveyor 42 loaded with a substantially uniform thickness of material. This tumbling or rolling action generally contributes to the decompacting of the refuse fuel in hopper 32. The load of refuse fuel on flights 44 which does not fall back onto the pile is eventually dumped through chute 62 for use in the combustion chamber, air heater, kiln or boiler (not shown). If utilized, optional magnet 64 attracts and holds ferrous particles, which may then be periodically removed through hinged door 34.
It will be understood that the refuse fuel discharged through chute 62 is eventually burned, thereby releasing energy. The energy released may be measured using well known temperature or pressure sensors, such as sensor 61, providing signals to the combustion control system 60. Combustion control system 60 in turn controls motor 59 which can be speeded up or slowed down to control the rate at which fuel is delivered for combustions. Motor 59 may be disposed at any convenient location for imparting rotary motion to the conveyor. In FIG. 1, motor 59 is shown at the bottom of conveyor 42, while in FIG. 5, motor 59 is shown at the top of conveyor 42. The bulk density of the fuel delivered for combustion after decompacting within hopper 32, has been found to be on the order of 5 pounds per cubic foot. In this comparatively loose, low density state, the refuse fuel burns evenly, giving off a relatively uniform amount of energy per unit volume. As the energy demand changes, combustion control system 60 responds by altering the rate at which fuel is removed from hopper 32. Level sensors 36, sensing the quantity of refuse fuel in hopper 32, in turn adjust the rate or volume of refuse fuel discharged from hopper 10 to maintain the desired fuel level in hopper 32.
The refuse feeder thus described may be used alone or a number of such refuse feeders acting in concert may be used to feed a single furnace, boiler or other device. The invention permits each feeder to receive a signal from the combustion control system, thus making it possible to bias the feed rate of one feeder with respect to the feed rate of the others in order to optimize the combustion process and to conserve energy. Such an arrangement would also permit shutting down one of the feeders to remove tramp and undesirable material while leaving the others in service. The remaining feeders would automatically step up the feed rate thus the boiler, heater, kiln, etc. can remain on line at full power.
While a presently preferred embodiment of this invention has been illustrated and described in detail, it will be understood that modifications as to details of constuction and design are possible without departing from the spirit of the invention or the scope of the following claims.
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A metering feeder for delivering solid fuels, such as municipal or industrial refuse, for combustion includes a pair of generally vertically arranged hoppers. An upper hopper containing relatively compacted or intertangled fuel discharges metered amounts of fuel into a lower hopper through the action of a ram-type pusher. Fuel discharged from the upper hopper is dropped into the lower hopper to develop sufficient kinetic energy to decompact the fuel. An upwardly inclined conveyor removes fuel from the lower hopper at an independently metered rate under optional control of a combustion control system. The action of the inclined conveyor further decompacts the fuel by underraking and mixing, thereby providing a well controlled, uniform, loose density fuel for combustion. The conveyor has a closed course of cleats which cyclically moves to remove fuel. The cleats extend in acute angular relation to the direction of movement for improved performance.
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BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates generally to circuits for facilitating magnetic reading, writing and erasing. More specifically, this invention relates to providing bias and erase signals which are independent of power supply fluctuations.
2. Description of the Prior Art
Representative of the closest known prior art patents are U.S. Pat. Nos. 2,810,073; 3,038,036; 3,201,713; 3,305,795; 3,346,821; 3,354,270; and 3,424,871. These patents were developed during a novelty search. Of these U.S. Pat. Nos. 2,810,073 and 3,354,270 are considered the closest in that sinusoidal outputs are generated. The first basically deals with output amplitude stabilization which is accomplished through regulating the power supply voltage. With the subject invention, the circuit is made insensitive to the supply voltage. The second discloses a push/pull circuit configuration rather than a negative resistance oscillator. In addition, the IBM Model 271 Recorder utilizes a soundhead to form a part of an LC tank circuit, but a separate stable reference voltage is not used.
When a low distortion sinusoidal bias and erase oscillator is to be provided for use in portable or miniature battery operated magnetic media recorders, a number of problems are encountered. In addition to low distortion, the amplitude and frequency of the oscillator must be insensitive to battery voltage fluctuations, the required battery drain must be low, and the number of circuit components must be low and small in size. These problems are overcome with the oscillator circuit of this invention.
SUMMARY OF THE INVENTION
An oscillator circuit is provided for obtaining low distortion signals for bias and erase. The circuit is made up primarily of two sections. One of the sections is a frequency determining LC tank. Low distortion oscillation is produced with a low Q tank, and supply current is low relative to the tank current. The other is an AC coupled negative resistance element.
The LC tank is made up of a first inductor, and a second inductor which is the erase winding. The tank also has a series combination of first and second capacitors. The negative resistance element is formed by a differential pair of first and second transistors. This pair of transistors is DC biased to a reference voltage through a first resistor, with a capacitor providing decoupling. A second resistor provides a load for the reference voltage. The base of the first transistor is biased by a third resistor. The DC current through the first and second transistors is adjusted by a fourth resistor, while fifth and sixth resistors make the current through the fourth resistor split nearly evenly through the transistors.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates the overall oscillator circuit of this invention;
FIG. 2 shows an AC equivalent of the frequency determining LC tank section of the circuit shown in FIG. 1; and
FIG. 3 illustrates the AC coupled negative resistance element portion of the circuit shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1 there is shown the overall circuit diagram for the bias/erase oscillator of this invention. Low distortion sinusoidal oscillations are effected by combining an LC tank with a two transistor negative resistance element. Low distortion is provided even though the Q of the LC tank is low. The frequency of oscillation is determined by the LC tank, thereby making it insensitive to supply voltage fluctuations. The oscillation amplitude is determined by a separate stable reference voltage, and is also insensitive to supply voltage fluctuations. Low battery drain is obtained by keeping the emitter and base voltage excursions of the transistors to a minimum. The circuit uses the erase winding itself as part of the LC tank in order to eliminate an additional driver. The erase current is determined directly by the oscillation amplitude and shares all of the stability advantages of the oscillator.
Referring next to FIG. 2 there is shown the AC equivalent of the LC tank section of FIG. 1. This tank is comprised of a first inductor L1 in parallel with an erase winding LE which is in turn in parallel with a series combination of capacitors C3 and C4. Capacitor C1 is in series with erase winding or inductor LE and is used to prevent DC current from entering the erase winding.
The tank input is driven from the collector of transistor Q1 (FIG. 1) which is DC biased to the supply Vcc through inductor L1. The output from the tank is derived from between capacitors C3 and C4 which form a capacitive divider. The tank output is applied to the base of transistor Q2 which is the input to the negative resistance element shown in FIG. 3.
The negative resistance element is formed by the differential pair of transistors Q1 and Q2. The pair is DC biased to a reference voltage Vref through resistor R3 (FIG. 1) with capacitor C2 providing decoupling. Resistor R2 basically is for providing a load for the reference voltage Vref.
The two bases of the transistors Q1 and Q2 are biased closely together by resistor R4. Transistors Q1 and Q2 are conventional NPN transistors. Resistor R4 is representative of a resistance between C2+ and Q1 on one side, and C4+ and Q2 on the other. The DC current through transistors Q1 and Q2 is adjusted by variable resistor R1, while resistors R5 and R6 make the current through resistor R1 split approximately equally through the two transistors Q1 and Q2.
Since resistors R5 and R6 reduce the DC gain of the differential pair of transistors Q1 and Q2, capacitor C5 is included to allow the pair to have a maximum AC gain regardless of DC bias.
The capacitively divided tank voltage is used to drive the negative resistance element in order that emitter voltage excursions will be relatively small and thereby maintain nearly constant current through resistor R1.
Since the input to the pair (the base of transistor Q2) is connected to the output (the collector of Q1) through capacitor C3, the input and output can be considered as being the same AC node. When the voltage at the base of transistor Q2 rises, the output current decreases. Therefore, the transistor pair Q1 and Q2, taken as one element, has a negative resistance characteristic.
The amplitude of oscillation will stabilize at the point where the energy added to the tank by the negative resistance element is just equal to the tank losses. The peak-to-peak tank voltage may exceed the supply voltage being limited eventually by saturation of transistor Q1.
During normal operation, the circuit will cause relatively low distortion during oscillation, and will not clip.
From the above, an AC coupled negative resistance element is used, a low distortion oscillation is produced with a low Q tank, the supply current is low relative to the tank current, a two terminal erase winding with no DC erase current present is utilized in conjunction with a capacitive voltage divider as frequency determining element and sensitivity to minor transistor mismatch is negligible.
In summary, an oscillator circuit is provided for obtaining a low distortion signal for bias and erase. The circuit is made up primarily of two sections. One of the sections is a frequency determining LC tank. Low distortion oscillation is produced with a low Q tank having a capacitive voltage divider, and supply current is low relative to the tank current. The other is an AC coupled negative resistance element.
The LC tank is made up of a first inductor, and a second inductor which is the erase winding. The tank also has a series combination of first and second capacitors. The negative resistance element is formed by a differential pair of first and second transistors. This pair of transistors is DC biased to a reference voltage through a first resistor, with a capacitor providing decoupling. A second resistor provides a load for the reference voltage. The base of the first transistor is biased by a third resistor. The DC current through the first and second transistors is adjusted by a fourth resistor, while fifth and sixth resistors make the current through the fourth resistor split nearly evenly through the transistors.
While the invention has been shown and described with reference to a particular embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention.
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A low distortion sinusoidal oscillator made up of a two transistor negative resistance element combined with an LC tank for generating bias and erase signals for battery powered magnetic media recording apparatus.
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BACKGROUND OF THE INVENTION
This invention relates generally to scintillator screens for converting radiation to visible light and, more particularly, to phosphor input layers or X-ray image intensifier tubes.
As part of a diagnostic imaging system, an image intensifier tube is used to convert the incident X-ray information to a visible light image of increased brightness. Such an image intensifier tube typically includes at its input end, a faceplate, a phosphor layer or screen for absorbing the incident X-ray photons and for emitting light photons, and a photocathode or photo-emitting layer which absorbs the light photons from the phosphor and emits photoelectrons. The tube acts to accelerate and focus these photoelectrons to form an intensified or brightened image on the output screen of the tube. The brightened image is then processed with conventional means to obtain display on a monitoring screen.
One of the factors which affects the quality of the final image is the thickness of the fluorescent screen. Generally, it is desirable to have the phosphor coating thick enough to absorb all of the X-rays and to thereby avoid excessive electron penetration or "crutch through" of the phosphor that causes excessive noise; however, as the phosphor layer is made thicker, both the resolution and the contrast are decreased because of a phenomena known as "lateral spreading." So, a trade off must be made to have the X-ray screen thick enough to absorb all of the X-ray quanta but, on the other hand, thin enough in order to give a well-resolved image.
In addition to the thickness consideration, the lateral spreading phenomena may also be affected by changes in the processes by which the screens are made. And, therefore, changes in the actual structure of the scintillator screens. In the development of this technology, it has been found that vapor deposition techniques result in higher packing density of phosphor material than could be realized by the conventional tarter preparation procedures. A preferred material for this vapor deposition technique has been cesium iodide or, more specifically, CsI:Na. Moreover, the resolution of a vapor-deposited screen can be improved by suppression of lateral scattering of generated light. Recent development in this field has brought about the use of structured substrates, such as selectively etched metal sheets or wire gauzes or the like for producing regular crack patterns perpendicular to the surface so as to act as light barriers. Screens having the largest number of light barriers of this type are expected to produce the best resolution. The next step in this process has been to anneal the deposit layer to eliminate the electron traps which may exist and which cut down on the light output of the screen. Typical annealing cycles for conventional screens are from one-half to several hours at a temperature range of 200° C. In addition to the desirable elimination of electron traps, this process tends to cause a re-crystallization of the individual phosphor fibers. Because of their close proximity to one another, the fibers have a tendency to fuse together, and, when this occurs, tube resolution suffers. Typically, a screen is formed by alternately depositing layers and annealing layers to form multiple and serial depositions which finally extend to the desired thickness.
In the normal process of vapor deposition, the source is located directly under the substrate on which it is deposited. As the phosphor vapor rises to the substrate, it first contacts the central portion thereof and then flows to the peripheral portions thereof. Accordingly, the resulting deposit layer of phosphor tends to be thicker in the central region than at the edges of the screen. Such a screen with thinner edges is undesirable because it tends to enhance the inherent loss of image brightness which exists at the edge of a screen due to the nature of the tube electron-optic designs. Thus, instead of having thinner edges on the screens, it would be preferable to have thicker edges to offset this phenomena.
In view of the problems and deficiencies discussed hereinabove, it is therefore an object of the present invention to provide an improved scintillator screen and method of making such a screen.
Another object of the present invention is a provision for fabricating a scintillator screen having improved quantum-detection efficiency (QDE) characteristics.
Still another object of the present invention is the provision for fabricating a scintillator screen which is substantially comprised of a plurality of columnar elements extending substantially perpendicularly from a substrate.
Still another object of the present invention is the provision for fabricating a scintillator screen with minimal re-crystallization caused by annealing.
Yet another object of the present invention is the provision for a scintillator screen having a single layer of phosphor material deposited at a sufficient thickness to provide relatively high quantum-detection efficiency characteristics.
Still another object of the present invention is the provision for a scintillator screen structure having a greater thickness at its edges than in its center.
These objects and other features and advantages become more readily apparent on reference to the following description when taken in conjunction with the appended drawings.
SUMMARY OF THE INVENTION
Briefly, in accordance with one aspect of the invention, a plurality of structured substrates are installed in a planetary arrangement within a vacuum deposition apparatus. The individual substrates are therefore offset from the center line of the apparatus and are rotated such that points on their edges move continuously between a position near the center line of the apparatus in a peripheral position substantially offset therefrom. The source is located directly below and on the center line of the planetary apparatus. However, a thermal-radiation shield is placed over the source so as to be disposed directly between the source and the substrates and allows the phosphor vapor to pass only through a central aperture along the axis of the apparatus. In this way, the rotating substrates are allowed to remain at a relatively low temperature during the deposition process. Further, because of the offset positions of the substrates with respect to the glowing vapor, the phosphor layer, which is deposited on the substrate, is thicker at the edges than in the center portion thereof. The thickness in the perimeter is maintained by the revolving and rotating movement of the substrate within the planetary system.
By another aspect of the invention, the source of the evaporator has a relatively high capacity in terms of heat and phosphor, and the phosphor is evaporated at a relatively low rate for relatively long periods of time to obtain a single-layer deposition of substantial size and thickness. Such a single layer presents fewer discontinuities in the perpendiculary-extending column of fibers to thereby result in higher quantum-detection efficiency.
By yet another aspect of the invention, the phosphor screen is annealed for a relatively short period of time and then allowed to cool. Because of the differences in the rates of expansion and contraction of the substrate and that of the evaporated film, the screen is caused to further crack in the structured format of the substrate. These cracks which are generally perpendicular to the substrate surface act as light barriers to suppress the lateral scattering of generated light to thereby increase the quantum-detection efficiency of the screen. Because of the relatively short time period that the screens are heated during the anneal cycle, minimal re-crystallization within the screen occurs to thereby maintain integrity of the individual fibers of the screen.
In the drawings as hereinafter described, a further embodiment is depicted; however, various other modifications and alternative constructions can be made thereto without departing from the true spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of an image intensifier tube for which the scintillator screen of the present invention is applicable;
FIG. 2 is a schematic illustration of a vapor-deposition apparatus in accordance with the present invention;
FIG. 3 is a schematic illustration showing the process for the fabrication of a scintillator screen in accordance with the present invention;
FIGS. 4A and 4B are photographic views of a conventional cesium-iodide scintillator screen in accordance with the prior art; and
FIGS. 5A and 5B are photographic views of the microstructure of a cesium-iodide scintillator screen made in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A typical image-intensifier tube for converting incident X-ray information to a visible light image of increased brightness is shown in FIG. 1 and comprises an evacuated glass bulb 11 having an input screen 12 applied to its faceplate 13, a photocathode 14 deposited on the inner side of the input screen 12, and an output screen 16 deposited on the output end of the glass bulb 11. The input screen 12 is comprised of a phosphor or fluorescent material, such as cesium iodide, and supplied in a layer having a thickness in the range of 5 to 12 mils. The photocathode 14 is comprised of a photo-emitting material which is deposited in a thickness of approximately 100 angstroms. The output screen 16 is similar to the input screen in that it is comprised of a phosphor material; however, it is generally planar in shape rather than arcuate as is the input screen.
In operation, the incident X-ray photons penetrate the glass faceplate and are absorbed by the input screen 12 which responsively emits light in proportion to the intensity of the X-ray beams across its surface. The emitted light is absorbed by the photocathode which in turn emits electrons in the direction of the output screen 16. An electrical potential of 25 to 30 kilovolts across the tube acts to accelerate the flow of the electrons, and a plurality of electron lenses 17 disposed within the glass bulb 11 act to direct and focus those electrons selectively to the input screen so that, when the electron beams impinge on the fluorescent coating of the output screen 16, light is emitted in proportion to the flux density of the incident electrons to thereby present an image substantially identical to, but brighter than, the image on the input screen 12.
It is well known that as the input screen absorbs a greater percentage of the entering X-rays, the signal-to-noise ratio of the image increases. However, because of the lateral movement of light photons within the phosphor layer, as discussed hereinabove, both resolution and contrast of the image tend to degrade as the phosphor screen increases in thickness. The present invention is designed to provide a scintillator screen structure with improved resolution and contrast characteristic, while at the same time maintaining a sufficient thickness for a high signal-to-noise ratio. This is accomplished by a vacuum deposition process which results in a single, substantially thick layer of the scintillator phosphor wherein the structure is made up substantially of columnar fibers aligned normally to the substrate to thereby significantly limit the lateral travel of light photons within the structure and thereby result in a quantum detection efficiency in the range of 60-70 percent.
The apparatus which is employed to produce the scintillator screen structure of the present invention is shown in FIG. 2. The outer structure comprises a base plate 18 and an overlying bell jar 19, the purpose of which is to place the system under a vacuum in a manner similar to that of the conventional vacuum deposition apparatus. Within the envelope, and in a vacuum environment represented by the numeral 20, there exists a source of powdered cesium iodide 21 which is heated by conventional means, such as by a heating coil from bus bars 22. As the cesium iodide powder is heated, the vapor rises, and as it settles on the substrate, it is condensed to form the crystalline screen structure. In order to protect the substrate structures from the heat of the source, a thermal-radiation shield 23 having a central aperture 24 formed therein is placed over the source as shown.
Located directly over the source 21 is a planetary fixture hub assembly, which, together with the substrate holders 26 located laterally from the source, act to hold and to move the individual substrates in predetermined positions. The substrates 27, which are formed of a metal material as will be more fully described hereinafter, are positioned in the planetary fixture assembly as shown such that they are offset from the central axis along which the phosphor vapor tends to flow. A number of substrates as, for example three or four, can be located around the central axis in this manner. The planetary fixture apparatus then acts to cause the substrates to revolve around a central axis and at the same time to rotate on an individual substrate axis to thereby present a constantly-moving edge to that area near the central axis where the vapor tends to form and be deposited. Thus, it will be seen that, rather than the vapor being directed to the central portion of the substrate as in conventional systems, it will be directed to the edge portions of the substrates, in an evenly-distributed manner, to thereby result in a deposited layer having a greater thickness at the edges than at the central portion of a substrate. To say this in another way, where the phosphor vapor is caused to flow upwardly to be condensed and formed on a substrate which is placed relatively close to the source, the vapor tends to flow in a generally cosine distribution form. With the apparatus as shown and described hereinabove, the distribution is still of a cosine nature, but, because of the relative positioning of the substrates with respect to the source, and because of the revolving and rotating movement of the substrates, the vapor will tend to flow more heavily on the edges of the substrate and will be therefore built up in such a way that the edges are thicker than the central portions. This structure is of course preferred for reasons as discussed hereinabove.
The process of forming this scintillator screen will now be described with reference to the process flow chart of FIG. 3. The substrate material can be chosen from any of a number of well-known metal or glass materials which are suitable for this purpose. A preferred material is a type EC-O aluminum. The aluminum disc, having a diameter up to 10 inches, is photoetched by lithography techniques or the like to transpose a mesh on its surface. The resultant array pattern on the aluminum substrate exhibits land areas fixed to 10 microns wide with depressed areas substantially square in shape and being roughly 5 microns deep. The photoetched aluminum disc is then subjected to pressure molding in order to make it concave in shape. The substrate is then degreased and prepared to receive the evaporated cesium iodide layer.
A number of the substrates are then placed in the appropriate positions on the driving hub of a modified planetary fixture as described hereinabove. The evaporation source is placed directly at the center of the hub approximately 71/2 inches away from the center of each substrate. The source is then surrounded by a thermal-radiation shield as shown in FIG. 2. The function of the thermal-radiation shield 23 is to maintain the substrate temperature below 65° C. throughout the cesium iodide deposition cycle. Because of the so-called "hidden source" arrangement, the only exposed area of the source that can influence the substrate temperature is the aperture 24 through which the cesium iodide vapor will evolve.
The vacuum system is now actuated, and the space within the bell jar 19 is evacuated to a pressure of approximately 5×10 -6 torr. The substrates are then outgassed by exposing them to a temperature of 320° C. for two hours to thereby rid the substrate surface of any contaminants, such as monolayers of water, organics, and so forth, which may come in intimate contact with the condensing cesium iodide vapor. After the substrates have been outgassed, they are allowed to cool down to room temperature while the vacuum system is still operating.
While maintaining a vacuum of 2×10 -6 torr or better, and while maintaining the temperature of the substrate at substantially room temperature, the deposition process is commenced. The initial current is applied to this source 21 at a very slow rate in order to maintain the integrity of the chamber pressures. This is necessary because, as the source heats up, trapped gasses in the polycrystalline cesium iodide phosphor powder tend to evolve and cause chamber pressure to increase. Preferably, the total time involved in the ramping of the source temperature up to 640° C. and purging the phosphor of trapped gasses amounts to approximately 30 minutes. Throughout the entire source-purging operation, the substrates are moving in a planetary motion, that is, revolving on the axis with respect to the source and rotating on the axes with respect to their centers. As the cesium iodide vapor evolves, the source temperature is continuously maintained at 640° C. and the system pressure is not allowed to exceed 5×10 -6 torr during the phosphor deposition. When operating within these parameters, the evaporation and subsequent deposition occurs at a relatively slow rate such that the growth of the layer does not exceed 3 microns per minute. This relatively slow deposition rate, when used with the planetary system as described hereinabove, allows for a deposition of a single layer having a thickness in the range of 5 to 15 mils, while still maintaining the columnar structure which is desired for the abatement of lateral light flow.
Because of the close proximity of a hidden source to the substrates, and because of the geometric positioning of the substrates within the planetary system, the bulk of the evaporated cesium iodide is directed towards the edges of the substrate. As a result, the edges of an evaporated screen will be thicker than the center of the screen. For example, a screen having a 10 mils center thickness will have an edge thickness between 12 and 13 mils. This contouring effect is desirable for X-ray image intensifiers because it tends to offset the loss of image brightness which occurs at the edge of conventional screens due to the nature of all tube electron-optic designs. This brightness-loss phenomena is especially critical in larger-diameter tubes, such as those being addressed in the present case.
It will be recognized that as contrasted from the conventional procedure of alternately depositing and annealing several layers, the present practice employs only a single deposition step to form a single layer having a substantial thickness. Hence, it is necessary to have a source with a substantial capacity that is one which will hold up to a kilogram of cesium iodide. Further, because of the planetary arrangement, wherein a plurality of substrates are simultaneously exposed to the evaporated cesium iodide, the heat capacity requirement is substantially increased from that of conventional systems.
After the source has depleted itself of phosphor powder, the deposition process is complete and the annealing process is begun. During this time period, the screens, while remaining in the vacuum, are exposed to 320° C. temperatures for a period of 5 to 15 minutes. The purpose of this step is to induce cracking in the input screen which results from the thermal stressing caused by the differences in rates of thermal expansion and contraction for the cesium iodide covering the land areas of the substrate as compared with that of the cesium iodide covering the depressed areas of the substrate. In this way, the annealing process acts as a thermal-shocking medium. Cracks tend to propagate at right angles to one another, following the mosaic array of the photoetched meshed pattern. The extent of propagation of these cracks is controlled by the land width and etch depth of the photoetched substrate and by the desired screen thickness. Crack frequency for cesium iodide evaporated on photoetched substrates and conventional substrates is also strongly dependent on the differences in the coefficients of thermal expansion of the substrate material and of the cesium iodide.
Because of the very brief period of time that the screens are exposed to the anneal cycle, minimal re-crystallization within the cesium iodide screen occurs such that the integrity of the individual cesium iodide fibers is maintained between the substrate/screen interface to the screen surface. In this way, fusion of the cesium iodide columnar fibers is inhibited while at the same time providing for the thermal shocking and cracking function while is desirable for the proper light-flow characteristics.
The structure of the scintillator screen formed in the manner described hereinabove will be seen in FIG. 5 and can be easily distinguished over the structure resulting from the conventional process as shown in FIG. 4. In FIG. 4A, there is illustrated a microscopic photo of the surface of a cesium iodide screen which has been made using conventional techniques. As will be seen, the cracks are formed in a random manner and are relatively low in number. FIG. 4B shows the associated cross-sectional view of the cesium iodide screen formed by such a conventional technique. It will be recognized that, although there are some structural elements which are extending generally in a longitudinal direction through the screen to provide for the flow of light in that direction, the structure is relatively random in structural size, shape, and alignment, such that, as light is generated within the structure, it will tend to be scattered laterally rather than to flow in a direction perpendicular to the substrate as is desired.
It will be seen by reference to FIG. 5A that the surface of a structured cesium iodide screen evaporated on an aluminum substrate as described hereinabove produces regular crack patterns with controlled dimensions and much greater density than that of the screen shown in FIG. 4A. Because these cracks tend to propagate in a direction perpendicular to the substrate when prepared in the manner described hereinabove, the resulting cross section of a structured cesium iodide screen evaporated on an aluminum substrate in the inventive manner described hereinabove will appear as shown in FIG. 5B. It will be recognized that the columnar fibers extend in a generally perpendicular direction with respect to the substrate and are continuous throughout the dimensions of the layer such that lateral scattering of generated light is supppressed and the flow of light from the input screen to the photocathode is enhanced. It has been found that a cesium iodide scintillator screen made in a single layer to a thickness of 12 mils by use of the techniques described hereinabove will result in an input screen having a quantum-detection efficiency in the range of 75 to 80 percent. This should be compared with other known methods of multilayer screen preparation wherein the quantum-detection efficiency is in the range of 45 to 60 percent.
Although the present invention has been described in terms of a preferred embodiment, it will be recognized that the particular process may be varied to obtain similar results while remaining within the scope of the invention. Further, it should be mentioned that, although the invention has been described in terms of an image intersifier tube, it is not the intention to limit the invention to such a screen. Thus, whereas the exemplary structural embodiment and in particular method of manufacture are both merely exemplary rather than definitive of the bounds of the invention, the specific novelty and scope of the invention is defined in the claims appended hereto.
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A phosphor screen is produced by a vacuum deposition process using a planetary structure for simultaneously rotating and revolving structured substrates within a chamber. A thermal radiation shield is provided at the central axis and, because of the offset positions of the substrates, the deposited phosphor layers are formed with thicker edges than centers to thereby inherently exhibit uniformity correction characteristics. The process allows for single-layer depositions of relatively great thicknesses which, when annealed for relatively short periods of time, are comprised primarily of columnar fibers aligned normally to the substrate to inhibit lateral scattering of generated light within the screen.
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BACKGROUND OF THE INVENTION
The present invention relates to mechanical power actuators. It finds particular application in conjunction with high force, low travel extensible actuators for brakes, clutches, and the like, and will be described with particular reference thereto. However, it is to be appreciated that the invention will also find application in conjunction with tension control mechanisms, automated chuck mechanisms, chain tension mechanisms, presses, drum brakes, collar brakes, and the like.
Applicant's prior U.S. Pat. Nos. 5,025,627, 5,177,969, and 5,419,133 illustrate a mechanical actuator which provides forces equal to and exceeding the forces that are readily available from hydraulics. Heat is applied, typically in the form of an electrical current through a resistance heater, to a wax or polymer material within a confined chamber. Heating causes expansion of the wax or polymer material, causing a piston or other mechanical member to extend. Selecting a wax or polymer which goes through a phase change during the heating accentuates the expansion of the polymer and the force/travel of the extensible member. At relatively short travels, these prior actuators achieve forces on the order of 10,000-20,000 psi, and higher.
Although successful, one drawback of these prior thermochemical/mechanical actuators resides in coordinating the movement of multiple actuators. Through the use of feedback control circuitry, the applicant has been able to control the extension of these actuators with high precision. However, such feedback control circuits tend to be relatively expensive and bulky.
The present invention contemplates a new and improved sealed chamber actuator which overcomes the above-referenced problems and others.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, a new and improved electromechanical actuator is provided. An elongated passage contains polymeric material which expands and flows when heated. A heater element is disposed along the elongated passage. A plurality of chambers are disposed in fluid communication with the elongated passage. An extensible member is mounted in each chamber such that as a polymeric material expands and flows, a common force is exerted on each of the extensible members urging each to extend.
In accordance with a more limited aspect of the present invention, the elongated passage is annular.
In accordance with another more limited aspect of the present invention, extension of the extensible members causes engagement of a thrust bearing which urges frictional contact between selectively mating friction members, such as a clutch or brake.
In accordance with another aspect of the present invention, a brake or clutch assembly is provided. First and second clutch or brake friction members are selectively movable between a frictional engaging relationship and a spaced, disengaged relationship. An actuator selectively moves the friction plates between the spaced, disengaged relationship and the frictional engaging relationship. The actuator includes a housing which defines at least one chamber therein. An extensible member is mounted at least partially within the chamber for selective movement between a retracted position and an extending position. A polymeric material is disposed in the chamber below the extensible member. A heater disposed in thermal communication with the polymeric material selectively heats the polymeric material, causing it to flow and expand.
In accordance with a more limited aspect of the present invention, the housing includes a plurality of the chambers each containing the polymeric material and an extensible member. An elongated passage interconnects the chambers.
One advantage of the present invention is that it enables a plurality of extensible members to extend with like extension and force characteristics.
Another advantage of the present invention resides in its relative simplicity.
Other advantages of the present invention reside in its low cost and high reliability.
Still further advantages of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating a preferred embodiment and are not to be construed as limiting the invention.
FIG. 1 is a cross-sectional view of an annular thermochemical mechanical actuator in accordance with the present invention in combination with a thrust bearing and a clutch or brake plate;
FIG. 2 is a top view of the annular actuator of FIG. 1;
FIG. 3 is a detailed view of one embodiment of a heater for the annular actuator of FIGS. 1 and 2;
FIG. 3A is a cross-sectional view through section 3A--3A of FIG. 3;
FIG. 4 is another embodiment of the heater of FIG. 3;
FIG. 4B is a sectional view through section 4A-4A of FIG. 4;
FIG. 5 is an alternate, annular piston embodiment of the thermochemical/mechanical actuator;
FIG. 5A illustrates a cross-section of one embodiment of the actuator of FIG. 5;
FIG. 5B illustrates a cross-section of another embodiment of the actuator of FIG. 5;
FIG. 6 illustrates another alternate embodiment of the thermochemical/mechanical actuator in which force is transmitted radially;
FIG. 7 illustrates an alternate, linear embodiment of the actuator; and, FIG. 8 illustrates an alternate, triangular version of the actuator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A thermochemical/mechanical actuator A which includes a body portion 10 is fixed against longitudinal, and preferably rotational movement. A plurality of axial, longitudinally extensible members 12 extend from the body during actuation. The extensible members 12 press against a longitudinally movable, but preferably rotationally stationary, plate 14 of a thrust bearing B, a hydrodynamic bearing, or other actuation mechanism. Ball or roller bearings 16 connect the first plate 14 of the thrust bearing with a second or output plate 18 which is connected with a shaft 20. When the longitudinally extensible members 12 extend, pressure on the first thrust bearing plate moves the whole thrust bearing assembly, including the output plate and the shaft 20 longitudinally, engaging a brake or clutch plate 22 of a friction member assembly C.
In the clutch embodiment, the clutch plate 22 is connected with a second shaft 24. One of shafts 20 and 24, preferably shaft 24, is connected with a source of motive power, such as an engine or motor. The other shaft, preferably shaft 20, is connected with associated equipment that is selectively connected to the motive power source and disconnected from the motive power source. Extension of the members 12 moves the thrust bearing and friction member assembly into locking frictional engagement such that the shafts 20 and 24 are frictionally locked to rotate together.
In a brake embodiment, one of the shafts 20, 24, preferably shaft 24, is connected with a rotating member, e.g., the wheel of a vehicle. The output plate 18 of the thrust bearing is locked against rotational movement. Actuation of the actuator presses the thrust bearing, or an associated braking surface, against the brake plate 22, causing frictional braking. It will be appreciated that in this embodiment, the shaft 20 is locked against rotation or can be eliminated.
In a tension control embodiment, a sensor 26 senses the rotational speed of the output shaft, e.g., shaft 20, the tension on a web that is driven by rotation of shaft 20, or the like. In response to the sensed condition, an actuator control 28 adjusts the degree of extension and/or amount of force of the longitudinal extension members 12 to adjust the degree of frictional engagement between the thrust bearing B and the friction member assembly C which is connected to the source of motive power.
With continuing reference to FIG. 1 and further reference to FIG. 2, the body member 10 of the thermochemical/mechanical actuator A defines an elongated, preferably annular channel 30 which extends around the body member. For manufacturing simplicity, the body is preferably constructed of two steel members which are welded. An electrical heater 32 is mounted in the annular channel 30 for selectively heating a polymer, wax, metal alloy, or other phase change or thermally expansible material therein. The housing further defines a plurality of bores 34, three in the preferred embodiment, in communication with the annular channel 30. The pin or other longitudinally extensible member 12 is disposed in each bore. Other suitable extensible members include snap domes, bellows, differential pistons, and the like. More specifically to the preferred embodiment, each bore receives a bearing and seal 36 about an upper portion of the bore. A compression sleeve 38 compresses a gasket, such as an O-ring 40, sufficiently to provide an effective seal to prevent the polymer from flowing along the sides of the longitudinally extensible member and escaping. Other gasket or seal mechanisms, such as a diaphragm, bellows, other gasket configurations, or the like, are also contemplated.
In operation, the control 28 causes the heater element 32 to commence heating the polymer material, melting and expanding it. Polymer along the heater element melts first, establishing a fluid reservoir of the polymer extending along the heating element. With continued heating, more of the polymer melts and expands, causing the elements 12 to extend. The fluid path between the bores 34 defined by the flowable polymer surrounding the heater element provides a pressure equalization path such that the same pressure is developed in each bore. Equalized pressure in the bores causes the extension members 12 to extend with like force. When the heater is turned off, the polymer cools and contracts, causing a like contraction of the members 12. Preferably, a spring force is provided which urges the extension members to return to their initial position.
Various heat removal techniques may be employed to accelerate cooling and retraction. The housing body 10 may simply have sufficient heat capacity or be thermally connected with other structures which do. Alternately, air or other gaseous fluids may be passed over the housing body 10 to cool it. As another embodiment, liquids may be passed over or through passages in the housing body 10 to cool it. For example, the entire body may be immersed in a coolant bath such as oil or water. Alternately, passages can be defined within the body 10 through which a coolant fluid is circulated. The coolant circulation may be controlled by a pump connected with the output shaft. In this manner, if the unit starts to overheat, the extension members 12 extend engaging the clutch and commencing the pumping of the coolant.
With reference to FIGS. 3 and 3A, the heater element 32 of the preferred embodiment is a cable or tube type heater. A resistive heating element 50 extends along the center of the heater, such as an Imonel, nichrome, nickel, or other resistance wire. The wire is surrounded by a magnesium oxide or other electrical insulator 52 which has good thermal conductive properties. A sheath, such as a stainless steel sheath 54 surrounds the assembly. In DC applications, the sheath 54 provides a current return path for the current flowing through the resistive element 50. In AC applications, a grounded return is provided within the sheath. Alternately, the coil could extend in a full loop such that both ends of the resistance wire pass through a high pressure fitting 56, that provides a high pressure seal with the housing body.
With reference to FIGS. 4 and 4A, other heaters are also contemplated. For example, an annular carrier 60 of insulating material defines a multiplicity of openings 62 therethrough, at least adjacent the chambers 34. The opening provides transverse passages to permit the polymer to flow across the carrier and into the bores 34. Inner and outer annular edges 64 and 66 provide clamping edges for clamping the carrier 60 centered within the annular passage 30. An adhesive layer 68 fixes the position of each of a plurality of windings of resistive wires 70, such as copper, nichrome, nickel, or the like. optionally, other wire mounting mechanisms, such as a series of clips or guides, may also be utilized. optionally, another adhesive or mounting layer may be mounted to the opposite face of the polymeric carrier 60 to accommodate a second set of heater wires. Moreover, a plurality of these units can be stacked. In a direct connection embodiment, ends of the windings 70 are connected through a high pressure feedthrough and are connected with the heater control 28. In an inductive embodiment, the ends of the windings 70 are connected to each other in a loop to function as the secondary winding of a transformer. A primary winding is disposed adjacent the housing and the power is conveyed by induction from the primary to the secondary winding. In this manner, high pressure feedthroughs are eliminated.
In FIGS. 5 and 5A, the plurality of individual pistons are replaced with a single, annular piston 80. The annular piston 80 is disposed in an annular bore 82 with appropriate seals (not shown). The annular bore 82 connects with the annular passage 30 within which the heater element 32 is disposed.
In the embodiment of FIG. 5B, the annular passage 30 is connected with a plurality of bores 34. A piston, bellows, diaphragm, or other movable member 84 is slidably disposed in each bore with appropriate seals (not shown). The bores 34 extend between the annular path 30 and an annular groove in the housing in which the annular piston member 80 is slidably disposed. In this manner, a plurality of piston or other extensible elements 84 are disposed between the polymer ring 30 and the annular piston 80.
With reference to FIG. 6, it is to be appreciated that the extensible members 12 need not extend longitudinally. Rather, the members can extend radially outward from the housing member 10, radially inward, or both. A member with outward radially moving extension members can be utilized as a drum brake element, a clutch which engages a surrounding clutch cylinder, or the like. The embodiment with radially inward extending members can be utilized as a collar brake or clutch to engage a shaft extending therethrough. The inward, radially extending members may also engage elements of a chuck for engaging tools or workpieces, or the like.
With reference to FIG. 7, it is to be appreciated that the passage 30 need not be a full annulus, and need not be annular. Rather, an elongated passage 30' of another shape, such as linear, extends between a plurality of bores 34'. Extensible members 12' are disposed within each of the bores with appropriate seals. The extensible members can extend from a common side of the body to provide a linear pressing movement. Alternately, the extensible members 12' can extend from opposite sides of the body member to create force in two directions to increase the effective travel of the actuator.
The elongated passage may have other shapes than linear and circular. In general, the passage may extend between any two or more points at which extensible members are to be extended with like force characteristics. For example, as shown in FIG. 8, the elongated path may extend along a triangular shape. Bores with extensible members can be located at various points along the triangle such as at the midpoints, the corners, or the like. Other patterns such as square, rectangular, hexagonal, irregular, and the like are also contemplated.
The invention has been described with reference to the preferred embodiment. obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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An actuator (A) includes a body (10) in which a plurality of chambers or bores (34) are defined. The bores are interconnected at an inner end by an elongated passage (30). A heater element (32) extends along the elongated passage. The elongated passage and the inner portion of each chamber or bore are filled with a polymeric material which expands and flows on heating, preferably undergoing a solid to liquid phase change. Extensible members (12), such as pistons, diaphragms, bellows, or the like, are mounted in the bores or wells. When the heater heats the polymeric material causing it to expand and flow, the extensible elements (12) extend under high force with limited travel. In one embodiment, the extension of the extensible members moves a thrust bearing (B) causing frictionally engageable plates (18, 22) of a friction member assembly (C) to engage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for cutting and separating sheets of accurate length from long lengths of sheet or web material and for stacking each sheet in a very accurate position relative to printed lines on the sheet and on an adjacent sheet on the stack of sheets.
Although the apparatus of the present invention has wide application it is particularly suited for cutting, separating and accurately stacking sheets of web material, such as paper or cloth, for example, or metal material such as aluminum, for example, in the preparation of forming an uniform cellular structure, for example, a honeycomb mass or block.
2. Prior Art
It is well known to form a uniform cellular structure or block, such as a honeycomb mass or block, by cutting sheets from a continuous web on which has previously been applied, adhesive, cement or glue stripes, in a precise predetermined pattern across one surface of the web and stacking the sheets one on top of the other. The stack of sheets with the adhesive stripes on a common surface are subjected to pressure and heat to activate and/or cure the adhesive so that each sheet becomes adhered to its adjacent sheet in a particular pattern so that the sheets, when separated, form a cellular block with each cell of the structure the same shape and size.
U.S. Pat. No. 4,301,700 issued Nov. 24, 1881 discloses a cutting apparatus suited particularly for cutting sheets of very accurate length from a long, continuous supply of web, metal or other material generally used for preparing stacks of sheets used in making cellular blocks.
It has been found that in the manmaking honeycomb process, accuracy and uniformity in the spacing and width of the adhesive or cement stripes or lines set down on surface of the web or metal material used, the cutting to length and stacking of the cut sheets and the positioning of each sheet relative to its adjacent sheet are extremely important for the generation of a block of a man-made honeycomb, with uniform cells.
The adhesive, glue or cement stripes or lines may be applied to a long sheet or web across its width, i.e., perpendicular to the length of the web. The adhesive may be an epoxy, applied to the web in a liquid form using, for example, a printer. After the adhesive lines are printed across the web, the adhesive material printed on the web is dried so as to make the adhesive dormant.
State of the art printers print adhesive lines in a sharply defined pattern, relative to width of adhesive line, the spacing between adhesive lines and repetition of the pattern along the web or other material.
The width of the adhesive lines and the spacing between lines is a function of the size of the cell in the honeycomb mass to be manufactured. For example a honeycomb block made up from 1/8 inch cells may be generated by using adhesive stripes or lines 0.070 inches wide with a spacing of 0.280 inches between adhesive stripes or lines.
U.S. Pat. No. 4,301,700 teaches apparatus for cutting a continuous web into sheets of the same predetermined length, repetitively, by feeding the a continuous material on to an aligning table which aligns the continuous material without subjecting the material to a tension which may injure the adhesive stripes on the material. The continuous material is held flattened and stiffened at or near the termination point of the material. The continuous material or web may then be sheared or cut across its width by a conventional cutter to form a termination of the material.
SUMMARY OF THE INVENTION
The present invention provides improved apparatus for handling the material of a continuous web or other material prior to cutting the continuous web into sheets of accurate length. The invention includes a novel approach for offset stacking of the cut sheets and a novel apparatus for maintaining the offset relation between adjacent sheet in the stack when the stack of sheets is removed from the stacking table and during curing of the adhesive for cementing adjacent sheets together.
In general, a long roll, sometimes referred to as a continuous roll, of material such as a web or flexible material such a paper, for example or thin metal, such as aluminum, for example is pre-processed. The preprocessing includes placing stripes of an adhesive or cement in predetermined pattern, on a common face of the continuous roll.
As previously stated the material may be a web material such as cloth or paper or other web or, may be a metallic material, such as thin aluminum or other metallic foil or other material. For convenience, such material will be referred to as web, without limitation intended.
Each stripe of adhesive or cement set down across the face of the web is sharply defined in width and spacing. This may be accomplished by passing the length of the web through a printer which prints an adhesive stripe such as an epoxy in liquid form, on to the surface of the web. The adhesive or cement stripe is then dried by passing the printed portion of the web through a conventional drier. The web is then re-rolled to facilitate handling. However, the web may proceed to the rest of processing without rerolling.
In the process of printing the adhesive on the face of the web, a second, nonadhesive stripe is laid down along the edge of the web, at the start of the web, at the finish or end of the web and at any recognized defect, to indicate both the start of the web and the end of the web and any portion of the web that appears to be defective. This second line or stripe runs parallel to the edge of the web.
The roll of the web material is placed on a stand or retainer so that the web may be unrolled. In some cases the stand includes a drive mechanism of a conventional type, for example or the web may be pulled off the roll by other means.
The end of the web is fed to a table having a moving surface such as an endless belt, which moves the web forward or downstream.
The present invention includes at least first and second endless belt tables each in the form of a vacuum table. Each table has a vacuum manifold located under the top of the table, which is a moving surface formed by the upper surface of the endless belt. The endless belt, which is a porous belt, seals the manifold so that the vacuum pulls through the belt and holds the web firmly, but without tension, against the surface of the belt. This vacuum hold assists the moving belt in advancing the web uniformly.
With the web held firmly against the moving belt by the vacuum exerted through the manifold, the moving belt carries the web forward. When the endless belt travels beyond the influence of the vacuum against the belt, the web continues its forward movement.
Downstream from the first vacuum table, in the direction of travel of the web, is positioned a cutting or shearing apparatus for cutting the web into sheets.
Along the first endless belt table, at a position adjacent and upstream from the web shearing mechanism, is a first sensor, such as a photo sensor or electric eye sensitive to change in color, for example. This sensor is positioned to detect any stripe placed along the longitudinal edge of the web and to provide an output when such stripe passes through the zone of sensitivity of the sensor. A signal, generated in response to actuation of this first sensor, alerts a second sensor positioned just downstream from the cutting apparatus. This signal also slows down the motor driving the endless belt carrying forward this section of the web.
When the second sensor, which may be similar to the first sensor, detects the stripe on the longitudinal edge of the web, a signal is generated by the second sensor which causes the motor driving the endless belt to stop. This stops the forward movement of the web. A trapdoor, downstream from the cutting apparatus, for receiving waste cut off the web is also opened. The cutting apparatus shears the web perpendicular to the line of travel of the web, forming a waste piece forward of the cut.
The waste piece cut from the continuous web will be disposed of by dropping the piece through the trapdoor into a container. The trapdoor will then be closed and the motor driving the endless belt will be started so that the first or upstream table will continue moving the web forward or downstream.
When another stripe along the longitudinal edge of the web appears, the process to remove waste will be repeated.
Downstream from the shearing apparatus is a second endless moving belt table. Over this second table are two sensor devices, spaced a short distance from each other in the direction of travel of the web. Both sensors may be photo sensors designed to distinguish between light and dark, or contrasting color for example. The first of this pair, or the third sensor, is positioned upstream from the second of this pair or the fourth sensor. The third sensor looks for the leading edge of the web. When the leading edge of the web is detected by the third sensor, a signal is provided which signals the motors driving the moving belt on both tables to be slowed down and when the fourth sensor detects the same leading edge of the web, the motors are stopped so that the belt drive carrying the web is stopped. The cutting apparatus then cuts the web forming a cut piece laying downstream from the cutting apparatus. The function of the third and fourth sensors is to precisely stop the downstream advance of the web so that the web can be cut to an accurate length. After being cut, the cut piece is advanced by the second moving belt toward a fifth sensor. The fifth sensor may be a photo sensor that is actuated by or detects the leading edge of the cut sheet or some characteristic on the sheet and provides a signal in response thereto. The fifth sensor is positioned downstream from the second endless moving belt table. Upon actuation, the fifth sensor provides a signal used to stop the advance of the cut sheet.
The fifth sensor could be any type of detector or sensor that is actuated by the cut sheet or by a characteristic of the cut sheet. The fifth sensor is actuated by the cut sheet as the cut sheet moves on to an orientation table. Actuation of this sensor or detector provides a signal used to signal the motors driving the endless moving belts to stop thus stopping the advance of the cut sheet in a predetermined position.
It is desired that the cut sheet be stopped in a predetermined location on the orientation table so that the sheet may be grasped by each of a pair of sheet grippers at predetermined locations on the sheet. Preferably each sheet gripper, of a pair of sheet gripper, grasps a sheet at opposite corners of the leading edge and at a predetermined location relative to the same adhesive stripe on the sheet. Thus, each sheet is grasped in the exact same locations by each of two grippers. This is accomplished while the sheet is stopped on the orientation table.
In a preferred arrangement of the invention, each sheet gripper is carried by its own linear motor along a rail. Each motor moves its associated sheet gripper along the rail independent of the other, prior to gripping the sheet. Each motor is operated to location by a sensor individual to the motor. Prior to grasping the stopped sheet, the sheet gripping assembly, including a linear motor, a sheet gripper carried on the motor and a sensor carried on the motor, is located down stream from the stopped sheet. The sheet gripping assembly travels upstream and downstream in the direction of travel of the cut sheet along an overhead rail. In the sheet gripping procedure, the sheet gripping assembly travels toward the stopped cut sheet. The sensor looks at the surface of the sheet on which is printed the adhesive stripes or lines.
In order to ensure that a contrast in color exists between the normal color of the continuous web or substrate and the color of the adhesive stripes printed on the continuous web, a color may be added to the adhesive prior to the printing process.
The sensor carried on the linear motor and looking at the surface of the sheet effectively controls the motor relative to locating the sheet gripper for grasping the sheet. The sensor is adjusted so as to ignore the first adhesive stripe off the leading edge whether that stripe be a whole stripe or part of a whole stripe. The sensor will then stop the linear motor, or will provide a signal to stop the linear motor when the zone of sensitivity of the sensor is split by the next appearing clear stripe and the following adhesive stripe. When the motor is stopped the sheet gripper is closed so as to grasp the sheet. In this way each cut sheet is grasped exactly the same way in exactly the same place relative to the same adhesive stripe on the sheet.
The cut piece is now held by each gripper of the pair of grippers and by the vacuum holding the piece against the upper surface of the endless moving belt of the second table now stopped. The linear motors are then moved uniformly downstream carrying the grippers now holding the leading edge of the cut sheet. This applies a forward pulling pressure on the sheet at the leading edge and a resistance to the forward pulling pressure by the vacuum exerted on the sheet through the porous belt of the second endless moving belt. This results in drawing the cut sheet into a flat, taut condition. The linear motors move downstream drawing the sheet to a predetermined position relative to a fixed pair of hole punching devices. When the sheet is in such predetermined position, the pair of hole punching devices punch two spaced holes in the sheet, one hole adjacent each edge of the cut sheet.
It will be seen that each gripper was oriented into position to grasp the sheet by aligning the sensor associated with the gripper on the same adhesive stripe on the sheet. Thus with the linear motors now drawing the sheet forward or downstream uniformly to a predetermined position under a pair of fixedly located hole punching devices, the holes punched in the sheet by the fixed hole punching devices are related in position to the adhesive stripes on the cut sheet.
It is desired that successive appearing sheets are punched with holes in offset relationship, relative to the same adhesive stripes on the sheets. Thus, with the hole punching devices held in a fixed position along the path of travel, every alternate sheet is drawn to the same one of two positions. This results in successive sheets having holes offset from each other with the offset of the holes related to the adhesive stripes on the sheet.
After each sheet is punched with a pair of holes, the sheet is drawn by the grippers to a stacking table where the sheets are stacked.
The stacking table includes a pair of upright aligning pins which are spaced so that the longitudinal axis of each pin aligns with the center of one of the holes respectively, that are punched in the sheet. The pins are passed through the holes as the sheet settles on the bed of the stacking table. This automatically aligns the sheets in the stack in interleave configuration, i.e., in a staggered relationship relative to adjacent sheets in the stack. The gripping devices release the sheet and move so as to clear the sheet and permit the sheet to lie flat on the stacking table bed. The spaced hole aligning pins are a snug fit in the holes in the sheet so that each sheet is precisely offset relative to adjacent sheets.
Since each sheet was precisely grasped relative to the same correspondingly positioned adhesive stripe and each alternate sheet was moved to one of two precise positions respectively, for hole punching, then with the sheets stacked on aligning pins passing through the holes in the sheets, the adhesive lines on adjacent sheets are precisely offset in horizontal planes, as a function of the stacking and are offset in vertical planes as a function of the offset holes on the aligning pins.
It has been found that during removal of the stacked sheets from the aligning pins the sheets very often slide, relative to each other destroying the alignment and offset attained. In order to avoid slippage between sheets of the stack, the sheets are secured one to the other, at the edges, while the sheets are on the aligning pins. Preferably the sheets are secured, one to the other, at their edges, as the sheets are stacked, such that each sheet is secured to its adjacent sheet.
In the preferred embodiment of the invention structure is provided to cut a succession of sheets of precisely the same length from a continuous web having one surface containing a precise pattern of adhesive stripe extending across the width thereof. Each successive sheet is drawn to a predetermined position along a path of travel and is grasped by each of a pair of sheet grippers in exactly the same location, relative to the adhesive stripes on the sheet. Each sheet is drawn by the sheet gripping device to a predetermined position relative to a pair of fixed position hole punching devices so that two spaced holes may be punched in each successive sheet. Each successive sheet is moved to a different one position, of two positions, under the hole punching devices so that the holes punched in successive sheets are offset in zigzag form. Since each successive sheet is grasped by the sheet gripping devices in the same identical place, relative to an identically located adhesive stripe on the sheet and each alternate sheet is moved to an identical position of two different positions, then the holes punched on each successive sheet will be offset alternately from correspondingly located adhesive stripes on successive sheet.
Alternatively, each sheet may be grasped in the same location on the sheet and the sheet grippers may either hold the sheet in a fixed position or move each successive sheet to the same, identical location and the hole punching devices may be re-positioned, first to one position for one sheet, then to a second position for the next sheet, then to the first position for the following sheet and so forth.
With the holes punched in successive sheets in offset location between successive sheet, when the sheets are stacked successively on aligning rods passing through the holes, a stack of sheets is generated in which the adhesive stripes on adjacent sheets are offset in horizontal planes, which is a function of the stacking, but are also offset in vertical planes, which is a function of the aligning the offset holes in the sheets.
Securing of the stacked sheets, one to the other to prevent slippage between sheets may be accomplished after all the sheets are stacked or may be accomplished one on one, as the sheets are stacked. Preferrably, adhesive spotting of adjacent sheets, at their edge, is done on a diagonal, up the side of the stack.
As the sheets are being stacked, a counting device may be used to count the sheets placed on the stacking table so the number of sheets in the stack is known, Stacks of sheets of predetermined number may be removed from the cutting and stacking apparatus and placed on a pressure and heat applying apparatus which may cure the adhesive so that each sheet becomes cemented to its adjacent sheet in a predetermined pattern. After curing, the stack of sheets may be opened, forming a cellular structure.
It is within the state of the art to control the various motors relative to stop and go, speed and distance of travel by a computer. The various signals generated by the sensors or detectors may be fed into the computer, and the computer may be programmed to operate the machine. This will include the opening and closing of the trap door for waste material and the operation of the shearing device and sheet gripper assembly. The securing of the sheet edges, one to the other, in the stack of sheets may also be computer controlled.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 1a fit together to represent a preferred embodiment of the invention;
FIG. 2 represents a section of a continuous web, prepared with an adhesive stripe pattern and a termination or defect stripe printed thereon;
FIG. 3 represents a group of stacked, offset sheets in exploded view, located on aligning pins;
FIG. 4 represents a sheet gripper assembly unit over a sheet;
FIG. 4a represent the sheet gripper closed on the sheet with a sensor showing the projected zone of sensitivity; and,
FIG. 5 represents a stack of sheets on aligning pins with securing spots and a spot applying device.
DESCRIPTION OF THE INVENTION
The FIGS. 1 and 1a are assumed connected, as indicated by the arrows, forming a continuous web cutting and stacking apparatus.
A roll 10 of a prepared continuous web is supported on a roll-off stand. The web 15 is represented as passing under a roller 16, which may be an idler roller or a driven roller which draws the web from the roll 10. Two web moving tables 18 and 19 are represented, each of which support an endless belt arrangement for moving the web forward. The table 18 supports a variable speed motor 20 connected to and driving a drive bar 21, by a drive belt 22. Arrows indicate the direction of travel of the belts. The motor is connected to a control, (not shown) which controls the on/off status and the speed of the motor. The roller 21 drives an endless belt 23 in the direction indicated by the arrow 24. The idler bars 26 and 27 are supported in the table and hold the belt 23 so the belt portion between the bars 26 and 27 forms the surface of the table 18. Under the belt 23 between the idler rollers 26 and 27 is a vacuum manifold 30. The under surface of the belt 23 is in sliding contact with the edge of a vacuum manifold 30, forming a seal over the face of the manifold. The endless drive belt is porous so that the vacuum draws through the drive belt 23 above the manifold.
A spring 31, connected to the drive bar 21 keeps the drive belt 22 and endless belt 23 taut. The drive belt assembly is supported on a table or table frame represented by the legs 33 and 34. A tube 35 leads from the vacuum manifold 30 to a vacuum device (not shown).
The web 15 from the roll 10 is fed under the roller 16 and on to the upper surface of the endless belt 23. In practicing the invention a holder 37 is used at the edge of the table 18, where the web 15 is introduced to ensure that the web is hold flush against the endless belt in order that the vacuum, drawing through the porous endless belt, pulls the web flat against the upper surface of the endless belt. This holder may be a group of rollers or ball bearings set in a frame which ride on the top of the web as the web is introduced to the endless belt 23.
With respect to the sheet material of the continuous web, a portion of the prepared sheet is represented in FIG. 2. The sheet 15 has printed, on one of the surfaces, a pattern of stripes of adhesive 40, spaced by clear spaces 42. It will be noted that the leading edge 44 of the continuous web may not be straight across and a defect or termination mark 45 is printed along the edge, running parallel with the direction of travel indicated by arrow 46. This termination mark is also put on the end of the long sheet and at places between the ends where a defect in either the sheet and/or the printing of the adhesive stripes has been noted.
The termination mark 45 may be a contrasting colored stripe that may be detected by a sensor 50 which provides a signal indicating that the motor 20 driving the endless belt 23 should be slowed down. The same signal is also used to alert a sensor 51 that the stripe is approaching. The sensors 50 and 51 may be photo sensors which respond to change in light and dark or contrasting colors and provide signals in response to a change in the character or change in color of the material passing through the zone of sensitivity of the sensor. The sensor 51 is positioned close to and upstream from a cutter or shearing apparatus 52. By incorporating a delay in the detection signal of sensor 51 passage of the termination or defect stripe beyond the cutter 52 may be assured. In response to a combination of signals provided by sensors 50 and 51, the trapdoor 54 is opened, the motor 20 is stopped, thus stopping the endless belt 23, and the cutter 52 cuts the web 15 transverse to the direction of travel of the web. A container 55 catches the waste cut portion 15a of the web which falls through an opened trap door 54.
After cutting or shearing the raw edge of the continuous web, the cutter returns to standby position, clear of the web and a signal is provided. In response to this signal the trapdoor is closed, the motor 20 is started, and the web 15 is advanced to the table 19.
It will be appreciated that the various signals may be fed to a control box or into a computer that is programmed to control the apparatus. The apparatus may also be controlled manually. Automated operation, under computer control, is the preferred operation of this apparatus, as automated operation will produce optimum production over the long range.
Table 19 includes an endless belt 57, driven by a variable speed motor 58. The belt 57, which is porous, is supported by two idler bars which are mounted in the table 19. The moving endless belt 57 forms the surface of the table 19. The moving belt 57 covers the top of a vacuum manifold 60 which forms a vacuum chamber, such as described on table 18. The vacuum used in conjunction with the vacuum manifold 60 is independently controlled, relative to the vacuum used in conjunction with vacuum manifold 30, of table 18. Alternatively motors 20 and 58 can be combined into one motor with a variable gear ratio so that belt 57 travels faster than belt 23. The newly cut leading edge of the web is advanced by the drive belt 57, with the web 15 held firmly against the surface of the belt on table 19 by the vacuum in manifold 60. As the leading edge advances downstream, the leading edge is detected by a sensor 61, which provides a signal indicating that the web advance should be slowed down. This avoids override of the motor when the motor is stopped. The signal also alerts sensor 62 that the leading edge is approaching. When the sensor 62 detects the leading edge the advance of the web is precisely stopped and the cutter cuts the web. The sensors 61 and 62 may be the same type of sensor as sensor 50 or 51, for example.
The position of sensor 62 and/or the location of the leading edge when the advance of the web is stopped determines the length of the sheet cut from the web.
The cut sheet is advanced rapidly to the orientation table 63 while the main portion of the web with a newly cut leading edge is advanced over the closed trap door toward the drive belt 57. The motors 20 and 58 are independently controlled and may be operated at different speeds, as required.
At this stage, the leading edge of the cut sheet is advancing toward a predetermined position on the orientation table 63 while a trailing portion of the sheet is on the endless belt 57 of table 19, held against belt 57 by the vacuum in vacuum manifold 60. When the leading edge of the cut sheet is detected by a sensor 59 as entering a predetermined position on orientation table 63 a signal from sensor 59 is provided, indicating that the motor 58 driving endless belt 57 is to be stopped.
The predetermined position, for stopping the advance of the cut sheet on the orientation table is when the leading edge of the sheet is far enough on to the orientation table so that the surface of the leading portion of the sheet may be scanned by each of a pair of sensors 67 and 68 and each sheet gripper of a pair of sheet grippers may grasp the sheet just inside the leading edge of the sheet and the trailing section of the sheet is remains held against the surface of the endless belt 57 by the vacuum in vacuum manifold 60.
The sheet gripping assembly is more clearly represented in FIGS. 4 and 4a.
The sheet gripping assembly includes a pair of rails 66 and 66a suspended over the surface of the table 63. On each rail, which may be a pair of rails each, rides a linear motor carrying a sensor and a sheet gripper with sheet gripper actuator.
The linear motor 64 rides on rail 66 and carries sensor 67 and sheet gripper 70 along with sheet gripper actuator 72.
Linear motor 65 rides on rail 66a and carries sensor 68 and sheet gripper 71 along with sheet gripper actuator 73.
The rails 66 and 66a are positioned and spaced so that each sheet gripping unit is located over the plane in which the cut sheet lies and just inside the edges of the sheet that is, edges as opposed to the leading end, referred to as the leading edge of the sheet.
The linear motors are, when approaching the leading edge of the sheet independently driven but when the sheet has been grasped by each unit, the linear motors 64 and 65 are effectively operated uniformly, in unison.
Mounted on each motor, essentially in identical locations is a sensor 67, on motor 64 and a sensor 68, on motor 65. Each sensor looks down on the sheet seeing the surface which has the pattern of adhesive lines and spaces thereon. Each sensor is sharply tuned and adjusted to ignore the first adhesive stripe 40 on the sheet and to provide an optimum or useful signal when its zone of sensitivity is exactly split by the first clear strip 42 on the sheet and the second adhesive stripe 40 on the sheet. This is represented in FIG. 4.
When the respective sensor 67 or 68 sees this combination, the linear motor, under the control of the particular sensor is stopped. In this condition the bottom jaw of the sheet gripping device is under the sheet and the upper jaw is above the sheet. A jaw actuator 72 closes the sheet gripping device by lowering the upper jaw on to the top of the sheet so that the sheet is grasped between the upper and lower jaws of the sheet gripping device. The jaw actuator may be a solenoid, for example.
Both sheet gripping devices and both sensors are identically mounted on respective linear motors so that with each sensor 67 and 68 finely and sharply tuned each sheet gripping device 70 and 71 will grasp the sheet in exact corresponding positions near opposite edges of the sheet.
Prior to gripping the sheet, driving the respective sheet gripping unit of the assembly is independently carried out, with the positioning of each sheet gripping unit relative to the same adhesive stripe on the same sheet. After each unit of the sheet gripping assembly has independently secured the sheet, the movement of each linear motor is preferably simultanious and identical, relative to each other.
The hole punching devices are in fixed positions. Thus, the location of the holes punched in the sheet are related to the same adhesive stripe on the sheet. By driving the motors carrying the sheet to a first predetermined position for a first sheet, then to a second predetermined position for the second sheet then to the first predetermined position for the third sheet, then to the second predetermined position for the fourth sheet and so on, the holes punched by fixedly located hole punching devices will be offset between successive sheets and when the sheets are stacked with hole aligning pins through the punched holes, the sheets in the stack will lie with the adhesive stripes of adjacent sheets offset from one another.
In order to preserve the offset relationship between adhesive lines or stripes on adjacent sheets in the stack of sheets, adjacent sheets may be adhered to each other, this to prevent sliding of the sheets in the stack.
FIG. 5 represents a stack of sheets 15a through 15g on a bed 85 with aligning pins 80/81 extending through the holes in the sheets. The thickness of the individual sheets is exaggerated to show the offset relationship between adjacent sheets and the adhesive spotting of common edges of adjacent sheets. The "X's" 95 show that the adhesive spots adhering the edges of adjacent sheets are in zig-zag arrangement. The "X's" 95a show that adhesive spots may be on a diagonal along the edge of the stack, if desired.
Adhesion of adjacent sheets may be accomplished by gluing, such as represented at 90 or by soldering or by heat fusion, if desired.
By using edge spot adhesion, slippage between sheets of the stack is avoided when the aligning pins 80/81 are removed.
FIG. 3 represents the offset orientation of successive sheets 15a through 15e stacked, with aligning pins passing through the holes. The offset relationship of the adhesive stripes 40 and clear stripes 42 is also indicated. The width and spacing of the adhesive stripes has been exaggerated.
After holes are punched in the sheet, the sheet gripper assembly draws the sheet to a position over the stacking pins where the holes in the sheet are aligned with the pins. The sheets form a stack of sheets on the bed 85 with the aligning pins passing through the holes in each sheet of the stack.
The aligning pins 80 and 81 are preferably standing upright on the bed and are tapered at the top or tip of the pin to provide a clearance when the pin first enters the hole in the sheet in the stacking process. The lower portion of the shaft of the pin has a diameter that fits snugly in the hole so as to positively orient the sheet on the pins.
The sheet grippers release the sheet and the gripper assembly returns to prepare to grasp the next cut sheet. The sheet gripper assembly may include a sheet flattening apparatus which flattens the sheet on the stack during return of the gripper assembly to secure the next sheet.
The stacking table 85 may be moved up and down to receive the cut sheet from the grippers. This may be accomplished in several ways, one of which is indicated. The legs 86 and 87 may be pivotally attached to the bed of the stacking table 85. The extreme or floor ends of the legs may be changed in spacing so as to raise or lower the table. Alternatively the pins 80 and 81 may be raised or lowered, as desired, by a drive or solenoid (not shown) for example.
The stack of sheets secured in their offset position by the pins through the punched holes may then be removed from the table and further processed.
The continuous web 10 is printed with adhesive stripes on only one side or face of the web. Preferably, the web 15 is introduced on to the surface of the table 18 with the printed face up or exposed, placing all the adhesive stripes on the upper or exposed surface of the web 15 and the cut sheet during the cutting and stacking operations. When the sheets are stacked on the stacking table all the sheets in the stack will be facing in the same direction. This is represented in FIG. 3.
As previously stated the continuous web from which the sheets are cut had been previously prepared with adhesive stripes printed, very accurately and sharply defined and spaced, extending from edged to edge across the width of one surface of the web. The other surface is clear. When the sheets are stacked the face of the sheets containing the adhesive stripes are all facing the same direction. The sheets in the stack are stacked sheet face to sheet back and thus the pattern of adhesive stripes on one sheet of the stack is in a different horizontal plane than the pattern of adhesive stripes on the adjacent sheet in the stack. This is a function of stacking. However, there is an offset between adhesive stripes of adjacent sheets obtained by the present invention. This offset is in vertical planes.
In order to accomplish the making of a block of cells, such as a honeycomb block, for example, offset of the adhesive stripes or lines between adjacent sheets in vertical planes need be very accurate and sharply defined. This is because of the width and spacing of the adhesive stripes printed on the surface of the web. For example, for the formation of a cellular structure with 1/8 inch cells, adhesive stripes 0.070 inches wide are laid down or printed across the width of a continuous web at a spacing of 0.280 inches. The offset, in the vertical plane between adhesive stripes on adjacent sheets in a stack of sheets need be 0.175 inches. It will be appreciated that cellular structures formed with cells other than 1/8 inch will require different width adhesive stripes at different spacing between adhesive stripes and a different offset between adhesive stripes of adjacent sheet in a stack of sheets.
Positioning of the various components of the apparatus of the invention and movement of the sheet gripper assembly may be adjusted to provide sheets of different length, as desired and provide different offset between adhesive stripes of adjacent sheets and still maintain consistence accuracy.
It should be mentioned that when the cut sheet is secured by the grippers of the gripper assembly, the sheet may be held in a substantially flat position by having the leading portion of the sheet pulled forward by the grippers and having the vacuum through the endless belt retard the advancement of the sheet. Although advancement of the sheet is retarded by the vacuum hold on the sheet, the sheet may be pulled and/or slide along the belt when pulled by the grippers. This combination of forces provides a flat, taut sheet when the gripper assembly pulls the sheet forward against the vacuum hold. The vacuum through the belt permits the sheet to move or slide forward on the belt under a forward pulling pressure, without damage to the sheet or the adhesive stripes on the sheet.
The invention has been shown and described in representation from. The type of individual component used, such as a sensor, endless belt, shear apparatus, vacuum system, punch, etc., will depend greatly on the material content of the continuous roll. Although several alternatives have been mentioned, other changes and modifications may be made, as will become apparent to those skilled in the art, without departing from the invention as defined in the appended claims.
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Apparatus for cutting a continuous web into precise length sheets and precisely stacking the sheets, relative to each other, includes first and second moving endless belt tables for advancing the web, a sheet orientation table and a stacking table. A vacuum holds the web firmly, without tension, against the respective belts. A shearing device is disposed between the first and second endless belts. Web, detectors positioned along the line of travel of the web, detect printed or colored lines on the web to obtain accurately cut sheets. Individually driven and positioned sheet grippers grasp the cut sheet positioning each sheet under dual hole punching devices which punch precisely positioned holes in each sheet. A pair of aligning pins on a sheet stacking bed are used as guides for orienting the sheets in interleave configuration. Each sheet is secured to its adjacent sheet to maintain sheet orientation.
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Background of the Invention
1. Field of the Invention
The present invention relates to a handy terminal for use in accessing a computer to classify, maintain and manage various data, which should be manually acquired as in a case where no sensors are employed for automatic acquisition of the data, such as data which represents conditions of a patient in a ward which must be measured several times a day (e.g., body temperature, blood pressure, pulse or sphygmus, etc.), based on the types of data and the number of times the data items have been measured, and a data processing method executed by the handy terminal.
2. Description of the Related Art
The prior art will be explained below with reference to data management of patients in a ward.
In a ward, a nurse usually checks the patients several times a day to measure their body temperature, blood pressure, pulse, respiration number and the like, and records the data on a check sheet. These data are manually classified and written on a sheet called a temperature chart for each patient.
Since the number of measuring items, the number of times each item is measured and the like differ for each patient, it can become very troublesome to write the data on the temperature charts for each patient. Further, in various industries, it is often necessary to manually acquire and manage data, like patient data, whereas no sensors can be used in the acquisition of the data, thus requiring a troublesome manual data management.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a data processing apparatus which can edit data, if input in a disorderly manner, based on the input time and the items which were measured, and maintain the data in a format which facilitates the preparation of the necessary charts, graphs and the like at a later time.
A data processing method employed by the data processing apparatus of this invention uses a file which has sequentially arranged records each having a data area for designating the number of measurements for each object or target to be measured, a data area provided for each of a plurality of pre-set measurement items (categories), and a data area for storing data relating to the times at which the data items were measured. When measured data of each item are entered in the file, the time which has elapsed since the preceding measured data entry is determined. If the time is greater than a predetermined time, or if it is smaller than a predetermined time but the measured items are the same as the previously-measured items, then the data of the number of the preceding measurements is updated, the current measured data is stored in the data areas of the associated measurement items of the next record, and the data representing the time at which the current data items were measured is stored in the measuring time data area of that record. If the time which has elapsed is within the predetermined time and the measured items differ from the previous ones, the current measured data is stored in the data areas of the associated measurement items of the same record as used for recording the preceding measured data.
According to this invention, a data entry interval is discriminated from the time at which the measured data is entered, and if the interval is found to be greater than a predetermined time, the entered data is considered to be the next measured data, the number of times the data has been measured is updated and the current measured data and the current data representing the time at which the data is measured are stored in the next record. If the data entry interval is within the predetermined time and the measurement items are the same as the previous ones, the entered data is considered to be the next measured data and the measured data is stored in the above manner. If the data entry interval is within the predetermined time with the current measurement items differing from the previous one, the entered data is not considered to be the next measured data, so that the number of times the data has been measured is not updated and the currently measured data is stored in the same record as used for recording the previous measured data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart illustrating the sequence of the data processing applied to a handy terminal according to one embodiment of this invention;
FIG. 2A is a block diagram illustrating a data processing system, which includes a plurality of handy terminals for executing the data processing of FIG. 1, and a host computer linked to the handy terminals to edit data therefrom;
FIG. 2B is a block diagram illustrating the internal arrangement of each handy terminal shown in FIG. 2A;
FIG. 3 is a flowchart illustrating the operational sequence of the data processing system shown in FIG. 2A;
FIG. 4 is a diagram exemplifying the file structure for data processed by each handy terminal shown in FIG. 2A;
FIGS. 5A to 5D are detailed diagrams of the file structure shown in FIG. 4;
FIG. 6 is a diagram for explaining the flow of data from each handy terminal, shown in FIG. 2A, to the host computer;
FIGS. 7A to 7C are detailed diagrams exemplifying the file structures, as shown in FIG. 6, in the individual handy terminals;
FIGS. 8A to 8D are detailed diagrams exemplifying the file structures used when the data in the file shown in FIG. 7 is edited by the host computer;
FIG. 9 is a flowchart illustrating the data editing sequence executed by the host computer shown in FIG. 2A; and
FIGS. 10A to 10E are diagrams exemplifying the file structures after the data has been edited by the host computer shown in FIG. 2A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of this invention will be explained below referring to the accompanying drawings.
In FIG. 2A, HT-1 to HT-n are handy terminals (hereinafter simply referred to as HT). Measured data is manually entered. The present system includes a plurality of handy terminals HT-1 to HT-n and data may be entered through any HT. The acquired data is all transferred to host computer 1 by linking the associated HT to computer 1 and the HT is initialized when host computer 1 acknowledges the data reception. Host computer 1, upon receipt of the measured data, classifies and files the data based on the measurement items and the times at which the data were measured. Upon request made through keyboard 3, host computer 1 can display the filed measured data, as maintenance data, on CRT display 2 in an easily legible form or can prepare graphs and charts of the filed measured data through X-Y plotter 4.
FIG. 2B illustrates the internal arrangement of each handy terminal HT (HT-1 to HT-n) shown in FIG. 2A.
Terminal HT comprises, for example, 8-bit CMOS microprocessor 50 (hereinafter referred to as MPU) and peripheral devices 51 to 61. The operating system of MPU 50 and the other system programs are stored in ROM 51 in advance. RAM 52 stores data to be processed by MPU 50. MPU 50 is coupled to timer 53 which also serves as a clock generator to generate its operational clocks, and uses this timer 53 to record the time at which data is entered.
The data input to MPU 50 is entered through I/O interface 54 by means of keyboard 55. The entered data or data processed in MPU 50 is displayed through I/O interface 56 on display 57, which may be a liquid crystal display type panel.
The data entered in or processed in MPU 50 is transferred through I/O interface 58 to microfloppy drive 59, for example, of a 3.5 inch size or RAM card writer 60 (which can be an IC card writer, a magnetic card writer, etc.) to be recorded on a floppy disk or a RAM card. The recorded data is later read out by floppy drive 6 or RAM card reader 7 of host computer 1 and stored in a memory bank within the computer 1.
The individual handy terminals HT may be coupled through serial communication port 61 to host computer 1 to build a local area network (LAN).
FIG. 3 illustrates the operational sequence of a ward control system embodying this invention. Information about the patients is transferred in advance to the individual handy terminals from host computer 1, which may be located in a nurse station (step ST30).
A nurse makes the round of his/her assigned block and enters the data representing the physical conditions of the patients into his/her own HT (step ST31; YES in step ST32). Upon entering the necessary data (NO in step ST32), the nurse transmits the acquired data to host computer 1 through a communication line (LAN) (step ST33); the data transmission can be executed at a desired timing. Upon reception of the data, host computer 1 sends a data clear command to the HT. Editing steps (ST34 and ST35) in FIG. 3 will be described later.
FIG. 4 illustrates the file structure used in the HT. In the figure, numeral 10 designates the entire structure of the file, numeral 11 represents a detailed file structure of one patient, and numeral 12 designates a detailed file structure for a single measuring of data for one patient.
The data for each item measured is edited in the HT as shown in FIG. 1. Upon reception of the data clear command from host computer 1, each HT initializes an input confirmation flag to be described later (step ST10 in FIG. 1). After the aforementioned initialization process, data entry is then permitted. In this example, the nurse is to measure 5 data items for each patient (body temperature, sphygmus, blood pressure (high), blood pressure (low), and respiration). The number of data items to be acquired in a single measurement can be arbitrarily set within the range between one to five for individual patients, and the number of measurements per day can also range between one to seven depending on the patient. In this example, the time interval between the i-th measurement and the (i+1)-th measurement for one patient is set to be equal to or greater than K hours.
FIGS. 5A-5D illustrate the status of the file within the HT when the (i+1)-th measurement for patient A is carried out, provided that the measured data of patient A up to the i-th measurement has been entered.
FIG. 5A illustrates the file status prior to the (i+1)-th measurement; D il , D i3 , and D i4 in record R 1 indicate the data of the previous measurements stored in measurement item data areas (12-1, 12-3, and 12-4 in FIG. 4), and "/" indicates that there is no data in the marked measurement item data areas (12-2 and 12-5).
The input confirmation flag IF (11b) representing the number of measurements is set at the i-th bit. T i represents the time at which the previous measuring occurred.
The following explains the status of the file after the (i+1)-th data has been entered for the different cases.
CASE 1
As shown in FIG. 5B, measured data D i+1 ,1, D i+1 ,3, and D i+1 ,4 for the same items as the previous measured data (12-1, 12-3, and 12-4) are entered (YES in step ST11 in FIG. 1). In this case, irrespective of whether T i+1 -T i is greater or smaller than K hours, the (i+1)-th measurement is assumed to have been carried out (YES in step ST13 or ST14), the input confirmation flag (11b) is set at the (i+1)-th bit (updating of the number of measurements) (step ST16). Then, measured data D i+1 ,1, D i+1 ,3, and D i+1 ,4, and time data T i+1 , are stored in the associated data areas (12-1, 12-3, 12-4) of next record R 2 (step ST17). The data processing in this case is executed in the sequence of steps ST13, ST14, and ST16-ST19 in FIG. 1.
CASE 2
In this case, as shown in FIG. 5C, either of measured data Di+1,2 and Di+1,5 of different items (12-2, 12-5) than the previously-measured items (12-1, 12-3, 12-4) is entered; D i+1 ,1, D i+1 ,3, and D i+1 ,4 of the same items as the previously-measured items are not entered; and time difference ΔT between previous measuring time T i and current measuring time T i+1 is (T i+1 -T i )≧K (YES in ST13). In this case, the (i+1)-th measurement is determined to have been carried out, and measured data D i+1 ,2 and D i+1 ,5 and time data T i+1 are stored in their respective data areas (12-2, 12-5, 13) of next ((i+1)-th) record R 2 . The input confirmation flag (11b) is set at the (i+1)-th bit. The data processing in this case is executed in the sequence of steps ST13 and ST16-ST19 in FIG. 1.
CASE 3
This is the case in which, as shown in FIG. 5D, either of measured data D i+1 ,2 and D i+1 ,5 of different items (12-2, 12-5) than the previously-measured items (12-1, 12-3, 12-4) is entered; D i+1 ,1, D i+1 ,3 and D i+1 ,4 of the same items as the previously-measured items are not entered; and time difference ΔT attained in step ST12 is (T i+1 -T i )<K (NO in step ST13). In this case, the current measurement is determined to be the i-th one and measured data D i+1 ,2 and D i+1 ,5 are stored in their respective data areas (12-2, 12-5, 13) of record R 1 used for the i-th measurement (step ST15). The input confirmation flag remains set at the i-th bit (no updating of the number of measurements). The data processing in this case is executed in the sequence of steps ST13, ST14, and ST15 in FIG. 1.
Based on the items of the measured data or the different times at which the items were measured, the measured data can be sequentially managed.
Then, individual handy terminals HT-1 to HT-n, in which various data have been collected in the above manner, are coupled through a transmission line to host computer 1, so that the collected data is sent to host computer 1 (step ST33 in FIG. 3).
Host computer 1 edits the measured data transferred from a plurality of handy terminals to provide a single file. That is, as shown in FIG. 6, the data of input files Fl-Fn of a plurality of handy terminals HT-1 to HT-n are edited to provide measured data file DF1 of host computer 1 (step ST34 in FIG. 3).
An example of the editing process will be explained below.
If the data of input files Fl-Fn of individual terminals HT-1 to HT-3 are as shown in FIGS. 7A-7C, the measured data, after editing has taken place, becomes as shown in FIG. 8B or 8D.
In FIGS. 7A-7C, it is assumed that terminals HT-1, HT-2, and HT-3 are respectively initiated in three measurements, two measurements and two measurements. T ni represents the measuring time, D ij n represents the data for each measured item, and "/" indicates that no data has been input which corresponds to the designated data item areas, where n corresponds to the one-decremented number of handy terminal HT, i represents the number of measurements, and j, the data item number (j=1 to 5 in the case of FIG. 4).
The measured data is edited on the basis of time T ni and measurement items (12-1 to 12-5 in FIG. 4) as the data processing described earlier with reference to FIG. 1. As a result, the data file in host computer 1 becomes the one shown in FIG. 8B or 8D.
FIG. 8A illustrates the relationship between the different times at which the data items were measured with respect to HT-1 to HT-3, and FIG. 8B illustrates the file structure after completing the editing of the measured data acquired in this case. FIG. 8C illustrates another relationship between the different times at which the data items were measured with respect to HT-1 to HT-3, and FIG. 8D illustrates the file structure after the editing of the measured data acquired in this case has taken place.
The file structures shown in FIGS. 7 and 8 are associated with the same patient. Generally, two to three HTs (three in this example) are provided in a ward, and a nurse uses any available one of the three HTs to enter the measured data of patients. Therefore, the measured data of one patient is often stored in different HTs; in this example, such data is distributed over three handy terminals HT-1 to HT-3. In this respect, all of HT-1 to HT-3 are finally coupled to host computer 1 which in turn edits the transferred data to make a single file.
In the embodiment of FIG. 1, the predetermined time K which is used for discriminating time difference AT between the previous measurement and the current measurement is set to be one hour.
The following explains the case as shown in FIGS. 8A and 8B. In FIG. 8A, the first measurement is carried out with HT-3 (n=2) at time T 20 , measured data D 0 2 2 and D 0 2 4 and time data T 20 , are stored in record R 1 , and the input confirmation flag is set at the first bit (i=1).
The next measurement is carried out with HT-2 (n=1) at time T 10 , and the time which has elapsed since the first measurement falls within one hour, i.e., (T 10- T 20 )<K. Since the current measurement includes the same measurement item (D 04 ) as the previous measurement, the measured data D 0 0 1 and D 0 1 4 and time data T 1O are stored in the next record R 2 , and the input confirmation flag is set at the second bit (i=2). (The number of measurements i is updated to i+1.)
The next measurement is carried out with HT-2 (n=1) at time T 11 , and the time relationship between the current measurement and the previous measurement is (T 11 -T 10 )<K. Since the current measurement includes the same measurement item as the previous measurement, the measured data D 1 1 4 is stored in the next record R 3 , and the input confirmation flag is set at the third bit (i=3).
The next measurement is carried out with HT-1 (n=0) at time T 00 . In this case, since the time relationship between the current and previous measurements is (T 00 -T 11 )<K, and the current measurement includes different items from those of the previous measurement, the measured data D 0 0 1 and D 0 0 3 are stored in the same record R 3 as used for the previous measurement. The input confirmation flag remains set at the third bit (i=3).
With regard to the time data, the latter time data T 00 is stored. (Although, previous time data T 11 may instead be stored.) Similarly, data measured at times T 01 and T 21 are stored together in record R 4 . Since the time relationship between the current measurement at time T 02 and the previous measurement is (T 02 -T 21 )>K, the measured data is stored in record R 5 . In this case, the input confirmation flag is set at the fifth bit (i=5).
In the case shown in FIGS. 8C and 8D, the measured data is edited on the basis of the measuring times and the measurement items to make a single file in the same manner as in the above explained case.
With the above file structure, data which relates to the physical condition of each patient can easily be plotted on a graph or a table using CRT 2, X-Y plotter 4, or the like, shown in FIG. 2A.
FIG. 9 is a flowchart illustrating the data editing procedures performed by the host computer as shown in FIG. 2A. FIGS. 10A-10E illustrate examples of the file structure which is attained after the data has been edited by the host computer as shown in FIG. 2A. In these examples, T ni indicates the i-th measuring time of the (n-1)-th HT, D ij indicates the data of the j-th item acquired by the i-th measurement, and K indicates a predetermined time (e.g., one hour). (In this example, the maximum value [imax] of i is 6, and j varies between 1 to 5 according to the types of measured data 12-1 to 12-5.)
In FIG. 9, data D ij collected from the individual HTs are sorted by host computer 1 in accordance with measuring time T ni (FIG. 10A) to prepare a new file (FIG. 10B) (step ST90). Then, file indexes (0-6) corresponding to record numbers R 1 -R 7 are assigned to the data D ij and measuring time data T ni , so that a managed file (FIG. 10C) is prepared (step ST91).
Then, i is set to 0 (step ST92) and the time difference (T 1 -T 0 ) is compared with the predetermined time K (one hour) (step ST93). When this time difference is smaller than K (YES in step ST93), it is determined whether or not the previous measured data D ij and the current measured data D.sub.(i+1)j are associated with the same measurement items (step ST94). If the previous and the current measured data are not associated with the same measurement items (YES in step ST94), record R i+1 is merged with record R i+2 (step ST95), and the input confirmation flag (one bit) is reset (step ST96).
Then, i is incremented to i+1 (step ST97) and this incremented value is compared with its maximum value imax (=6) (step ST98). If the increment value i is smaller than 6 (NO in step ST98), the process returns to step ST93. If the increment value i is 6 (NO in step ST98), steps ST90 to ST98 are repeated with respect to measuring time T ni with the incremented of i. When the sorting operation of steps ST90-ST98 is completed (YES in step ST99), the editing operation preformed by host computer 1 is completed.
Provided that the file attained with respect to the time relationship shown in FIG. 10A is as shown in FIG. 10D, this file can be as illustrated in FIG. 10E when the form shown in FIG. 7 is used.
The following is a summary of the above operation. A nurse collects measured data using HTs, and couples the HTs to the host computer at a later time to transfer all the collected data to the host computer. The host computer classifies the collected data on the basis of the measurement items and measuring times, and provides a hard or soft copy corresponding to a temperature chart using the X-Y plotter or the like coupled to the computer. The data transferring work, which is to be manually performed according to a prior art systems, can be automatically executed using HTs and the host computer, so that data can easily be managed in a single file.
The above embodiment has been explained with reference to a control system in a ward; however, it can also be applied to data management in a plant, for example.
As has been explained above, according to this invention, data, even if entered in a disorderly manner, can be edited on the basis of the measurement items and measuring times in such a form as to easily provide tables and graphs at a later time.
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A data processing method uses a file which has sequentially arranged records each having a data area for designating the number of measurements for each object or target to be measured, a data area provided for each of a plurality of pre-set measurement items, and a data area for storing data relating to the different times at which the items were measured. When measured data of each item are entered in the file, the time which has elapsed since the entry of the preceding measured data is determined. If the time is greater than a predetermined time, or if it is smaller than the predetermined time but the measured items are the same as the previously-measured items, then the data of the number of the preceding measurements is updated, the current measured data is stored in the data areas of the associated measurement items of the next record, and the data of the current measuring time is stored in the measuring time data area of that record. If the time which has elapsed is within the predetermined time and the measured items differ from the previous ones, the current measured data is stored in the data areas of the associated measurement items of the same record as used for recordintg the preceding measured data.
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FIELD OF THE INVENTION
[0001] The present invention relates to a line for producing vehicles of different models while conveyance devices carrying vehicle bodies thereon are conveyed along a conveyance line.
BACKGROUND OF THE INVENTION
[0002] Choosing automobiles that match one's lifestyle is a recent trend, and a stronger demand exists for compact (small-sized) automobiles having a smaller occupant capacity (two to three people) in the same way as for ordinary (regular-sized) automobiles that have a regular occupant capacity (five people).
[0003] Since compact automobiles have an occupant capacity of two to three people, they need only one row of seats, and the total length of the automobile can be shortened to approximately half the length of an ordinary automobile.
[0004] A production line designated for compact automobiles must be newly prepared in order to manufacture the compact automobiles. However, the need to prepare a new production line designated for compact automobiles raises the equipment costs of production lines and poses an obstacle to keeping the costs of such compact automobiles low.
[0005] Additionally, extra space must be ensured within the production factory in order to prepare a new production line designated for compact automobiles.
[0006] One example of a production line is a mixed production line for producing vehicles of different models, such as sports cars or station wagons, as is disclosed in the Japanese Publication JP 63-013857 A or Japanese Patent No. 3008220.
[0007] Sports cars, stations wagons, and other vehicle models each have different numbers of components. A mixed production line for producing vehicles with different numbers of components is provided with a bypass conveying line.
[0008] For example, mixed production with vehicles having a small number of components is adjusted by causing vehicles having a large number of components to go through the bypass conveying line.
[0009] It is possible to absorb the difference in the number of components by using a bypass production line because sports cars, station wagons, and other vehicles merely have small differences in the numbers of components.
[0010] However, compact automobiles have approximately half the number of components of ordinary automobiles. Consequently, in the mixed production line disclosed in JP 63-13857 A, when compact automobiles are incorporated into an ordinary automobile production line, the number of steps for assembling a compact automobile is approximately half the number of steps for assembling an ordinary automobile.
[0011] When the number of steps for assembling a compact automobile decreases by half, it is difficult to adequately absorb the difference in the number of components by using the bypass conveying line disclosed in JP 63-13857 A. In this case, the solution is to set the assembly operation time for compact automobiles in accordance with the assembly operation time for larger automobiles.
[0012] Therefore, there is much idle time in the assembly operation for compact automobiles, and it is difficult to produce compact automobiles efficiently.
SUMMARY OF THE INVENTION
[0013] It is therefore an object of the present invention to provide a production line for vehicles of different models that can produce compact automobiles more efficiently when compact automobiles having different numbers of components than ordinary automobiles are incorporated into an ordinary automobile production line.
[0014] According to a first aspect of the present invention, there is provided a production line for vehicles of different models, including a plurality of conveying mechanisms for conveying along a conveying line respective conveyance devices with vehicle bodies carried thereon in such a manner as to allow components to be installed on the vehicle bodies, wherein each of the conveying devices is adapted to carry two of the vehicle bodies.
[0015] Compact automobiles herein have approximately half the number of components of an ordinary automobile, for example. It is possible to form a single unit from the vehicle bodies of two compact automobiles in the production line by mounting two compact automobile vehicle bodies on a conveying hanger.
[0016] Two unitized vehicle bodies have approximately the same number of components as an ordinary automobile, and the number of assembly steps is approximately the same as an ordinary automobile. Consequently, two unitized vehicle bodies can have the same number of assembly steps as the vehicle body of an ordinary automobile. Thereby, when the vehicle bodies of compact automobiles and ordinary automobiles are produced together, compact automobiles can be produced more efficiently without any idle time in the steps of assembling the compact automobiles.
[0017] In the production line described above, it is preferred that in a state in which two vehicle bodies are mounted on a conveyance device, the total length of the two mounted vehicle bodies be equal to the maximum total length of an ordinary vehicle body that can be conveyed along the conveying line. Consequently, conveyance devices for mounting two vehicle bodies can be placed at the same intervals as conveyance devices for mounting one vehicle body of an ordinary automobile. Two unitized vehicle bodies can thereby be conveyed at the same intervals as vehicle bodies of ordinary automobiles, and compact automobiles can be produced more efficiently.
[0018] In a state in which two vehicle bodies are mounted on a conveyance device, it is preferred that the total length of the two mounted vehicle bodies be less than the maximum total length of an ordinary vehicle body that can be conveyed along the conveying line.
[0019] In a state in which two vehicle bodies are mounted on a conveyance device, it is preferred that each of the two mounted vehicle bodies is the body of a vehicle having an occupant capacity of two people.
[0020] In a state in which two vehicle bodies are mounted on a conveyance device, it is preferred that the two mounted vehicle bodies be mounted on the conveyance device so that rear parts thereof face each other.
[0021] According to a second aspect of the present invention, there is provided a production line for vehicles of different models, which comprises: a conveying line; and a plurality of conveyance devices adapted to be conveyed along the conveying line and designed to carry a single first vehicle body, wherein one of the conveyance devices is configured to carry two second vehicle bodies of a different model than the first vehicle body.
[0022] The first vehicle body may, for example, be a vehicle body of an ordinary automobile according to the embodiments, and the second vehicle body may be a vehicle body of a compact automobile. The total length of two compact automobiles is approximately equal to the total length of one ordinary automobile.
[0023] The conveyance device preferably has multiple brackets for supporting a first vehicle body or two second vehicle bodies in the anteroposterior direction of the mounted vehicles. Therefore, the conveyance device can support a single first vehicle body, and can also support two second vehicle bodies.
[0024] According to a third aspect of the present invention, there is provided a method for producing vehicles of different models, comprising the steps of: conveying multiple conveyance devices, each of which is used for mounting a single first vehicle body, along a conveying line; and mounting two second vehicle bodies on each of the conveyance devices when the second vehicle bodies of a different model than the first vehicle body are incorporated into the conveying line.
[0025] According to a fourth aspect of the present invention, there is provided a production line for vehicles of different models, comprising: a conveying line; a plurality of first conveyance devices conveyed along the conveying line and used for mounting a first vehicle body; and a sub-line whereby a plurality of second conveyance devices that are the same as the first conveyance devices and that carry second vehicle bodies are supplied to the conveying line with short intervals when the second vehicle bodies of a different model than the first vehicle body are incorporated and assembled in an array of the first vehicle bodies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Certain preferred embodiments of the present invention will be described in detail below, by way of example only, with reference to the accompanying drawings, in which:
[0027] FIG. 1 is a side elevational view showing a compact automobile produced in a production line according to the present invention;
[0028] FIG. 2 is a top plan view showing the compact automobile of FIG. 1 ;
[0029] FIG. 3 is a schematic view showing a production line for vehicles of different models according to a first embodiment of the present invention;
[0030] FIG. 4 is a side elevational view showing an ordinary vehicle body placed on a conveyance device shown in FIG. 3 ;
[0031] FIG. 5 is a side elevational view showing two compact vehicle bodies placed on the conveyance device of FIG. 3 ;
[0032] FIG. 6 is a schematic view showing the step of painting ordinary vehicle bodies and compact vehicle bodies in the production line of FIG. 3 ;
[0033] FIG. 7 is a schematic view showing the step of installing engines, suspension systems and other components in ordinary vehicle bodies and compact vehicle bodies in the production line of FIG. 3 ;
[0034] FIG. 8 is a schematic view showing the step of assembling exterior and interior components in ordinary vehicle bodies and compact vehicle bodies in the production line of FIG. 3 ; and
[0035] FIG. 9 is a schematic top plan view showing the production line for vehicles of different models according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] A first embodiment of the present invention will now be discussed with reference to FIGS. 1 to 8 . As shown in FIGS. 1 and 2 , a compact automobile 10 comprises an engine 13 disposed at the front of a vehicle body 11 , a right side door 14 disposed on the right side of the vehicle body 11 , a left side door 15 disposed on the left side of the vehicle body 11 , a driver seat 17 disposed on the right side within a passenger compartment 16 , a passenger seat 18 disposed on the left side within the passenger compartment 16 , left and right front wheels 21 , 21 disposed at the front of the vehicle body 11 , and left and right rear wheels 22 , 22 disposed at the rear of the vehicle body 11 .
[0037] The compact automobile 10 is a vehicle having an occupant capacity of two people, including the driver seat 17 and the passenger seat 18 .
[0038] The total length L 1 of the compact automobile 10 is approximately half the total length L 2 of an ordinary automobile 25 shown in FIG. 3C .
[0039] The first embodiment relates to a compact automobile 10 having an occupant capacity of two people, but this automobile may also have an occupant capacity of three people, in which case a center seat (not shown) is provided between the driver seat 17 and the passenger seat 18 , for example.
[0040] Referring to FIG. 3 , a vehicle production line 30 comprises a painting area 31 for painting a vehicle body 26 of the ordinary automobile 25 and the vehicle body 11 of the compact automobile 10 ; a drive system installation area 32 for installing drive systems composed of engines, suspension systems, and the like into the vehicle body 26 of the ordinary automobile 25 and the vehicle body 11 of the compact automobile 10 ; and an exterior and interior installation area 33 for installing side doors and seats in the vehicle body 26 of the ordinary automobile 25 and the vehicle body 11 of the compact automobile 10 .
[0041] The vehicle production line 30 further comprises a first conveying mechanism 35 for conveying the vehicle body 26 of the ordinary automobile 25 and vehicle bodies 11 , 11 of compact automobiles 10 in a suspended state; and a second conveying mechanism 36 for conveying the vehicle body 26 of the ordinary automobile 25 and vehicle bodies 11 , 11 of compact automobiles 10 in a mounted state.
[0042] In the exterior and interior installation area 33 shown in FIG. 3C , after side doors and seats are installed in the vehicle body 26 of the ordinary automobile 25 and the vehicle body 11 of the compact automobile 10 , front wheels 21 , 21 and rear wheels 22 , 22 are installed in the vehicle body 26 of the ordinary automobile 25 and the vehicle body 11 of the compact automobile 10 , thereby completing the assembly steps of the ordinary automobile 25 and the compact automobile 10 .
[0043] The first conveying mechanism 35 conveys the vehicle body 26 of the ordinary automobile 25 and the vehicle body 11 of the compact automobile 10 in a suspended state through the painting area 31 , and also conveys the vehicle body 26 of the ordinary automobile 25 and the vehicle body 11 of the compact automobile 10 in a suspended state through the drive system installation area 32 as shown in FIG. 3B .
[0044] The second conveying mechanism 36 conveys the vehicle body 26 of the ordinary automobile 25 and the vehicle body 11 of the compact automobile 10 in a mounted state on a belt conveyor through the exterior and interior installation area 33 .
[0045] FIG. 4 shows the vehicle body 26 of an ordinary automobile mounted on the first conveying mechanism 35 , and FIG. 5 shows vehicle bodies 11 , 11 of compact automobiles mounted on the first conveying mechanism 35 .
[0046] The first conveying mechanism 35 comprises a guide rail (conveying line) 41 provided above the painting area 31 and the drive system installation area 32 shown in FIG. 3 , a carrier 42 moveably suspended from the guide rail 41 , a conveying hanger (conveying device) 43 provided to the suspended carrier 42 , and a moving device (not shown) for moving the carrier 42 along the guide rail 41 .
[0047] The suspended carrier 42 is linked to the guide rail 41 via a support arm 45 . Rollers (not shown) are provided at the top end of the support arm 45 . The suspended carrier 42 is disposed to be movable along the guide rail 41 via the rollers.
[0048] The conveying hanger 43 is composed of right and left front hanger frames 46 , 47 provided at the front end of the carrier 42 , right and left rear hanger frames 48 , 49 provided at the rear end of the carrier 42 , a right support 51 provided at the bottom ends of the right front hanger frame 46 and the right rear hanger frame 48 , and a left support 52 provided at the bottom ends of the left front hanger frame 47 and the left rear hanger frame 49 .
[0049] The right and left front hanger frames 46 , 47 are bilaterally symmetric, as are the right and left rear hanger frames 48 , 49 .
[0050] A first right bracket 51 a is provided at the front end of the right support 51 , a second right bracket 51 b is provided at the rear end, a third right bracket 51 c is provided behind the first right bracket 51 a (in proximity to the right front hanger frame 46 ), and a fourth right bracket 51 d is provided in front of the second right bracket 51 b (in proximity to the right rear hanger frame 48 ).
[0051] A first left bracket 52 a is provided at the front end of the left support 52 , a second left bracket 52 b is provided at the rear end, a third left bracket 52 c is provided behind the first left bracket 52 a (in proximity to the left front hanger frame 47 ), and a fourth left bracket 52 d is provided in front of the second left bracket 52 b (in proximity to the left rear hanger frame 49 ).
[0052] The right and left supports 51 , 52 are bilaterally symmetrical, and the first through fourth right brackets 51 a to 51 d, as well as the first through fourth left brackets 52 a to 52 d, are also bilaterally symmetrical.
[0053] One example of the aforementioned moving device is a setup in which the suspended carrier 42 is connected by a chain (not shown), and the chain is driven to move the suspended carrier 42 along the guide rail 41 as shown by the arrow.
[0054] An example of mounting the vehicle body 26 of the ordinary automobile 25 on the conveyance device 43 will be described with reference to FIG. 4 . The vehicle body 26 of the ordinary automobile 25 is hereinbelow referred to as a “ordinary vehicle body 26 .”
[0055] The third right bracket 51 c of the right support 51 and the third left bracket 52 c of the left support 52 bear the front part 26 a of the ordinary vehicle body 26 . The fourth right bracket 51 d of the right support 51 and the fourth left bracket 52 d of the left support 52 bear the rear part 26 b of the ordinary vehicle body 26 . The ordinary vehicle body 26 is mounted facing forward on the conveying hanger 43 .
[0056] An example of mounting a vehicle body 11 of a compact automobile 10 on both the front half 43 a and rear half 43 b of the conveying hanger 43 will be described with reference to FIG. 5 . Hereinbelow, the vehicle body 11 of the compact automobile 10 mounted facing forward on the front half 43 a of the conveying hanger 43 is referred to as the “forward-facing compact vehicle body 11 ,” and the vehicle body 11 of the compact automobile 10 mounted facing backward on the rear half 43 b of the conveying hanger 43 is referred to as the “backward-facing compact vehicle body 11 .”
[0057] The first right bracket 51 a of the right support 51 and the first left bracket 52 a of the left support 52 bear the front part 11 a of the forward-facing compact vehicle body 11 . The third right bracket 51 c of the right support 51 and the third left bracket 52 c of the left support 52 bear the rear part 11 b of the forward-facing compact vehicle body 11 . The forward-facing compact vehicle body 11 is mounted facing forward on the front half 43 a of the conveying hanger 43 .
[0058] The second right bracket 51 b of the right support 51 and the second left bracket 52 b of the left support 52 bear the front part 11 a of the backward-facing compact vehicle body 11 . The fourth right bracket 51 d of the right support 51 and the fourth left bracket 52 d of the left support 52 bear the rear part 11 b of the backward-facing compact vehicle body 11 . The backward-facing compact vehicle body 11 is mounted facing backward on the rear half 43 b of the conveying hanger 43 .
[0059] Thus, the forward-facing compact vehicle body 11 is mounted facing forward on the front half 43 a of the conveying hanger 43 , and the backward-facing compact vehicle body 11 is mounted facing backward on the rear half 43 b of the conveying hanger 43 , whereby two compact automobiles 10 are mounted on a single conveying hanger 43 .
[0060] The compact automobiles 10 shown in FIG. 5 have a total length L 1 ( FIG. 3 ), and the ordinary automobile 25 shown in FIG. 3 has a total length L 2 ( FIG. 2 ). The total length L 1 is reduced to about half of the total length L 2 .
[0061] For the sake of convenience, the total length L 2 of the ordinary automobile 25 is assumed to be the maximum total length of a vehicle body that can be conveyed along the guide rail 41 .
[0062] With the two compact vehicle bodies 11 mounted on the conveying hanger 43 , the total length L 3 of the two mounted compact vehicle bodies 11 is either approximately equal to the maximum total length L 2 of a vehicle body that can be conveyed along the guide rail 41 , or is kept smaller than the maximum total length L 2 .
[0063] In the first embodiment, the total length L 3 of the two mounted compact vehicle bodies 11 is described as being approximately equal to the maximum total length L 2 .
[0064] The following is a description, made with reference to FIGS. 6 through 8 , of an example of assembly in which four compact vehicle bodies 11 are incorporated among multiple ordinary vehicle bodies 26 in the vehicle production line 30 .
[0065] Two compact vehicle bodies 11 are formed into a single unit by being mounted on a conveying hanger 43 , as shown in FIG. 6 . The total length L 3 of two unitized compact vehicle bodies 11 is approximately equal to the total length L 2 (maximum total length L 2 ) of an ordinary automobile 25 .
[0066] Consequently, in the painting area 31 , both the conveyance devices 43 on which two compact vehicle bodies 11 are mounted as a single unit, and the conveying hangers 43 on which ordinary vehicle bodies 26 are mounted can be moved along the guide rail 41 at equal intervals P 1 in the direction of the arrow.
[0067] The surface area of a compact vehicle body 11 is approximately half the surface area of an ordinary vehicle body 26 . Therefore, the surface area of two unitized compact vehicle bodies 11 is approximately equal to the surface area of an ordinary vehicle body 26 .
[0068] Consequently, the time required to paint two unitized compact vehicle bodies 11 can be approximately equal to the time required to paint an ordinary vehicle body 26 .
[0069] Thus, two unitized compact vehicle bodies 11 can be conveyed at the same interval P 1 as an ordinary vehicle body 26 , and the painting time for a single unit of two compact vehicle bodies 11 can be approximately equal to the painting time for an ordinary vehicle body 26 . Consequently, when two unitized compact vehicle bodies 11 are incorporated among ordinary vehicle bodies 26 and painted, the compact vehicle bodies 11 can be painted in approximately the same time as an ordinary vehicle body 26 . The compact vehicle bodies 11 can thereby be painted efficiently.
[0070] FIG. 7 shows the steps of installing engines, suspension systems, and other components in ordinary vehicle bodies and compact vehicle bodies.
[0071] In the drive system installation area 32 , the ordinary vehicle bodies 26 and the compact vehicle bodies 11 are conveyed by conveying hangers 43 , similar to the painting area 31 . In the drive system installation area 32 , conveying hangers 43 on which two unitized compact vehicle bodies 11 are mounted, as well as conveying hangers 43 on which a single ordinary vehicle body 26 is mounted, are moved along the guide rail 41 at equal intervals P 1 in the direction of the arrow.
[0072] In the drive system installation area 32 , components that include engines 61 , front and rear suspension systems 62 , 63 , and the like are installed in the ordinary vehicle bodies 26 .
[0073] Similarly, components that include engines 13 , front and rear suspension systems 65 , 66 , and the like are installed in the compact vehicle bodies 11 .
[0074] The engines 13 of the compact vehicle bodies 11 are smaller and lighter than the engines 61 of the ordinary vehicle bodies 26 . The front and rear suspension systems 65 , 66 of the compact vehicle bodies 11 are smaller and lighter than the front and rear suspension systems 62 , 63 of the ordinary vehicle bodies 26 .
[0075] Consequently, the time required to install the engines 13 , front and rear suspension systems 65 , 66 , and the like in two of the unitized compact vehicle bodies 11 can be approximately equal to the time required to install the engine 61 and front and rear suspension systems 62 , 63 in one of the ordinary vehicle bodies 26 .
[0076] Thus, two unitized compact vehicle bodies 11 can be conveyed in the same interval P 1 as an ordinary vehicle body 26 , and the time required to install the engines 13 , front and rear suspension systems 65 , 66 , and the like in two of the unitized compact vehicle bodies 11 can be approximately equal to the time required to install the engine 61 , front and rear suspension systems 62 , 63 , and the like in one of the ordinary vehicle bodies 26 .
[0077] Consequently, when two unitized compact vehicle bodies 11 are incorporated among ordinary vehicle bodies 26 , and engines and suspension systems are installed in the two unitized compact vehicle bodies 11 , the assembly time can be approximately equal to the assembly time of an ordinary vehicle body 26 .
[0078] The engines 13 , front and rear suspension systems 65 , 66 , and other components can thereby be efficiently installed in the compact vehicle bodies 11 .
[0079] FIG. 8 shows the steps of installing exterior and interior components in ordinary vehicle bodies and compact vehicle bodies.
[0080] The ordinary vehicle bodies 26 and compact vehicle bodies 11 are conveyed through the exterior and interior installation area 33 on a belt conveyor (conveying line) 67 in the second conveying mechanism 36 .
[0081] Two of the compact vehicle bodies 11 are conveyed as a unit in the exterior and interior installation area 33 as well, similar to the painting area 31 ( FIG. 6 ) and the drive system installation area 32 ( FIG. 7 ).
[0082] Consequently, the two unitized compact vehicle bodies 11 can be moved by the belt conveyor 67 in the direction of the arrow at the same intervals P 1 as the ordinary vehicle bodies 26 .
[0083] In the exterior and interior installation area 33 , right and left front side doors 68 , 69 , right and left rear side doors 71 , 72 , driver seats 73 , passenger seats 74 , rear seats 75 , and other components are installed in the ordinary vehicle bodies 26 .
[0084] Similarly, right and left side doors 14 , 15 , driver seats 17 , passenger seats 18 , and other components are installed in the compact vehicle bodies 11 .
[0085] Thus, two doors, namely the right and left side doors 14 , 15 , are installed in each of the compact vehicle bodies 11 . Four doors, namely the right and left front side doors 68 , 69 and the right and left rear side doors 71 , 72 , are installed in each of the ordinary vehicle bodies 26 . Consequently, the time required to install side doors in two of the unitized compact vehicle bodies 11 is approximately equal to the time required to install side doors in one of the ordinary vehicle bodies 26 .
[0086] Furthermore, two seats, namely the driver seat 17 and the passenger seat 18 , are installed in each of the compact vehicle bodies 11 . Four seats, namely the driver seat 73 , the passenger seat 74 , and the rear seats 75 , are installed in each of the ordinary vehicle bodies 26 . Consequently, the time required to install seats in two of the unitized compact vehicle bodies 11 is approximately equal to the time required to install seats in each of the ordinary vehicle bodies 26 .
[0087] Thus, two of the unitized compact vehicle bodies 11 can be conveyed in the same interval P 1 as one of the ordinary vehicle bodies 26 , and the time required to install two side doors 14 , 15 , two seats 17 , 18 , and the like in the two unitized compact vehicle bodies 11 is approximately equal to the time required to install four side doors 68 , 69 , 71 72 , four seats 73 , 74 , 75 , and the like in the ordinary vehicle body 26 .
[0088] Consequently, when two unitized compact vehicle bodies 11 are incorporated among ordinary vehicle bodies 26 , and exterior and interior components are installed in two unitized compact vehicle bodies 11 , these components can be assembled in approximately the same time as the assembly time for an ordinary vehicle body 26 .
[0089] The right and left side doors 14 , 15 , driver seats 17 , passenger seats 18 , and other components are thereby efficiently installed in compact vehicle bodies 11 .
[0090] Furthermore, unitizing two compact vehicle bodies 11 makes it possible, for example, to install interior components such as roof panels, linings, and carpets in passenger compartments in pairs.
[0091] The installation costs of roof panels, linings, carpets, and other components of passenger compartments can thereby be reduced.
[0092] As described above, in the vehicle production line 30 of the first embodiment, two unitized compact vehicle bodies 11 can be painted in approximately the same amount of time as an ordinary vehicle body 26 , and the components of the two unitized compact vehicle bodies 11 can be installed in approximately the same amount of time as the components of the ordinary vehicle body 26 .
[0093] Consequently, two of the unitized compact automobiles 10 can be produced in approximately the same amount of time as one of the ordinary automobiles 25 .
[0094] Thereby, when the vehicle bodies 11 , 26 of the compact automobiles 10 and the ordinary automobile 25 are produced together, the compact automobiles 10 can be produced more efficiently.
[0095] Next, a vehicle assembly apparatus 80 of a second embodiment will be described with reference to FIG. 9 . In the vehicle assembly apparatus 80 of the second embodiment, components identical or similar to those in the vehicle assembly apparatus of the first embodiment are denoted by the same numerical symbols, and descriptions thereof are omitted.
[0096] FIG. 9 shows an example of a drive system assembly area in the vehicle assembly apparatus of the second embodiment.
[0097] The total length L 4 of a compact automobile 81 is sometimes less than the total length L 2 of the ordinary automobile 25 shown in FIG. 3 , and greater than half the total length L 2 .
[0098] In this case, when the vehicle bodies (hereinafter referred to as “compact vehicle bodies”) 82 of compact automobiles 81 are mounted in units of two on the conveying hanger 43 , the total length of each two of the unitized compact vehicle bodies 82 is greater than the total length L 2 of each of the ordinary vehicle bodies 26 . Therefore, it is difficult to mount and unitize the compact vehicle bodies 82 in pairs on the conveying hanger 43 .
[0099] In view of this, in the vehicle assembly apparatus 80 of the second embodiment, for example, the drive system assembly area 84 comprises a sub-line 86 , and dollies 42 and conveying hangers 43 can be provided to the guide rail 41 after the sub-line 86 .
[0100] In other words, when the compact vehicle bodies 82 are assembled together with the ordinary vehicle bodies 26 , the dollies 42 for mounting compact vehicle bodies 82 held in the sub-line 86 are added to the guide rail 41 during intervals.
[0101] The intervals P 2 between the dollies 42 for mounting the compact vehicle bodies 82 are thereby smaller than the intervals P 1 between the dollies 42 for mounting the ordinary vehicle bodies 26 .
[0102] Each of the compact automobiles 81 has fewer components than each of the ordinary automobiles 25 . Therefore, the intervals P 2 between the dollies 42 for mounting the compact vehicle bodies 82 are reduced to make the number of steps for assembling the multiple compact automobiles 81 match the number of steps for assembling each of the ordinary automobiles 25 . As an example, the number of steps for assembling five of the compact automobiles 81 matches the number of steps for assembling three of the ordinary automobiles 25 . Therefore, the time required to assemble five of the compact automobiles 81 is approximately the same as the time required to assemble three of the ordinary automobiles 25 , multiple automobiles of different models can be assembled with one assembly line, and the vehicles are produced more efficiently at low cost.
[0103] In the vehicle assembly apparatus 80 of the second embodiment shown in FIG. 9 , an example of a drive system assembly area 84 was described, but this description also applies to a painting area and an exterior and interior assembly area.
[0104] In the exterior and interior assembly area, the compact vehicle bodies 82 and ordinary vehicle bodies 26 can be conveyed by a conveyer instead of dollies 42 and conveyor hangers 43 on a guide rail 41 . Consequently, in the exterior and interior assembly area, the interval between the compact vehicle bodies 82 conveyed by the belt conveyor is P 2 , and the interval between the ordinary vehicle bodies 26 is P 1 .
[0105] As described above, in the vehicle assembly line 80 of the second embodiment, the number of steps for assembling multiple compact automobiles 81 can be matched with the number of steps for assembling ordinary automobiles 25 by reducing the intervals P 2 between dollies 42 for mounting compact vehicle bodies 82 . Thereby, when the compact automobiles 81 and ordinary automobiles 25 are produced together, the compact automobiles 81 can be produced more efficiently.
[0106] The shapes of the dollies 42 and conveying hangers 43 depicted in the previous embodiments are not limited to the examples depicted, and the designs thereof can be appropriately varied.
[0107] Obviously, various minor changes and modifications of the present invention are possible in light of the above teaching. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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A production line for vehicles of different models is disclosed, wherein vehicle bodies for ordinary automobiles and vehicle bodies for compact automobiles are incorporated on the same production line, and multiple components are installed. Two compact vehicle bodies are carried on a conveyance device which is designed for carrying a single ordinary vehicle body. The number of components of a compact automobile is approximately half the number of components of an ordinary automobile, and therefore compact automobiles can be produced efficiently without any downtime.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national phase application based on PCT/IB2010/052659, filed Jun. 15, 2010, which claims the priority of Italian Application No. MI2009A001238, filed Jul. 13, 2009, and the benefit of U.S. Provisional Application No. 61/213,848, filed Jul. 21, 2009, the content of all of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process and an apparatus for building tires for vehicle wheels.
2. Description of the Related Art
A tire for vehicle wheels generally comprises a carcass structure including at least one carcass ply having respectively opposite end flaps in engagement with respective annular anchoring structures, integrated into the regions usually identified as “beads”.
Associated with the carcass structure is a belt structure comprising one or more belt layers, located in radially superposed relationship with each other and with the carcass ply and provided with textile or metallic reinforcing cords having a crossed orientation and/or being substantially parallel to the circumferential extension direction of the tire.
A tread band is applied at a radially external position to the belt structure, which tread band is made of elastomeric material like other semifinished products constituting the tire.
Respective sidewalls of elastomeric material are further applied at an axially external position to the side surfaces of the carcass structure, each extending from one of the side edges of the tread band until close to the respective annular anchoring structure to the beads.
After building of the green tire by assembly of respective semifinished products, a vulcanization and molding treatment is generally carried out, which aims at determining the structural stabilization of the tire by cross-linking of the elastomeric compounds and also at impressing the tread band, wound up around the carcass before vulcanization, with a desired tread pattern and the region close to the tire sidewalls with possible distinctive graphic marks.
Within the present description and in the following claims, by “elastomeric material” it is intended a composition including at least one elastomeric polymer and at least one reinforcing filler. Preferably, this composition further comprises additives such as cross-linking agents and/or plasticizers. Due to the presence of the cross-linking agents, this material can be cross-linked by heating, so as to form the final article of manufacture.
Document WO 2009/040534 in the name of the same Applicant, discloses a process for manufacturing tires for vehicle wheels, which process comprises the steps of: building the carcass structure of a green tire on a first forming drum in at least one carcass-building line, building a crown structure on a second forming drum in at least one crown-building line, shaping the carcass structure into a toroidal conformation, while it is being assembled to the crown structure in at least one assembly and shaping station. The assembly and shaping station is synchronized with the carcass-building line and the crown-building line. Each carcass structure is associated with the respective first forming drum on which it is built up to the end of the assembly and shaping step. The above mentioned stations are operatively associated with units adapted to supply elementary semi-finished products, such as continuous elongated elements of elastomeric material, strips of elastomeric material containing two or more textile or metallic cords, individual textile or metallic of coated with elastomeric material. Once the careen tire has been built, it is cured and molded in at least one vulcanization and molding line separated from the building line. In the above described work stations, said elementary semi-finished products can be wound up into coils disposed in side by side relationship and/or at least partly superposed, such as in the case of the continuous elongated elements for example, contributing to formation of the liner, under-liner, under-layers, fillers present in the regions of the beads, sidewalls, tread band.
In this regard, document EP 1 375 118 discloses a green tire, or a tire component, that is manufactured by winding into coils and rolling a rubber strip on a building drum. To this aim, a building device comprises a rigid support or building drum, on which the rubber strip is wound into coils and rolled, an extruder adapted to extrude the rubber strip, a winder for winding the rubber strip on the rigid support, and a flattening roller, adapted to flatten the projection of a step portion produced by a first part of the rubber strip and a second part of the same rubber strip overlapping the first one. Flattening prevents the residual air from remaining entrapped during vulcanization, in the regions close to the step portions between the outer surface of the tire component and the vulcanization mold and avoids the consequent presence of hollows and slits in the finished tire. The surface of the flattening roller is provided with a knurl. The step of spirally winding and rolling the rubber strip and the flattening step can be carried out simultaneously.
Document EP 1 754 592 discloses a method of building a tire, said method allowing elimination of the residual air between the step portions of an overlapped portion of a tire component and the vulcanization mold, so as to avoid formation of hollows, slits, etc. causing a reduction in the tire lifetime. The method comprises the steps of flattening a step formed at an overlapped portion of a tire component and optimizing the cross-section shape of said overlapped portion. The apparatus used for putting this method into practice comprises a building platform, an extruder for extrusion of a rubber strip and a pressure roller. A component of the tire is formed by spirally winding the rubber ribbon-like strip, extruded through the extruder, on the building platform and forming an overlapped portion of this rubber strip. A step of this overlapped portion that is exposed on the outer surface of the tire component is flattened under pressure through the pressure roller that is such disposed as to face the building platform by a specific angle relative to the extension direction of the rubber strip and is heated to the plasticization temperature in order to make the outer tire surface smooth.
SUMMARY OF THE INVENTION
The Applicant has noticed that, in addition to the air entrapped between the steps defined by the rubber strip and the cavity of the vulcanization mold, as described in documents EP 1 754 592 and EP 1 375 118 mentioned above, also air pockets or more generally gas pockets are formed under the continuous elongated element of elastomeric material already during laying of said element into at least partly superposed coils. During vulcanization, since the radially outermost (tread band) and radially innermost (the liner, for example) surface layers that are cured the first acquire imperviousness features, the air contained in these pockets remains entrapped therein or moves to the outer surface but does not escape therefrom, thus forming surface bubbles.
The Applicant has further noticed that the higher the laying temperature of the continuous elongated element is, the more important the just described phenomenon concerning formation of air pockets is, and that said temperature increases on increasing of the laying speed, or on decreasing of the time intervening between ejection of the compound of the continuous elongated element from the extruder and application of said element into coils on the respective forming drum.
The Applicant has therefore ascertained that this phenomenon is particularly significant in the processes for manufacturing tires for vehicle wheels like that described in the above mentioned document WO 2009/040594 in which the individual floor to floor times necessary for building the different tire portions such as the crown structure (belt structure and tread band) and carcass structure must be reduced to the minimum for obtaining high production rates.
The Applicant has perceived that by exerting pressure in a differentiated manner on the elongated element just laid, the air possibly entrapped between portions of the elongated element at least partly overlapping each other can escape easily and in a more efficient manner, avoiding the persistent presence of air pockets that can generate the above mentioned drawbacks.
The Applicant has finally found that, by exerting pressure on a central region of a portion of the continuous elongated element immediately after laying of same and by subsequently exerting pressure on the side regions of the same portion, it is possible to discharge the air possibly entrapped under said continuous elongated element and therefore avoid said air forming pockets and bubbles that would remain entrapped in the cured and molded tire.
More specifically, in a first aspect, the present invention relates to a process for building tires for vehicle wheels comprising the step of: assembling components of elastomeric material on a forming support, in which at least one of said components of elastomeric material is made by the steps of:
i) dispensing a continuous elongated element of elastomeric material;
ii) applying the continuous elongated element in the form of coils disposed in side by side relationship or at least partly superposed, wound up on the forming support in order to form said at least one tire component of elastomeric material;
iii) exerting a first pressure on a central region of a portion of the continuous elongated element applied onto the forming support;
iv) exerting a second pressure on side regions of said portion of the continuous elongated element applied onto the forming support.
It is the Applicant's opinion that the first pressure directs its force against the continuous elongated element squashing and pressing it in the middle, laterally moving the possible air bubbles entrapped thereby, while the second pressure spreads and smoothes the continuous elongated element on its sides forcing said air bubbles to the outside.
In accordance with a second aspect, the present invention relates to a tire for vehicle wheels built following the process as described and/or claimed.
In a third aspect, the present invention relates to an apparatus for building tires for vehicle wheels comprising: at least one forming support; at least one assembly device for assembling components of elastomeric material on the forming support; wherein said at least one assembly device comprises: at least one dispensing device for dispensing a continuous elongated element of elastomeric material; at least one application device for applying said continuous elongated element in the form of coils disposed in side by side relationship or at least partly superposed, wound up on the forming support, and forming said at least one component of elastomeric material of the tire; at least one pressure device operatively acting on an applied portion of the continuous elongated element; wherein the pressure device comprises a central roller and two side rollers, each laterally offset relative to the central roller and on the opposite side relative to the other side roller.
The present invention, in at least one of the above aspects can have one or more of the preferred features as hereinafter described.
Preferably step iv) follows step iii).
In this way, the pressure exerted on the central region moves possible air bubbles from the center to the sides of the continuous elongated element while, subsequently, pressures exerted on the side regions cause escape of the entrapped air from the side edges.
Preferably, between step ii) and step iii) a first time interval intervenes which is included between about 0 s and about 1 s.
In addition, preferably, between step iii) and step iv) a second time interval intervenes which is included between about 0 s and about 1 s.
The shorter the time intervening between distribution, application and compression of the continuous elongated element is, the greater the temperature and plasticity of the elastomeric material during the compression steps, and consequently the greater the ease with which the compound is deformed and molded.
In addition, preferably, during steps iii) and iv), said portion has an average temperature included between about 90° C. and about 110° C.
In a preferred alternative embodiment, along a direction orthogonal to the longitudinal extension of the continuous elongated element, the side regions are partly superposed on the central region according to a superposition width.
Preferably said superposition width is included between about 0.5 mm and about 5 mm.
Said superpositions ensure that pressure is exerted over the whole surface of the continuous elongated element so as to eliminate the persistent presence of underlying air bubbles.
In a preferred alternative embodiment of the process, during step iv) the second pressure is exerted on at least one side edge of the continuous elongated element.
In addition, preferably, during step iv), said at least one side edge is submitted to a hammering action.
By “hammering” it is intended application of micro-hits on the surface of the continuous elongated element, carried out by means of at least one roller for example, which is provided with a side work surface having raised elements and/or grooves (knurling),
Pressure exerted on the edge and hammering have a visual effect on the outer and visible components of the tire such as the tread band and sidewalls for example, because they squash the continuous elongated element wound into coils and create microfractures therein, so that the separation lines between adjacent coils become less visible also after vulcanization.
Preferably, step ii) is carried out at a linear application speed of the continuous elongated element included between about 0.1 m/s and about 2 m/s.
Compression of the continuous elongated element after application of same takes a fundamental importance for high application speeds, as those stated above, that are necessary for obtaining high production volumes. In fact, corresponding to the high speeds are high laying temperature to which the phenomena of air expansion and bubble generation are more important and frequent.
In a preferred alternative embodiment of the apparatus, the central roller has a rotation axis distinct from a rotation axis of the side rollers.
Preferably, along an application direction, the central roller is interposed between the application device and the two side rollers.
This structure allows pressure to be first exerted in the middle and subsequently on the side regions of the continuous elongated element.
Preferably, along an application direction, a first distance between the application device and the central roller is included between about 20 mm and about 200 mm.
Preferably, along an application direction, a second distance between the central roller and the two side rollers is included between about 10 mm and about 100 mm.
Since the application device too preferably comprises an applicator roller, these distances are intended measured between the contact points of the applicator roller and the rollers of the pressure device with the continuous elongated element applied onto the forming support.
Said distances must preferably be maintained within the stated limits for two reasons.
First of all, for compressing the continuous element when the compound is still very hot (the smaller the distance is, the shorter the time intervening between application and compression), for the already highlighted reasons; and in addition, for limiting a misalignment between the center line of the application device and the center line of the pressure device. In fact the continuous elongated element is spirally wound on the forming support according to a determined spiraling angle, measured between a longitudinal extension direction of the continuous elongated element and a plane orthogonal to the rotation axis of the forming support. Misalignment between the center line of the application device and the center line of the pressure device and, as regards the individual pressure device, misalignment between the center line of the central roller and the center line of the side rollers allow the just laid portion of the continuous elongated element to be correctly compressed. These misalignments that should be set at each laying cycle with suitable adjustment mechanisms based on the concerned geometries and speeds, can be neglected if the above mentioned distances are of rather small value.
According to a preferred embodiment, a peripheral work surface of the central roller at least partly faces at least one of the peripheral work surfaces of the side rollers.
Preferably, along a direction parallel to rotation axes of the central roller and side rollers, the peripheral work surface of the central roller has a superposition width with said at least one of the peripheral work surfaces of the side rollers included between about 0.5 mm and about 5 mm.
The relative position between the rollers ensures that the whole surface of the continuous elongated element is submitted to pressure.
According to a preferred embodiment, the central roller and each of the side rollers are movable irrespective of each other along a direction substantially orthogonal to the forming support.
Preferably, the pressure device comprises spring elements operatively associated with the central roller and the two side rollers, to maintain said rollers into contact with said portion of the continuous elongated element.
In addition, preferably, each of the spring elements is associated with one of the rollers in a manner independent of the others.
In addition, preferably, the spring elements are pneumatic cylinders.
Contact between each of the rollers and the continuous elongated element is ensured under any laying condition and for every speed and laying angle.
According to a preferred embodiment, the pressure device comprises: a supporting frame and a central small arm having a central portion thereof hinged thereon.
Preferably said central small arm carries the central roller on a first end thereof.
Preferably the pressure device further comprises a first spring element mounted on the supporting frame and secured to a second end of the central small arm.
More preferably, said pressure device comprises two side small arms positioned on opposite sides of the central small arm, each having a central portion thereof hinged on the supporting frame and carrying one of the side rollers on a first end thereof.
In a further preferred alternative solution, said pressure device comprises two second spring elements, each mounted on the supporting frame and secured to a second end of a respective side small arm.
The specific structure adopted is of simple and cheap structure and at the same time stiff and reliable, so as to ensure a correct and precise laying and pressing of the continuous elongated element.
According to a preferred embodiment, the assembly device comprises a head supporting the application device and pressure device.
Alignment between the application device and pressure device is ensured by the fact that they are mounted as a single assembly.
Preferably, the central roller has a peripheral contact edge having a radius of curvature in diametrical section that is included between about 0.5 mm and about 3 mm.
Preferably, each of the two side rollers has a peripheral contact edge having a radius of curvature in diametrical section included between about 0.5 mm and about 3 mm.
In addition, preferably, the diametrical section of each of the two side rollers is asymmetric and said peripheral contact edge is the external one.
Said radius of curvature and the position of the peripheral edge are such selected as to exert a predetermined pressure at a predetermined point of the continuous elongated element.
Preferably, a peripheral work surface of the central roller has a width included between about 3 mm and about 10 mm.
Preferably, a peripheral work surface of each of the side rollers has a width included between about 3 mm and about 10 mm.
Preferably, the side rollers have a minimum distance from each other included between about 3 mm and about 10 mm.
Preferably, the central roller has a maximum diameter included between about 20 mm and about 80 mm.
Preferably, each of the side rollers has a maximum diameter included between about 20 mm and about 80 mm.
The geometry and sizes of the rollers enable compression of the whole surface of the continuous elongated element to be compressed and also the steps defined by the superposed adjacent coils to be flattened, thus helping in eliminating the traces of the elongated element on the tread band and/or the sidewalls of the cured and molded tire.
Also helping in this second function is a peripheral work surface of the central roller and of each of the side rollers having raised elements for exerting a hammering action on the portion of the continuous elongated element.
Further features and advantages will become more apparent from the detailed description of a preferred but not exclusive embodiment of an apparatus for building tires for vehicle wheels in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
This description will be set out hereinafter with reference to the accompanying drawings, given by way of non-limiting example, in which:
FIG. 1 is a diagrammatic top view of a plant for tire production comprising an apparatus for building tires in accordance with the present invention;
FIG. 2 is a diagrammatic side view of an assembly device being part of the apparatus in question and comprising a pressure device in accordance with the present invention;
FIG. 3 shows an enlarged portion of the assembly device seen in FIG. 2 ;
FIG. 4 a is a side view of the pressure device seen in FIG. 2 ;
FIG. 4 b is a front view of the pressure device seen in FIG. 2 ;
FIG. 5 shows an enlarged portion of the pressure device in FIG. 4 b with a forming support carrying a continuous elongated element already laid and spaced apart from the pressure device, for the sake of clarity;
FIG. 5 a is a diagrammatic plan view showing rollers of the pressure device acting on the continuous elongated element;
FIG. 6 is a diagrammatic diametrical section of a tire for vehicle wheels obtained with the plant seen in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings, a plant for tire production comprising an apparatus 2 for building tires in accordance with the present invention has been generally identified with reference numeral 1 .
Plant 1 is intended for manufacturing tires 3 ( FIG. 6 ) essentially comprising at least one carcass ply 4 preferably internally coated with a layer of airtight elastomeric material or a so-called “liner”, two so-called “beads” 6 integrating respective annular anchoring structures 7 possibly associated with elastomeric fillers 7 a and in engagement with the circumferential edges of the carcass ply 4 , a belt structure 8 applied to the carcass ply 4 at a radially external position, a tread band 9 applied to the belt structure 8 at a radially external position, in a so-called crown region of the tire 3 , and two sidewalls 10 applied to the carcass ply 4 at laterally opposite positions, each at a side region of the tire 3 , extending from the corresponding bead 6 to the corresponding side edge of the tread band 9 .
Apparatus 2 for building tires preferably comprises a line for building carcass structures 11 , in which a carcass structure comprising at least one of the carcass plies 4 and the annular anchoring structures 7 is formed on a first forming drum 12 ′. Denoted in FIG. 1 are a plurality of work stations 13 belonging to said line 11 for building carcass structures and each dedicated to formation and/or application of a component of elastomeric material of tire 3 on the first forming drum 12 ′. The first forming drum 12 ′ is sequentially transferred from one station to the following one, by means of robotized arms, not shown, or other suitable devices.
By way of example, in a first station 13 liner 5 is made through winding of a continuous elongated element of elastomeric material into coils disposed mutually in side by side relationship and/or at least partly superposed and distributed along the forming surface of the first forming drum 12 ′. In at least one second station 13 manufacture of one or more carcass plies 4 can be carried out, which carcass plies are obtained by laying strip-like elements on the first forming drum 12 ′, in circumferentially approached relationship, said strip-like elements being formed by cutting to size a continuous strip of elastomeric material comprising textile or metallic cords disposed parallel in side by side relationship. A third building station 13 can be dedicated to integration of the annular anchoring structures 7 with said at least one carcass ply 4 , through application of said annular anchoring structures 7 at an axially external position to the flaps of said at least one carcass ply 4 knocked down in the direction of the rotation axis of said first forming drum 12 ′, which flaps will be subsequently turned up around the annular anchoring structures 7 .
Apparatus 2 for building tires further comprises a line for building crown structures 14 , in which a crown structure comprising at least the belt structure 8 and tread band 9 is formed on a second forming drum 12 ″. Denoted in FIG. 1 is a plurality of work stations belonging to said line 14 for building crown structures and each dedicated to forming and/or applying a component of elastomeric material of tire 3 on the second forming drum 12 ″. The second forming drum 12 ″ is sequentially transferred from one station to the subsequent one, by means of robotized arms, not shown, or other suitable devices.
At least one building station 15 can be dedicated to manufacture of the annular belt structure 8 obtained by laying strip-like elements in circumferentially approached relationship, which strip-like elements are obtained by cutting to size a continuous strip of elastomeric material comprising preferably metallic mutually parallel cords, and/or by winding a textile or metallic rubberized reinforcing cord into axially approached coils, in the crown portion of tire 3 . By way of example, a work station 15 can be intended for manufacture of the tread band 9 or sidewalls 10 . Tread band 9 and sidewalls 10 are preferably obtained by winding of at least one continuous elongated element of elastomeric material into mutually approached and/or at least partly superposed coils.
Apparatus 2 is further provided with an assembly and conformation station 16 operatively associated with line 11 for building carcass structures and line 14 for building crown structures. In the assembly and conformation station 16 the carcass structure is shaped and associated with the crown structure, so as to obtain a green tire.
Tires built by apparatus 2 are sequentially transferred to a vulcanization unit line 17 integrated into plant 1 from which cured and molded tires 3 are obtained.
As mentioned above, in accordance with the present invention, at least one of the components of only elastomeric material of tire 3 , such as liner 5 , fillers 7 a and/or other parts of elastomeric material of beads 6 , sidewalls 10 , tread band 9 , underliner, underbelt layer, underlayer of the tread band, abrasion-proof elements and/or others, is obtained by an assembly device denoted as a whole at 18 ( FIG. 2 ).
The assembly device 18 comprises a dispensing device in the preferred form of an extruder (not shown), producing a continuous elongated element 19 of elastomeric material. The extruder is provided with a cylinder into which elastomeric material is introduced. The cylinder heated to a controlled temperature, just as an indication included between about 60° C. and about 100° C., operatively houses a rotating screw, by effect of which the elastomeric material is pushed along said cylinder to an outlet orifice of the extruder.
Through the outlet orifice, the continuous elongated element 19 is dispensed at a desired linear speed, corresponding to a so-called “target value” of the volumetric flow rate, just as an indication included between about 10 cm 3 /s and about 60 cm 3 /s, and at a temperature just as an indication included between about 90° C. and about 110° C.
An application device 20 , operating downstream of the extruder, carries out application of the continuous elongated element 19 coming from the extruder, onto a forming support 12 . The forming support 12 can be said first forming drum 12 ′ or said second forming drum 12 ″.
During application, the forming support 12 , supported in overhanging by one of said robotized arms for example, is driven in rotation and suitably moved in front of the application device 20 for distributing the continuous elongated element 19 into approached and/or at least partly superposed coils, wound around such a forming support 12 , so as to form liner 5 for example, or any other component of elastomeric material of the tire being processed.
The application device 20 comprises ( FIG. 2 ) at least one roller or other applicator member 21 acting in thrust relationship towards the forming support 12 , for instance by effect of a pneumatic actuator 22 , for applying the continuous elongated element 19 onto the forming support 12 itself.
Operatively interposed between the extruder and the application device 20 is a conveyor 23 , the function of which consists in bringing the continuous elongated element 19 coming out of the extruder onto the forming support 12 and until the application device 20 .
In the preferred embodiment herein illustrated, the conveyor 23 comprises a conveyor belt 24 defined by a cogged rubber belt or a metal belt, passing over rollers 24 a , 24 b . The conveyor belt 24 on the upper part has a forward stretch supporting the elongated element 19 .
The continuous elongated element 19 coming out of the conveyor belt 24 at the end roller 24 a is continuously laid on support 12 by the applicator roller 21 . In particular, the applicator roller 21 presses the continuous elongated element 19 sliding under and against it, against the forming support 12 for determining adhesion of same. The applicator roller 21 therefore rotates in the opposite direction relative to rotation of the forming support 12 .
Downstream of the applicator member 21 there is a pressure device 27 which is preferably mounted on a head 28 also carrying the application device 20 . The applicator member 21 and pressure device 27 are further operatively supported relative to conveyor 23 . The head 28 is in fact mounted on a structure holding the conveyor 23 .
The pressure device 27 , better shown in FIGS. 3, 4 a , 4 b and 5 , comprises a substantially box-shaped supporting frame 29 formed with an upper wall 30 and a pair of side walls 31 a defining an inverted-U shape. A bottom wall 31 b connects the two side walls 31 a and is secured to head 28 .
Respective fixed arms are secured to lower portions of the side walls 31 a , which arms each have a first end 32 a integral with the supporting frame 29 and a second end 32 b . The second ends 32 b of the two fixed arms 32 face each other for supporting a central roller 33 a and two side rollers 33 b , as described in detail in the following.
In particular, a central small arm 34 is hinged, at a central portion thereof, on the second ends 32 b of the fixed arms 32 around a first articulation axis “X-X”. A first end 34 a of the central small arm 34 has a fork rotatably carrying the central roller 33 a . E second end 34 b of the central small arm 34 , opposite to the first one 34 a , is hinged on a spring element 35 in turn mounted on the supporting frame 29 . Preferably, as in the embodiment shown, the spring element 35 is a pneumatic cylinder. An end of the pneumatic cylinder 35 , belonging to the rod 35 a of the cylinder 35 itself is hinged on said central small arm 34 around a second articulation axis “Y-Y” and an opposite end, belonging to the body 35 b of the cylinder 35 , is hinged on a bracket integral with the upper wall 30 of the supporting frame 29 .
Two side small arms 36 are positioned on opposite sides of the central small arm 34 . The lateral small arms 36 are parallel to each other and cross the central small arm 34 . Each of the lateral small arms 36 has a central portion thereof hinged on the second ends 32 b of the fixed arms 32 and on the central small arm 34 around the first articulation axis “X-X”. A first end 36 a of each of the lateral small arms 36 rotatably carries one of the side rollers 33 b . A second end 36 b of each of the lateral small arms 36 , opposite to the first one 36 a , is hinged on a respective spring element 37 in turn mounted on the supporting frame 29 .
Preferably, as in the embodiment shown, each of the two spring elements 37 is a pneumatic cylinder an end of each of the pneumatic cylinders 37 belonging to the rod 37 a of cylinder 37 , is hinged on the respective lateral small arm 36 around a third articulation axis “Z-Z” and an opposite end, belonging to the body 37 b of the cylinder 37 , is hinged on a bracket integral with the upper wall 30 of the supporting frame 29 . Each of the pneumatic cylinders 37 is associated with one of rollers 33 b in a manner independent of the others.
The central roller 33 a , two side rollers 33 b and the applicator roller 21 have rotation axes that are substantially parallel to each other. The central roller 33 a is substantially aligned with the applicator roller 21 along a trajectory or application direction of the continuous elongated element on the forming support 12 . The two side rollers 33 b are coaxial to each other and offset towards opposite sides of the central roller 33 a ( FIGS. 5 and 5 a ).
The central roller 33 a has a rotation axis “A-A” distinct from the rotation axis “B-B” of the side rollers 33 b and the rotation axis “C-C” of the applicator roller 21 . In particular, along said application direction, the central roller 33 a remains positioned between the applicator roller 21 and the two side rollers 33 b ( FIG. 3 ).
The central roller 33 a has ( FIG. 5 a ) a maximum diameter “Da”, intended as the diameter of the radially outermost portion, included between about 20 mm and about 80 mm. Each of the side rollers 33 b has a maximum diameter “Db” included between about 20 mm and about 80 mm.
Immediately after laying carried out by the applicator member 21 , the central roller 33 a exerts a first pressure “P 1 ” on a central region 38 of the just laid portion of the continuous elongated element 19 , and subsequently the two side rollers 33 b exert respective second pressures “P 2 ” on side regions 39 of the same portion ( FIGS. 5 and 5 a ). The central 33 a and side 33 b rollers roll against the continuous elongated element 19 , that has already adhered to the forming support 12 and rotate in opposite ways relative to the rotation direction of said forming support 12 .
Downstream of the pressure device 27 , therefore, the continuous elongated element 19 laid on the forming support 12 has a central strip compressed by the central roller 33 a and two side strips compressed by the side rollers 33 b ( FIG. 5 a ).
The pneumatic cylinders 35 , 37 push rollers 33 a , 33 b against the continuous elongated element 19 and, through the central small arm 34 and lateral small arms 36 , maintain rollers 33 a , 33 b in contact with the continuous elongated element 19 . Due to the described structure, the central roller 33 a and each of the side rollers 33 b are movable independently of each other along a direction substantially orthogonal to the peripheral surface of the forming support 12 .
The portion of the continuous elongated element 19 that has just come out of the extruder and has been submitted to said pressures “P 1 ”, “P 2 ”, has an average temperature “t m ” substantially equal to or not much lower than the exit temperature and preferably included between about 90° C. and about 110° C.
Distance “d 1 ” between the rotation axis “C-C” of the applicator roller 21 and the rotation axis “A-A” of the central roller 33 a is preferably included between about 20 mm and about 200 mm. Distance “d 2 ” between the rotation axis “A-A” of the central roller 33 a and the rotation axis “B-B” of the side rollers 33 b is preferably included between about 10 mm and about 100 mm ( FIGS. 3 and 5 a ).
As a result, a first distance “ΔS 1 ” measured along the application direction between the application device 20 and central roller 33 a , intended as the distance measured between the contact point of the applicator roller 21 with the continuous elongated element 19 and the contact point of the central roller 33 a with the continuous elongated element 19 , is included between about 20 mm and about 220 mm.
A second distance “ΔS 2 ” measured along the application direction between the central roller 33 a and the two side rollers 33 b , intended as the distance measured between the contact point of the central roller 21 with the continuous elongated element 19 and the axis passing by the two contact points between the side rollers 33 b and the continuous elongated element 19 , is included between about 10 mm and about 110 mm.
The periods of time intervening between the action of the applicator roller 21 , the action exerted by the central roller 33 a and the action exerted by the side rollers 33 b on the same portion of continuous elongated element 19 depend on the above stated distances and the linear application speed “V” that is preferably included between about 0.1 m/s and about 2 m/s, more preferably between about 0.5 m/s and about 1.5 m/s.
Between laying of a portion of the continuous elongated element 19 and the pressing action carried out by the central roller 33 a on the same portion there is a first time interval “ΔT 1 ” included between about 0 s and about 1 s. In addition, between the pressing action carried out by the central roller 33 a and the pressing action carried out by the two side rollers 33 b there is a second time interval “ΔT 2 ” included between about 0 s and about 1 s.
In the embodiment shown, the peripheral work surface 40 a of the central roller 33 a has, in diametrical section, an arched and symmetric peripheral contact edge ( FIGS. 5 and 5 a ) which has a radius of curvature “r a ” preferably included between about 0.5 mm and about 3 mm. Also the peripheral work surface 40 b of each of the side rollers 33 b is arched and symmetric ( FIG. 5 ) and has a radius of curvature “r b ” preferably included between about 0.5 mm and about 3 mm.
In accordance with an alternative embodiment not shown, said peripheral work surface 40 b of each of the side rollers 33 b is asymmetric and the edge in contact with the continuous elongated one 19 is the outer edge.
In the embodiment shown in the accompanying drawings, the peripheral work surface 40 a of the central roller 33 a partly faces the peripheral work surfaces 40 b of the two side rollers 33 b . In other words, in a front view as the one in FIG. 5 , the peripheral work surface 40 a of the central roller 33 a is partly superposed on the peripheral work surfaces 40 b of both the side rollers 33 b . The facing or superposition widths “Δ 1 a ”, measured along a direction parallel to the rotation axes of the rollers, are included between about 0.5 mm and about 5 mm.
Width “La” of the peripheral work surface 40 a of the central roller 33 a is included between about 3 mm and about 10 mm. Width “Lb” of the peripheral work surface 40 b of each of the side rollers 33 b is included between about 3 mm and about 10 mm.
In addition, the two side rollers 33 b are mutually spaced apart by a minimum distance “d m ”, measure parallel to the rotation axes, included between about 3 mm and about 10 mm.
The central roller 33 a and each of the side rollers 33 b act on a common region of the continuous elongated element 19 . As a result, the continuous elongated element 19 has two parallel bands compressed both by the central roller 33 a and the side rollers 33 b ( FIG. 5 a ). The central region 38 and side regions 39 and, consequently, the aforesaid central strip and side strips are partly superposed at said bands according to superposition widths “Δls” preferably included between about 0.5 mm and about 5 mm.
Due to the width and position of the side rollers 33 b , the side edges 41 of the continuous elongated element 19 are compressed and preferably also squashed through an hammering action. To this aim, preferably, the peripheral work surface 40 a , 40 b of the central roller 33 a and/or of the side rollers 33 b has a knurling defining raised elements 41 delimiting corresponding grooves.
Alternatively, smooth rollers are used on softer and adhesive compounds for example, where surface working of the rollers could cling to the continuous elongated element of elastomeric material.
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A process and an apparatus for building tires for vehicle wheels wherein the process includes the step of assembling components of elastomeric material on a forming support, in which at least one of the components of elastomeric material is manufactured by the steps of: i) dispensing a continuous elongated element of elastomeric material; ii) applying the continuous elongated element in the form of coils disposed in side by side relationship or at least partly superposed, wound up on the forming support, so as to form the at least one component of elastomeric material of the tire; iii) exerting a first pressure on a central region of a portion of the continuous elongated element applied onto the forming support; and iv) exerting a second pressure on side regions of the portion of the continuous elongated element applied onto the forming support.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to medical devices, and more particularly to a sequential compression device for treatment and prophylaxis of deep vein thromboses (DVT).
2. Description of the Related Art
Deep vein thromboses (DVT) are blood clots that form in a vein deep in the body. Blood clots occur when blood thickens and clumps together. Most deep vein blood clots occur in the lower leg or thigh. The small saphenous vein (SSV) is located in the back of the leg calf. Such symptoms as leg pain, tenderness, edema, or swelling are typically associated with deep vein thromboses (DVT). Many times, deep vein thrombosis occurs for no obvious reason. Common symptoms include pain, swelling, and redness in the leg, arm, or other area. However, the risk of developing DVT is increased in certain circumstances, such as damage to a vein's inner lining, age, a long period of not moving, injury to a deep vein from surgery, pregnancy in the first 6 weeks after giving birth, and blood becoming thicker or more likely to clot than normal.
The goals of DVT treatment are to prevent thrombus growth, relieve symptoms, and to prevent DVT and pulmonary embolism (PE) recurrence. The use of compression stockings is an important adjunct to pharmacological treatment in patients with DVT. Compressions stockings help prevent swelling associated with deep vein thrombosis. These stockings are worn on the leg from the feet to about the level of the knees. This pressure helps reduce the chances that blood will pool and clot.
Although the application of compression stockings can appear simple, it must be considered that inappropriately worn stockings have the potential to cause significant problems. Excess pressure may break the skin, especially in older patients.
Thus, a sequential compression device for treatment and prophylaxis of deep vein thromboses solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
The sequential compression device for treatment and prophylaxis of deep vein thromboses includes a compression sock having a plurality of electromechanical units positioned along the calf muscle of a user's leg. Each of the electromechanical units includes front and rear housing components. The front housing component of the unit includes a compressor piston positioned in communicating relation with the user's calf muscle, and the rear housing component of the unit includes a magnet and a copper coil. The magnet is positioned in communicating relation with the compressor piston of the front housing component. Upon activation, the compressor piston pulsates against the user's calf to simulate the effect of the calf muscle during walking in order to promote the flow of blood back to the user's heart
These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is an environmental perspective view of an embodiment of a sequential compression device for treatment and prophylaxis of deep vein thromboses according to the present invention.
FIG. 1B is a perspective view of the sequential compression device of FIG. 1A .
FIG. 2 is an exploded perspective view of an exemplary electromechanical unit in the sequential compression device of FIG. 1A .
FIG. 3A is a perspective view of an exemplary assembled electromechanical unit of FIG. 2 , shown at rest.
FIG. 3B is a perspective view of the electromechanical unit of FIG. 3A , shown when activated.
FIG. 4 is a perspective view showing generation of an electromagnetic field in the electromechanical unit of FIG. 2 .
FIG. 5 is a schematic diagram of a control panel for the sequential compression device of FIG. 1A .
FIG. 6 is a diagram of exemplary electronic sequences for activation of the sequential compression device of FIG. 1A in different modes.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The sequential compression device for treatment and prophylaxis of deep vein thromboses is a stocking 12 worn on the leg 10 from the feet 18 to about knee level. The device generates sequential pressure only over the SSV vein (small saphenous vein) through six electromechanical units 20 , 22 , 24 , 26 , 28 , 30 allocated over the SSV vein that simulate the effect of the calf muscle during walking. The units 20 , 22 , 24 , 26 , 28 , 30 provide a gentle sequential compression to promote the flow of blood back to the heart. These units 20 , 22 , 24 , 26 , 28 , 30 are wired to the control panel 16 . The control panel 16 is attached to lateral side of the device 12 and houses the power supply batteries. The stocking is connected to the leg via belts 14 including mounting fasteners.
As shown in FIG. 2 the electromechanical unit 20 , as well as units 22 , 24 , 26 , 28 , and 30 , includes five pieces. It contains a powerful cuboid magnet 36 , which is a Rare Earth Neodymium N35 magnet. It also contains a copper coil 38 , which wired to the control panel 16 . The coil 38 and the magnet 36 are combined into an assembly in the rear housing component 34 . The front housing component 40 contacts the back of the leg calf 10 . The curvature of the front housing component 40 fits the curvature of the back of the leg calf. All six electromechanical units 20 , 22 , 24 , 26 , 38 ,- 30 are similar in their components, except the curvature of the front housing component 40 . The curvature of the front housing component 40 is different in each unit 20 , 22 , 24 , 26 , 28 , 30 according to the location or elevation of the unit on the back of the leg calf 10 . Referring to FIGS. 3A and 3B , the compressor piston 42 extends through a channel in the front housing component 40 and is magnetically attached to the magnet 36 . The compressor piston 42 has an elongate polygonal shaft keyed to the channel and a square or rectangular bearing plated centered at one end of the shaft. The compressor piston 42 converts the movement of the magnet 36 when the coil 38 gets electric power. The force and distance that the compressor piston 42 extends out of the channel in the front housing component 40 depends on the voltage and the duration of the electric current that flows in the coil 38 . Referring to FIG. 4 , the cuboid magnet 36 generates a magnetic field all of the time. The magnet 36 is in a loosened state until the coil 38 generates another magnetic field due to the flow of electric current. At this moment, the southern pole of the magnet 36 is attracted to the northern pole of the coil 38 . At the same time, the northern pole of the magnet 36 is also attracted to the southern pole of the coil 38 . The magnet 36 will be forced to occupy a new position in the direction 44 and pushes the compressor piston 42 out of the front housing component 40 .
As shown in FIG. 5 , there is a control panel 16 . The entire system is preferably low voltage and electrically powered, having a microcontroller board 44 and operating battery 56 , e.g., a 3.7V battery, which is connected to module 46 . Module 46 is a six-channel relay module shield. Each channel is wired to the coil 38 on of a corresponding electromechanical unit 20 , 22 , 24 , 26 , 28 , 30 . An external battery 58 can be connected to the relay module 46 to provide longer operational time of the device. The microcontroller board 44 holds the controller, which may be provided from any of a number of sources, an Arduino® microcontroller control board being exemplary. The controller output 62 is six pulse width modulation (PWM) signals. Each channel is wired to one module 46 . A USB connector 50 connects the control board 44 to computers. An infrared (IR) wireless remote control module 54 connects the control board 44 to an infrared remote control 60 . A Bluetooth module 64 may pair the control board 44 to a smart phone. An SD (secure digital) card interface module with SD slot socket 52 saves data and connects to the control board 44 . A 12V battery 48 operates the Microcontroller board 44 .
Software makes it easy to write code and to upload it to the board 44 through the USB connection 50 . Different code, which represents different operational modes, can be saved through the interface module 52 . The code environment is written in Java® and based on processing and other open-source software.
With respect to modes of operation, the sequential compression device has two main functions. The first function is to pump the blood in the SSV through a sequential squeezing along the vein, sequentially upward from the feet to about the level of knees. The compressor piston 42 in the electromechanical unit 30 will project and squeeze the vein. This action is accomplished by starting the electric current in the coil 38 at the lowest electromechanical unit 30 in response to the software code programmed into the microcontroller 44 , which connects the power from the battery 56 to the relay 46 and to the coil 38 . After an interval, the electromechanical unit 30 will release its pressure on the vein, and the magnet 36 will move rearward to release pressure on the vein. And so in sequence, the electromechanical units will compress and release the vein until reaching the upper electromechanical unit 20 , and then start another loop of sequential compression.
Alternatively, the electromechanically units 20 , 22 , 24 , 26 , 28 , 30 may be programmed to compress the vein in pairs, as detailed in sequence modes 600 shown in FIG. 6 . For example, in Mode 1 , in time interval 1 T, only unit 30 is activated. Then, in time interval 2 T, both units 28 and 30 are activated to apply compression to the vein. In time interval 3 T, both units 26 and 28 are activated, while unit 30 is off, the pattern of activation and inactivation continuing as shown in the pattern for Mode 1 . Mode 2 is similar to Mode 1 , but with the start of the next cycle of compression overlapping the end of the previous cycle.
The software code will control this sequential action and the microcontroller 44 will transfer the code instruction to electric current flow intended time period (T) to the coils 38 in the electro mechanical unit 20 - 30 . The total time to complete one loop or cycle is six times the period (T). Blood flow is high for a small time period (T). Normally, the blood speed in the vein ranges between 5 cm/sec to 15 cm/sec. The calculated time (T) ranges between 0.2 sec and 0.6 sec for a device of length 18 cm.
The value of time (T) is adjusted using the Infrared IR remote control 60 or using a smart phone paired to the Bluetooth module 64 . Thereby, the patient can adjust the blood flow in the SSV according to the recommendation of the physician. According to a pilot experiment, Unit 20 is subjected to 3.7 v of electric current; and the maximum force generated was measured as 205 grams, which is enough to compress the SSV. Less compression force can be generated for a patient of low Body Mass Index (BMI) by exchanging the compressor piston 42 with another having a bearing surface of less height.
The second function of the sequential compression device is to massage the SSV. This action can be done by vibrating mode for the upper units 20 , 22 , 44 , for very small period of time (T) that is ranged between 0.05 sec and 0.1. This is shown in Mode 3 of FIG. 6 , which shows a different activation pattern, showing unit 24 activated in the first time interval 0 , then unit 22 activated in the second time interval 1 T, and then an alternating pattern of both units 20 and 24 activated in the next time interval, followed by only unit 22 in the following time interval, an alternating pattern that continues through each cycle of vein compression, thereby massaging the vein.
These modes of operation are stored as software codes on an SD card interface 52 , and the patient can control different variables, such as mode of operation and the value of time interval (T), using the Infrared IR remote control 60 or using a smart phone paired to the Bluetooth module 64 . The external battery 58 can be wired to the device 12 to provide longer operational time of the device.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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The sequential compression device for treatment and prophylaxis of deep vein thromboses includes a compression sock having a plurality of electromechanical units positioned along the calf muscle of a user's leg. Each of the electromechanical units includes a front housing component and a back housing component. The front housing component of the unit includes a compressor piston positioned in communicating relation with the user's calf muscle and the back housing component of the unit includes a magnet and a copper coil. The magnet is positioned in communicating relation with the compressor piston of the front housing component. Upon activation, the compressor piston selectively compresses the small saphenous vein to simulate the effect of the calf muscle during walking and promote the flow of blood back to the user's heart.
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TECHNICAL FIELD
[0001] The present disclosure is related generally to mobile device configuration, and, more particularly, to a system and method for providing a remote imaging functionality for a modular portable communication device such as a cellular phone.
BACKGROUND
[0002] Portable communications devices such as high functionality (multi-function) cellular phones have become important tools for business as well as entertainment and pleasure. However, the more useful such a device becomes, the more likely the user is to carry the device. With this in mind, there is substantial interest in reducing the weight and thickness of such devices even as their capabilities continue to increase.
[0003] Component miniaturization and spatial efficiencies will continue to play important roles in this regard. In addition, device customization may be used to reduce the device footprint. For example, a user may wish to have a camera function but not a wireless speaker function; a device that has the former and lacks the latter can be provided, and will have a lower weight and thickness than a device having both features.
[0004] However, it is generally not practical for device manufacturers to maintain a large number of different production lines to supply differently-configured versions of the same base device. One approach that allows users to customize a completed device is a modular approach. With modularization, a base or primary device is produced and configured to be compatible with a number of secondary modules or devices that provide additional functions.
[0005] Thus, continuing with the example above, the primary device may include basic computing functionality and wireless communication capabilities, but may not include a camera function or a wireless speaker function. To serve the needs of various users, two secondary devices can be produced; the first secondary device may be a camera module and the second secondary device may be a wireless speaker module. By using the primary device coupled to the appropriate secondary module, each user is able to create a device that is customized to meet their needs.
[0006] While the present disclosure is directed to a system that can eliminate certain shortcomings or extend certain functions noted in this Background section, it should be appreciated that such a benefit is neither a limitation on the scope of the disclosed principles nor of the attached claims, except to the extent expressly noted in the claims. Additionally, the discussion of technology in this Background section is reflective of the inventors' own observations, considerations, and thoughts, and is in no way intended to accurately catalog or comprehensively summarize the art in the public domain. As such, the inventors expressly disclaim this section as admitted or assumed prior art with respect to the discussed details. Moreover, the identification herein of a desirable course of action reflects the inventors' own observations and ideas, and should not be assumed to indicate an art-recognized desirability.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] While the appended claims set forth the features of the present techniques with particularity, these techniques, together with their objects and advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:
[0008] FIG. 1 is a simplified schematic of an example device with respect to which embodiments of the presently disclosed principles may be implemented;
[0009] FIG. 2 is schematic view of a first device and a second device, showing the back of the first device and the back of the second device in accordance with an embodiment of the disclosed principles;
[0010] FIG. 3 is side view of the first device and the second device in accordance with an embodiment of the disclosed principles;
[0011] FIG. 4 is side view of the first device and the second device mated together via the back of the first device and the front of the second device in accordance with an embodiment of the disclosed principles;
[0012] FIG. 5 is schematic diagram of a system for remote imaging in accordance with an embodiment of the disclosed principles; and
[0013] FIG. 6 depicts an exemplary process for remote imaging in a device context such as that described by reference to FIG. 5 in accordance with an embodiment of the disclosed principles.
DETAILED DESCRIPTION
[0014] Before presenting a full discussion of the disclosed principles, an overview of certain embodiments is given to aid the reader in understanding the later discussion. In an embodiment, a modular portable electronic device such as a cell phone is configured to be physically attached to a second device such that the combined device has greater functionality than either of the two devices alone.
[0015] The first device may include a display, touch screen, first interconnect, first microphone (mic), first image signal processor (ISP), first imager, first wireless data link, battery, processor and memory in an embodiment. Similarly, the second device may include a battery, second interconnect, second mic, processor, memory, second ISP, second wireless data link, and second imager.
[0016] In a further embodiment, in addition to being useful as an add-on module, the second device is usable in conjunction with the first device to provide remote imaging. The first device is able to configure its operation with respect to the second device based on the state of the second device. For example, the first device may detect that the second device is not physically connected to the first device, e.g., by sensing that the first interconnect is not mated to the second interconnect. In this case, the display and touch screen of the first device provide a user interface control and viewfinder for the imager of the second device via a wireless data link.
[0017] The wireless data link may be activated between the two devices when they are undocked after previously being docked through their respective interconnects. The wireless data link may have been previously established and simply activated from a low-power standby mode. If the act of undocking occurs while the user is using the viewfinder mode on the first device with respect to the imager of the second device, the live viewfinder may need to be paused by the first device while the wired connection switches to a wireless connection, and then resume operation once the transfer is completed.
[0018] However, in an embodiment, if video was being captured while the devices were physically connected, the capture of video may continue uninterrupted while the viewfinder data is being transferred to wireless. This is because the capture is being controlled by the second ISP and second imager. In another embodiment, a single video may be captured using simultaneous image data from the first imager and the second imager, and simultaneous audio data from the first microphone and the second microphone. To account for wireless latency, the image data may be synchronized by adding a delay to the image data of the first imager. Alternatively, image data captured by both imagers may be later aligned via a known wireless latency delay. If the latency delay is not known, it may be generated by correlating audio data from the first microphone with audio data from the second microphone.
[0019] With some or all of these techniques, the user is able to seamlessly initiate use of the second as a remote imager whose view is displayed as a viewfinder on the first device. With this overview in mind, and turning now to a more detailed discussion in conjunction with the attached figures, the techniques of the present disclosure are illustrated as being implemented in a suitable computing environment. The following device description is based on embodiments and examples of the disclosed principles and should not be taken as limiting the claims with regard to alternative embodiments that are not explicitly described herein. Thus, for example, while FIG. 1 illustrates an example mobile device within which embodiments of the disclosed principles may be implemented, it will be appreciated that other device types may be used, including but not limited to personal computers, tablet computers and other devices.
[0020] The schematic diagram of FIG. 1 shows an exemplary component group 110 forming part of an environment within which aspects of the present disclosure may be implemented. In particular, the component group 110 includes exemplary components that may be employed in a device corresponding to the first device and/or the second device. It will be appreciated that additional or alternative components may be used in a given implementation depending upon user preference, component availability, price point, and other considerations.
[0021] In the illustrated embodiment, the components 110 include a display screen 120 , applications (e.g., programs) 130 , a processor 140 , a memory 150 , one or more input components 160 such as speech and text input facilities, and one or more output components 170 such as text and audible output facilities, e.g., one or more speakers.
[0022] The processor 140 may be any of a microprocessor, microcomputer, application-specific integrated circuit, or the like. For example, the processor 140 can be implemented by one or more microprocessors or controllers from any desired family or manufacturer. Similarly, the memory 150 may reside on the same integrated circuit as the processor 140 . Additionally or alternatively, the memory 150 may be accessed via a network, e.g., via cloud-based storage. The memory 150 may include a random access memory (i.e., Synchronous Dynamic Random Access Memory (SDRAM), Dynamic Random Access Memory (DRAM), RAMBUS Dynamic Random Access Memory (RDRM) or any other type of random access memory device). Additionally or alternatively, the memory 150 may include a read only memory (i.e., a hard drive, flash memory or any other desired type of memory device).
[0023] The information that is stored by the memory 150 can include program code associated with one or more operating systems or applications as well as informational data, e.g., program parameters, process data, etc. The operating system and applications are typically implemented via executable instructions stored in a non-transitory computer readable medium (e.g., memory 150 ) to control basic functions of the electronic device. Such functions may include, for example, interaction among various internal components and storage and retrieval of applications and data to and from the memory 150 .
[0024] Further with respect to the applications 130 , these typically utilize the operating system to provide more specific functionality, such as file system service and handling of protected and unprotected data stored in the memory 150 . Although many applications may provide standard or required functionality of the user device 110 , in other cases applications provide optional or specialized functionality, and may be supplied by third party vendors or the device manufacturer.
[0025] Finally, with respect to informational data, e.g., program parameters and process data, this non-executable information can be referenced, manipulated, or written by the operating system or an application. Such informational data can include, for example, data that are preprogrammed into the device during manufacture, data that are created by the device or added by the user, or any of a variety of types of information that are uploaded to, downloaded from, or otherwise accessed at servers or other devices with which the device is in communication during its ongoing operation.
[0026] The device having component group 110 may include software and hardware networking components 180 to allow communications to and from the device. Such networking components 180 will typically provide wireless networking functionality, although wired networking may additionally or alternatively be supported.
[0027] In an embodiment, a power supply 190 , such as a battery or fuel cell, may be included for providing power to the device and its components 110 . All or some of the internal components 110 communicate with one another by way of one or more shared or dedicated internal communication links 195 , such as an internal bus.
[0028] In an embodiment, the device 110 is programmed such that the processor 140 and memory 150 interact with the other components of the device 110 to perform certain functions. The processor 140 may include or implement various modules and execute programs for initiating different activities such as launching an application, transferring data, and toggling through various graphical user interface objects (e.g., toggling through various display icons that are linked to executable applications).
[0029] Turning to FIG. 2 , this figure presents a view of a first device and a second device, showing the back of the first device and the back of the second device in accordance with an embodiment of the disclosed principles. In the illustrated example, the back 218 of the first device 200 includes one or more alignment features 203 configured and placed to mate with mating features 225 on the back 221 of the second device 201 .
[0030] In addition, the back of the first device 200 in the illustrated embodiment includes a connector array 205 . The connector array 205 is located and configured to mate with a mating connector array 206 on the back 221 of the second device 201 . In the illustrated example, the back of the first device 200 further includes a built-in camera 207 and an associated flash 209 . It will be appreciated that the first device 200 may include different features or additional features as compared to the illustrated embodiment.
[0031] In the illustrated example, the second device 201 provides at least an enhanced camera function. To this end, the second device 201 includes on its front face a camera 215 (see FIG. 4 ) and an associated flash. Further, in the illustrated example, use of the camera 215 of the second device 201 does not preclude the use of the camera 207 of the first device 200 . As such, a hole 219 is provided in the second device 201 to allow a sight line for the camera 207 of the first device 200 .
[0032] FIG. 3 is a side view of the first device 200 and the second device 201 , not yet mated together. Continuing, FIG. 4 is a side view of the first device 200 and the second device 201 mated together at the back of the first device 200 and the front of the second device 201 in accordance with an embodiment of the disclosed principles. As can be seen, the devices 200 , 201 are in physical contact when mated. In should be noted that different embodiments of the second device 201 may vary significantly in thickness and shape from one another.
[0033] Before discussing exemplary processes for remote imaging via a modular device, a schematic illustration of the topology of the first and second devices 200 , 201 is given to assist in understanding the later-described process. In this regard, the schematic drawing of FIG. 5 illustrates the salient aspects of a modular device platform for remote imaging in keeping with an embodiment of the disclosed principles.
[0034] The illustrated schematic includes the first device 200 and the second device 201 . Those of skill in the art will appreciate that while a portable communications device necessarily includes a great many parts, only certain elements are being shown in the illustrated schematic to enhance clarity.
[0035] The first device 200 as illustrated includes a processor such as processor 140 of FIG. 1 , and a display or viewer such as display 120 of FIG. 1 . In addition, the first device 200 includes the interconnect array 205 previously discussed with reference to FIG. 2 . Also as noted above, the first device 200 may include a mic 507 and an ISP 509 . Finally, a wireless communication facility such as an RF (radio frequency) circuit and antenna (collectively 501 ) is also included as part of the first device 200 .
[0036] Similarly, the second device 201 includes at least a processor 505 , a camera 215 , e.g., a digital camera, the interconnect array 223 as discussed with reference to FIG. 2 , and a wireless communication facility, e.g., RF circuit and antenna 503 (collectively). Additionally, a mic 511 and an ISP 513 are provided as part of the second device 201 . The interconnect array 223 of the second device 201 is adapted and configured to physically mate with and electrically connect with the interconnect array 205 of device 1 . Similarly, the RF circuit and antenna 503 of the second device 201 are adapted to wirelessly communicate with the RF circuit and antenna 501 of the first device 200 . In each device 200 , 201 , the respective processor 140 , 505 is configured, via the computer execution of computer-executable instructions read from a non-transitory computer readable medium, to select either a wired or wireless medium for communications between the devices 200 , 201 .
[0037] In operation, as will be described in greater detail below, when the first device 200 and second device 201 are mated such that the interconnect array 205 of the first device 200 and the interconnect array 223 of the second device 201 are in direct electrical contact, the processor 140 of the first device 100 causes the display 120 of the first device 200 to display an image captured by the camera 215 and processed by the ISP 513 of the second device 201 In this way, the display 120 of the first device 200 acts as a view finder or monitor for the camera 215 of the second device 201 . In an alternate embodiment, the ISP 509 of the first device 200 processes the image data received from the second device 201 either after it is first processed by the ISP 513 of the second device 201 or without any processing by the ISP 513 of the second device 201 .
[0038] When the first device 200 and the second device 201 are separated, the interconnect array 205 of the first device 200 and the interconnect array 223 of the second device 201 are no longer in electrical contact. In this state, the processor 140 of the first device 100 cooperates with the processor 505 of the second device 201 such that the RF circuit and antenna 503 of the second device 201 transmits image data from the camera 215 of the second device 201 to the RF circuit and antenna 501 of the first device 200 . In this state, the ISP 513 of the second device 201 may process the image data prior to transmission. The processor 140 of the first device 200 then causes the received image data to be displayed on the display 120 of the first device 200 .
[0039] The mic 507 of the first device 200 and the mic 511 of the second device 201 may be used to capture audio data in conjunction with captured video data in either the mated or unmated configuration. Thus for example, when the devices are mated, the first device 200 mic 507 and second device 201 mic 511 may cooperate to capture audio linked to a single captured video. When the devices 200 , 201 are separated, the second device 201 may transmit both audio data from the mic 511 and image data from the camera 215 to the first device 200 over the wireless link.
[0040] Moreover, as mentioned briefly above, the mics 507 , 511 may be used to synch image data simultaneously captured on both devices 200 , 201 . In an embodiment, this is accomplished by synching the audio signals to synch the video signals. In particular, while captured video data taken from different vantage points will typically differ significantly, audio signals captured simultaneously at a scene from different vantage points will simply be scaled versions of each other. As such, synchronizing captured audio is fairly straightforward.
[0041] Continuing, FIG. 6 depicts an exemplary process 600 for remote imaging in a device context such as that described by reference to FIG. 5 . Although the process 600 will be described with occasional reference to the specific architecture shown, those of skill in the art will appreciate that other similar architectures may instead be used.
[0042] At stage 601 of the illustrated process 600 , the devices 200 , 201 are not mated and are not in communication with one another. The devices 200 , 201 are then docked or placed together at stage 603 , such that the respective interconnect arrays 205 , 223 are in electrical contact. The processor 140 of the first device 200 detects the linking of the devices 200 , 201 and synchs operation with the second device 201 . When a user then initiates an image capture operation at stage 605 , the camera 215 of the second device 201 captures image data, which is processed by the ISP 513 of the second device 201 and passed to the first device 200 via the respective interconnect arrays 205 , 223 at stage 607 . The processor 140 of the first device 200 then causes the captured image data to be displayed by the display 120 of the first device 200 at stage 609 of the process 600 .
[0043] At stage 611 , the processor 140 of the first device and the processor 505 of the second device 201 detect that the devices 200 , 201 have been physically separated, e.g., by detecting a disconnection of the interconnect arrays 205 , 223 , while the image capture process is ongoing. In response, the processor 104 of the first device 200 activates a wireless connection to the second device via the respective RF circuits and antennas 501 , 503 of the devices 200 , 201 at stage 613 .
[0044] The processor 505 of the second device 200 causes the ISP 513 of the second device 201 to process subsequently captured image data at stage 615 , and transfers the processed image data to the first device 200 at stage 617 . At stage 619 , the processor 104 of the first device 200 displays the captured, processed and transmitted image data on the display 120 of the first device 200 . In this way, the display 120 of the first device 200 acts as a view finder for the camera 215 of the second device 201 whether the devices 200 , 201 are mated or not. When the devices 200 , 201 are not mated, this results in a remote imaging capability.
[0045] In an embodiment, the first device 200 also includes a user interface through which the user may control the operation of the second device 201 with respect to the camera 215 . During image (video) capture, one or both mics 507 , 511 may be active.
[0046] Indeed, when both local and remote imaging are ongoing simultaneously, the audio data collected by the mics is used in an embodiment, not only as media, but also to synchronize the two streams of video data. More specifically, because one data stream is locally generated while the other data stream undergoes a wireless transmission, the remotely captured audio/video data will typically be slightly delayed relative to the locally captured audio/video data. This relative delay is referred to as wireless latency.
[0047] Various methods may be used to negate the wireless latency using the contemporaneously captured audio data. For example, the delay may be determined by comparing the audio data across streams, and then the determined delay can be added to the locally captured audio/video data. Alternatively, image and/or audio data may be synchronized via a known wireless latency.
[0048] It will be appreciated that a system and method for remote imaging have been disclosed herein. However, in view of the many possible embodiments to which the principles of the present disclosure may be applied, it should be recognized that the embodiments described herein with respect to the drawing figures are meant to be illustrative only and should not be taken as limiting the scope of the claims. Therefore, the techniques as described herein contemplate all such embodiments as may come within the scope of the following claims and equivalents thereof.
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A system and method of remote imaging allows a camera module in a modular portable electronic device environment to be removed from a base module without halting an image capture session being displayed on a display of the base module. In an embodiment, image data may be captured by both the camera module and the base module. A hardwired connection connects the devices when the camera module is docked on the base module, while a wireless connection maintains the connection between the devices when the camera module is undocked from the base module during an image capture session.
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BACKGROUND OF THE INVENTION
A phosphate enriched manure fertilizer is prepared by reaction of manure with an acid phosphate reactant comprising phosphoric acid such as orthophosphoric acid and an acid phosphate salt such as and particularly monopotassium acid phosphate.
In particular embodiments the invention further relates to the mineral supplementation of manure fertilizers by the addition of phosphate and by the addition of potassium.
In further embodiments of the invention, the reaction of phosphoric acid with manure is continued at elevated temperatures and for a prolonged period and in the presence of a buffering quantity of alkali metal acid phosphate salt, effecting hydrolysis of the protein content of the manure and the generation of free amino acids.
The invention further relates to method for production of phosphate enriched manure, potassium enriched manure, and free amino acid containing manure fertilizer products.
PRIOR ART
Mineral and element supplementation of manures is known. A variety of materials have been used including in some instances phosphoric acid and alternatively in the prior art phosphate salts. Among the patents known to applicants are U.S. Pat. No. 173,621 to Griffith, U.S. Pat. No. 129,739 to Loewenstein, U.S. Pat. No. 1,703,504 to Walton et al, U.S. Pat. No. 47,610 to Baugh, U.S. Pat. No. 517,661 to Powter, U.S. Pat. No. 673,167 to Giffen, and U.S. Pat. No. 1,420,596.
SUMMARY OF THE INVENTION
The invention has for its purpose the preparation of an improved fertilizer material, one comprising manure as the basic ingredient and having provision for supplementation of the manure with mineral and elemental materials specifically phosphate and potassium known to be beneficial to plant life and as well in certain embodiments the provision of free amino acids which, as is known, are directly assimmiable into the plant structure and which therefore are extremely efficient in the soil in plant nutrition.
In accordance with the purposes of the invention there is provided method for the production of phosphate enriched high organic content fertilizer comprising manure, including the steps of reacting the manure with at least one part by weight of an acid phosphate reactant per one part of manure, the reactant comprising a mixture of one part by weight of an alkali metal acid phosphate and from one to eight parts by weight of orthophosphoric acid, and recovering the product. In preferred embodiments the salt is monopotassium phosphate but the acid phosphate salt may have the formula MeH 2 PO 4 wherein Me is an alkali metal selected from potassium, sodium, lithium and cesium. In other embodiments the acid phosphate salt may have the formula Me 2 HPO 4 in which the metal is an alkali metal as mentioned. The orthophosphoric acid may be used as an aqueous solution containing about 85 percent by weight of the acid i.e. commercial orthophosphoric acid.
In certain embodiments it is preferred that the manure be first slurried in water prior to effecting reaction with the acid phosphate reactant.
Accordingly and in preferred carrying out of the invention there is provided method for the production of phosphate enriched high organic fertilizer comprising manure, including the steps of slurrying manure in up to five parts by weight of water per part of manure, mixing an acid phosphate reactant solution of one part by weight of monopotassium acid phosphate in from one to four parts of orthophosphoric acid with the manure slurry in an amount of one to four parts by weight of the acid phosphate reactant per part of manure and recovering the product.
In further embodiments of the invention three amino acids are generated within the enriched manure fertilizer product. In this respect the invention provides a method of producing free amino acids in the fertilizer product produced as above by heating the product at an elevated temperature above about 75° C for several hours and recovering the product. Typically, heating is continued for not less than 4 hours and preferably heating is carried out at about 90° C.
Accordingly, in a preferred form of the process there is provided method for the production of free amino acid-containing phosphate-enriched high organic content fertilizers comprising manure, including slurrying manure in up to five parts by weight of water per part of manure, mixing acid phosphate reactant solution of one part by weight of monopotassium acid phosphate with from one to four parts of orthophosphoric acid with the manure slurry in an amount of one to four parts by weight of the acid phosphate reactant per part of manure, heating the resulting mixture at about 90° C for not less than 4 hours to hydrolyze proteinaceous material in the manure into free amino acid, and recovering as product a manure fertilizer containing free amino acid, and enriched with phosphate and potassium.
The invention further relates to the products obtained by the foregoing methods.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In carrying out the invention use is made of manure i.e. animal excrement widely found in rural areas where fertilizer is most important. While manure is a natural fertilizer, it is desirable to augment its action in fertilizing plants by the addition of mineral and elemental supplements. It is to this purpose that the invention is directed. Specifically the invention provides for reacting manure with phosphoric acid in the first instance, but only in the presence of an acid salt of phosphoric acid whereby the reaction conditions are ameliorated to an extent permitting the effective reaction of phosphoric acid with the manure fertilizer. In addition, particularly where the acid phosphate salt is the monopotassium or dipotassium acid phosphate salt there is further added to the soil a quantity of potassium which is a necessary nutrient for plants.
As the phosphoric acid reactant we prefer to use orthophosphoric acid particularly in its commercial form i.e. 85 percent H3PO4 in aqueous solution.
As the acid phosphate salt reactant we prefer to employ an alkali metal i.e. potassium, sodium, lithium, or cesium metal, mono- or di- acid salt as the salt reagent in the process.
In practice the manure is slurried in water to facilitate mixing of the manure and acid phosphate reactant. Typical proportions are for each part of manure from one to eight parts and preferably up to five parts by weight of water.
Following slurrying of the manure the acid phosphate reactant is prepared. Typically, this is accomplished by dissolving in phosphoric acid the particular salt e.g. and for illustrative purposes monopotassium phosphate. The ratio of monopotassium salt as an illustration to phosphoric acid is in the range of, for each part of monopotassium acid phosphate salt, from one to four parts of orthophosphoric acid. In general, from one to four parts by weight of the acid phosphate reactant material comprising both the phosphoric acid and the acid phosphate salt is employed in the range of from one to four parts of the acid phosphate reactant per part of manure in the slurry.
The reaction is generally effected at room temperature and proceeds nicely in an aqueous slurry of manure with the concentrations of acid phosphate reactant set out. After reaction, the reaction product is dried and may be applied directly as fertilizer for an improved result in plant nutrition and soil supplementation.
As noted above, the invention further provides for the production of free amino acids within the modified fertilizer product prepared as just described. For this purpose, the proteinaceous material within the manure is hydrolyzed under particular conditions leading to the generation of free amino acid. It is believed, while not wishing to be bound to any particular theory, that the hydrolysis of proteinaceous material within manure produces usable free amino acids in the product while apparently similar processes do not, by virtue of the conjoint presence of both phosphoric acid and a complimentary phosphate salt such that the pH of the acid is buffered to approximately 25 percent to 50 percent higher than the acid per se whereby hydrolysis proceeds even at the elevated temperatures and for the prolonged heating periods recommended herein in such manner as to provide by virtue of the buffered hydrolysis such amino acids as cuistein phosphate, arginine phosphate, alanine phosphate, glycine phosphate, and histadine phosphate, and others.
It is noteworthy that in view of the buffered condition of the reaction system, amino acids generated are not destroyed and are thereby retained for use by the plant. It is known that amino acids may be directly assimilated by the plants and therefore the nutritional effect is immediate and remarkable.
The invention will be further described as to illustrative embodiments in the following examples in which all parts and percentages are by weight.
EXAMPLE 1
Cow manure, one part by weight, was slurried with water, five parts by weight, and thereto there was added one part by weight of an acid phosphate reactant comprising 0.5 part by weight of monopotassium acid phosphate and 0.5 part by weight of orthophosphoric acid. The slurry and acid phosphate reactant solution were stirred together and the product recovered by drying.
EXAMPLE 2
The reaction conditions of Example 1 were duplicated with the generation of free amino acids by heating the reaction product at 75° C for 4 hours. There was produced a reaction product, which exhibited a positive test for free amino acids.
EXAMPLE 3
Example 1 is duplicated employing four parts by weight of the acid phosphate reactant per part of manure.
EXAMPLE 4
Example 1 is duplicated employing as the acid phosphate reactant solution one containing 0.5 part of monopotassium acid phosphate and two parts of orthophosphoric acid. Results were equivalent.
EXAMPLE 5
Example 1 is duplicated employing eight parts by weight of water per part of manure in slurrying the manure. Results were equivalent.
EXAMPLE 6
Example 1 is duplicated employing as the acid phosphate reactant an also phosphoric solution of an alkali metal acid salt selected from sodium, lithium and cesium, mono- and dihydrogen acid phosphate salts. Results were equivalent.
EXAMPLE 7
Example 2 is duplicated using 90° C as the reaction temperature and heating for 4.5 hours. The reaction product tests positively for free amino acid.
The products of Examples 1 through 7 are tested for fertilizing efficiency in a truck garden by blending into the soil at the level of one bale per 1000 square feet the fertilizer products obtained. Garden vegetables are grown in the area and the results observed. It is noted that the plants are healthy, rapid growing and heavy bearing of fruit, the amino acid containing fertilizer areas having somewhat swifter results.
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Phosphate enriched, potassium supplemental manure product and method of production including reaction of manure with a solution of alkali metal acid phosphate salt in orthophosphoric acid, in some cases with prolonged reaction at elevated temperatures to hydrolyze manure protein to free amino acids.
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BACKGROUND AND SUMMARY OF THE INVENTION
In the conversion of coal to synthetic fuels by direct liquefaction, the coal is mixed with a recycle solvent and is hydrogenated in a three phase reactor at temperatures in the range 750° to 880° F. and pressures in the range 1000 to 3000 psi. The process is generally known as SRC-I, solvent refined coal having the acronym SRC. In this and similar processes, coal is mixed with solvent at low temperature (typically from 150° to 450° F.) and atmosphere pressure. The resulting slurry is pumped to a high pressure (for example, 2500 psi) and is then preheated in heat exchangers to a temperature of approximately 500° F. This temperature is chosen to be sufficiently low that dissolution and reaction of the coal has not commenced.
Hydrogen gas is then added to form a three phase mixture which is heated in a fired heater, prior to entry to the reactor vessel. This fired heater is a critical component in the direct liquefaction of coal. Because of the high operating pressure and temperature and the erosive corrosive nature of the coal slurry, expensive materials are required for the fired heater tubes making this unit a major cost item in the liquefaction process.
Further, reaction of the coal system commences in the fired heater, and coke formation from the coal products may occur at any location where very high temperatures are encountered, for example, at the surface of the heated tube wall. The avoidance of coke formation is an important consideration in the design since coke buildup will eventually cause tube plugging and may, in an extreme case, lead to tube wall temperatures sufficiently high to allow rupture of the tube.
A primary objective of this present invention is to optimize the tube wall temperature throughout the heater such that coking is minimized while utilizing the least possible surface in order to minimize the cost.
Problems which must be addressed in the design of a fired heater for coal slurry service are:
1. Swelling and dissolution of coal in solvent as it passes through the temperature zone from 500° to 650° F. lead to a large peak in the magnitude of the coal slurry viscosity. This region of high viscosity, termed the "gel region", has a low heat transfer coefficient. Immediately following this inlet and intermediate temperature region in the heater, the heat transfer coefficient increases rapidly. This variation of heat transfer must be accomodated in the design of the heater while avoiding the possibility of coke formation.
2. The flow of a slurry is preferably handled in a horizontal tube configuration. This prevents the possibility of flow blockage by settling which may occur in vertical tubes.
3. Tube erosion by the slurry must be avoided by limiting flow velocities and avoiding short radius tube bends.
A design of a fired heater which recognizies the latter two problems has been described in U.S. Pat. No. 4,013,402. In this patent, there is disclosed a radiant heater having a tube configuration containing the slurry flow in a horizontal racetrack arrangement with long radius return bends. This arrangement is not entirely satisfactory since it may cause unacceptable high tube wall temperatures in the inlet temperature range from 500° to 650° F. The heater configuration generates a maximum heat flux at the inlet area of the slurry tube circuit where the inside heat transfer coefficient is low. This could lead to high slurry film temperatures and coking in the coal gel formation zone of the heater.
Thus, this prior art design does not allow for variations of tube side heat transfer coefficients. Substantial variations in such heat transfer coefficients are probable in the heating of a coal slurry of the indicated type due to the effect of viscosity changes of the slurry during solvent absorption by the coal and the dissolution process. Hence, if the heat flux in the heater is maintained low to avoid the likelihood of coke formation, then the upper zones of the heater may require an unnecessarily large surface area.
As an alternative to the radiant fired heater, convective designs are known which have the advantage of obtaining more uniform heat transfer to the tubes and are not subject to the occurrence of local hot zones in the furnace due to such problems as flame impingement. In such a convective heater, hot discharge gases from a burner or burners are mixed with recirculated cooler gases. The gas mixture is passed over the outside of the tube bank in which the coal slurry is heated. The cooled exit gases are then divided into two streams, one part of the gas is exhausted to atmosphere, the second part provides the recirculated gases to mix with the burner discharge gases. In the tube bank, several circuits are arranged in parallel with the pipes transverse to the flue gas flow. The coal slurry flowing in the pipes has a flow configuration either cocurrent with or countercurrent to the flow gases.
In this type of prior heater, in order to obtain uniform flow of the flue gases, it is usually necessary to have several pipe circuits in parallel. This, in combination with other economic considerations which require minimization of the number of pump and pipe coal slurry flow circuits, determines that such heaters are primarily suitable for very large duties--for example, only one heater may be required for a 6000 T/Day coal liquefaction plant. This may be considered a disadvantage since the plant onstream capability may be adversely affected by an individual circuit failure.
The co- or countercurrent flow arrangement is most efficient when the heat transfer coefficient for the process fluid only exhibits small variations throughout the heater. Then, by the use of varying tube spacing and added external surface (fins) it is possible to optimize the heat flux distribution. When the process fluid heat transfer varies widely, as for a coal slurry, such an optimization is not practical and the heater must generally be designed for the lowest prevailing heat flux.
The heater construction in accordance with the invention is designed to obviate the above-discussed problems of the prior art heaters. To this end, heat flux variations on the fired side are minimized by utilizing a convective design. In addition, the fired side temperature profile is selected to minimize the possibility of the slurry film temperature exceeding the coking temperature. Moreover, the relative heat inputs to zones of the furnace are controllable. Furthermore, the design in accordance with the invention permits the use of two 50% duty units without a large cost premium when compared with a single 100% unit.
Briefly stated, the convective heater in accordance with the invention is constructed so that the flue gas flow is divided into two parallel paths across the slurry tube circuits. Three parallel slurry tube circuits are used and are arranged so that each tube circuit enters the heater at a central point in one path of the flue gas circuit and flows co-current to the flue gas exit. The tube circuit then crosses to the other flue gas path and flows counter-current to a location near its inlet. The tube circuit then returns to the first flue gas path and flows co-current to leave the heater adjacent to the entry location.
The advantages of the mixed flow arrangement of the invention are as follows:
1. Less surface is required;
2. Lower and more uniform maximum film temperatures are possible;
3. A 2×50% duty arrangement can be utilized with a minimum increase in cost.
In accordance with another feature of the invention there is provided a special cross-over arrangement of the return bends for the tube circuits to provide a compact tube arrangement while retaining a long radius for the return bends. This also provides a more uniform temperature relationship between the three tube circuits by interchange of the heat transfer contact between the coal slurry and different zones of the flue gas as the process flows progress through the heater.
Prior art heater constructions acknowledged herein are those disclosed in U.S. Pat. Nos. 1,833,130; 2,514,084; 2,669,099; 2,955,807; 3,258,204; 3,623,549; 4,201,191; and 4,230,177. These patents do not disclose the heater design of the present invention wherein the heating gas flow of a convective heater is divided into two flow passes with the tube circuit comprising a mixed co-current, counter-current arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a convective heater system in accordance with the invention;
FIG. 2 is a side elevation of a convective heater in accordance with the invention, with parts broken away for illustrative purposes;
FIG. 3 is a section on line 3--3 of FIG. 2;
FIG. 4 is a section on line 4--4 of FIG. 2 in schematic form;
FIG. 5 is a section on line 5--5 of FIG. 2 in schematic form;
FIG. 6 is a section on line 6--6 of FIG. 2 in schematic form;
FIG. 7 is a section on line 7--7 of FIG. 2 in schematic form;
FIG. 8 is a section on line 8--8 of FIG. 2 in schematic form;
FIG. 9 is a schematic illustration of the tube circuits in the convective heater shown in FIGS. 2-8;
FIG. 10 is a fragmentary view illustrating an alternate return bend construction;
FIG. 11 is a view taken on line 11--11 of FIG. 10;
FIG. 12 is a graph showing the temperature profiles in a convective heater for a coal slurry in accordance with the invention;
FIG. 13 is a graph showing typical heat transfer coefficients for an SRC-I coal slurry/hydrogen flow in an eight inch diameter pipe; and
FIG. 14 is a graph showing the relationship between the tube wall temperatures and the slurry temperature for fired heaters with cocurrent flow and countercurrent flow in comparison with the mixed flow arrangement in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The convective heater in accordance with the invention comprises a casing 13, which is rectangular in cross-section and is constructed with a tapered inlet 14 and a tapered outlet 15. A dividing wall 16 within casing 13 divides the heating chamber between inlet 14 and outlet 15 into two equal paths 18 and 20 for the flow of heating gases. Dividing wall 16 extends into outlet 15 to provide two outlet passages 21 and 22, which are provided with balance dampers 23 and 24, respectively.
As shown in FIG. 1, hot flue gases from the burner section 26 of the heater are delivered to inlet 14 by way of conduit 28. Burner section 26 is provided with a suitable burner 27 supplied with fuel and air for combustion as shown in FIG. 1. A blower 30 has its suction connected to outlet passages 21 and 22 by conduit 32 and has its discharge divided, one part being exhausted to the heater stack 33 and the other part flowing to the inlet end 34 of heater section 26 as shown in FIG. 1. The general arrangement shown in FIG. 1 for circulating flue gases is conventional. In accordance with the inventive design, the hot flue gases from burner section 26 flow upwardly through inlet 14 and divide into two heating gas flows that flow through paths 18 and 20 and outlet passages 21 and 22 under the regulation of balance dampers 23 and 24, which adjust the relative flow between paths 18 and 20. This permits alteration to the flue gas temperature profile and heat transfer coefficient for compensation of variations in the coal slurry heat transfer.
Conduit means are provided for the flow of process fluid to be heated, i.e., the coal slurry, through heating (flue) gas paths 18 and 20 in heat exchange relationship with the hot flue gas passing from inlet 14 to outlet 15. In accordance with the invention, such conduit means is constructed and arranged to provide a mixed-flow tube circuit in which the process fluid enters one of the flue gas paths 18 at a location between inlet 14 and outlet 15 to flow in a co-current direction with the flue gases flowing through this one path 18 to a location near outlet 15 whereat the tube circuit transfers to the other flue gas path 20 to then flow in a counter-current direction relative to the flue gas flow through this other path 20 to a location near inlet 14 whereat the tube circuit transfers back to the first path 18 to flow in a co-current direction to the entry location whereat the tube circuit leaves said one path 18.
To this end, there are provided three parallel mixed-flow tube circuits, each of which comprises tubes arranged in a serpentine-like arrangement passing back and forth transversely through the heating chamber with return bends located externally of casing 13. More particularly, there are provided three vertical stacks 41, 42 and 43 of transversely and horizontally extending tubes located in flue gas path 18 and three vertical stacks 44, 45 and 46 of transversely and horizontally extending tubes located in flue gas path 20. A plurality of return bends 51-56 are provided to interconnect adjacent transverse tubes of stacks 41-46, respectively. Return bends 51-56 are arranged to provide the above-described mixed-flow arrangement in cooperation with crossover tubes to be described hereafter. As is best shown in FIGS. 3, 5 and 7 the return bends 51-56 are provided externally of casing 13.
The slurry is delivered into flue gas path 18 through supply pipes 47, 48 and 49 which are connected to inlet transverse tubes 57, 58 and 59, respectively, of tube stacks 41, 42 and 43 as shown in FIG. 5. Inlet transverse tubes 57, 58 and 59 are located at a selected intermediate location in the vertical extent of the tube stacks 41, 42 and 43 pursuant to the design characteristics of the convective heater.
Referring to FIG. 6, the top transverse tubes of stacks 41-46 are interconnected by crossover tubes 61, 62 and 63. Crossover tube 61 interconnects the top transverse tubes of tube stacks 41 and 46, crossover tube 62 interconnects the top transverse tubes of tube stacks 42 and 45, and crossover tube 63 interconnects the top transverse tubes of tube stacks 43 and 44. By this arrangement, crossover tubes 61, 62 and 63 provide for the transfer flow of slurry from flue gas path 18 to flue gas path 20.
Referring to FIG. 8, the bottom transverse tubes of stacks 41-46 are interconnected by crossover tubes 64, 65 and 66. Crossover tube 64 interconnects the bottom transverse tubes of tube stacks 41 and 46, crossover tube 65 interconnects the bottom transverse tubes of tube stacks 42 and 45, and crossover tube 66 interconnects the bottom transverse tube of tube stacks 43 and 44. By this arrangement, crossover tubes 64, 65 and 66 provide for the transfer flow of slurry from flue gas path 20 to flue gas path 18.
Referring to FIG. 7, the slurry is discharged from flue gas path 18 through discharge pipes 71, 72 and 73 which are connected to outlet transverse tubes 67, 68 and 69, respectively, of tube stacks 41, 42 and 43. Outlet transverse tubes 67, 68 and 69 are located immediately below inlet transverse tubes 57, 58 and 59, respectively.
The slurry is caused to flow through the three parallel tube circuits described above by means of pumps 77, 78 and 79 connected to supply pipes 47, 48 and 49, respectively, as is shown in FIG. 2.
It will be apparent that the above-described parallel tube circuits will convey the slurry through flue gas paths 18 and 20 in a mixed-flow sequence as shown by the arrows in the Drawings. Thus, the slurry will enter flue gas path 18 at a medial location between inlet 14 and outlet 15 by way of pipes 47, 48 and 49 and inlet tubes 57, 58 and 59 and flow in a co-current direction in serpentine paths through tube stacks 41, 42 and 43 to the top transverse tubes thereof near outlet 15. The tube circuits then transfer the slurry to flue gas path 20 by way of crossover tubes 61, 62 and 63 and the slurry flows in a counter-current direction in serpentine paths through tube stacks 44, 45 and 46 to the bottom transverse tubes thereof at a location near inlet 14. The tube circuits then transfer the slurry back to the flue gas path 18 by way of crossover tubes 64, 65 and 66 and the slurry flows in a co-current direction to outlet transverse tubes 67, 68 and 69 near the slurry entrance location. The slurry then leaves flue gas path 18 by way of discharge pipes 71, 72 and 73.
Referring to FIGS. 2, 3 and 4, the region of the heating chamber immediately below outlet 15 is provided with a tube circuit 80 for the passage of hot oil or steam through the heating chamber in heat exchange relationship with the flue gases passing through this outlet region. Tube circuit 80 comprises an inlet pipe 81, and outlet pipe 82 and six serpentine tube circuit portions 84 arranged in parallel relation extending between pipes 81 and 82 as is shown in the Drawings.
In addition, the region of the heating chamber immediately above inlet 14 is provided with a tube circuit 90 similar to tube circuit 80. Tube circuit 90 is provided for the passage of hot oil or steam through the heating chamber in heat exchange relationship with the flue gases passing through this inlet region and comprises an inlet pipe 91, and outlet pipe 92 and six serpentine tube circuit portions 94 extending between pipes 91 and 92 in parallel relation as is shown in the Drawings.
The tube circuits 80 and 90 serve to control the temperature of the flue gases at the inlet and outlet regions of casing 16. Tube circuit 80 serves to mix and eliminate hot zones in the flue gas prior to entry into paths 18 and 20. Tube circuit 90 reduces the temperature of the flue gas to a temperature acceptable for low cost construction of the flue gas circulating blower 30. In use, tube circuits 80 and 90 will contain steam or hot oil circuits used for utilities requirements in the coal liquefaction process.
In FIGS. 10 and 11 there is shown a modified construction for the return bends extending between the transverse tubes of tube stacks 41-46. In this modified construction, the return bends cross back and forth between stacks 41-46 so that each tube circuit comprises portions of at least two of the tube stacks 41-43 and at least two of the tube stacks 44-46. More specifically, there is provided a group of return bends 101 extending between the transverse tubes in tube stacks 41 and 43, a group of return bends 102 extending between the transverse tubes in tube stacks 42 and 41, a group of return bends 103 extending between transverse tubes in tube stacks 43 and 42, a group of return bends 104 extending between transverse tubes in tube stacks 44 and 46, a group of return bends 105 extending between transverse tubes in tube stacks 45 and 44, and a group of return bends 106 extending between transverse tubes of tube stacks 46 and 45. The construction and arrangement of return bends 101-106 is illustrated in FIGS. 10 and 11.
The advantages of the return bend construction shown in FIGS. 9 and 10 are that (1) the transverse tubes of a tube stack can be placed closer together for a given radius of return bend and (2) the effect of temperature variations of the flue gases throughout the transverse extent of the heating chamber can be minimized and applied more evenly to the slurry flowing through the tube circuits.
An example of the temperature profiles which may be obtained in a heater configuration in accordance with the invention is shown in FIG. 12. The heat transfer coefficient between the flue gases and the tube wall is assumed to be constant for this calculation of the tube wall temperature. The coal slurry heat transfer coefficient varies as a function of slurry temperature in the manner shown in FIG. 13. The values shown are typical for flow of coal slurry plus hydrogen in an eight inch diameter pipe at SRC-I process conditions.
The calculated tube wall temperature is shown again in FIG. 14 for comparison with wall temperatures which would occur if the heater were designed for co-current or counter-current flow of flue gases and coal slurry. The important improvement is the increased uniformity of the wall temperature throughout the heater. At temperatures above 850° F., the rate of coke formation increases rapidly and thus the co-current or counter-current heater will require more frequent shutdown for decoking than a mixed flow heater in accordance with the present invention. Alternatively, the co-current or counter-current heaters will require more heat transfer surface area in order to limit the coking potential to be equal to the present invention.
It is to be understood that variations may be made in the above-described preferred embodiments without departing from the scope of the invention as defined by the following claims.
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A convective heater for heating fluids such as a coal slurry is constructed of a tube circuit arrangement which obtains an optimum temperature distribution to give a relatively constant slurry film temperature. The heater is constructed to divide the heating gas flow into two equal paths and the tube circuit for the slurry is arranged to provide a mixed flow configuration whereby the slurry passes through the two heating gas paths in successive co-current, counter-current and co-current flow relative to the heating gas flow. This arrangement permits the utilization of minimum surface area for a given maximum film temperature of the slurry consistent with the prevention of coke formation.
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FIELD
The present invention relates to a treatment for mechanical wood pulp that improves its characteristics during downstream processing.
BACKGROUND OF THE INVENTION
Wood pulps are generally produced through multistep processes. Initially, logs can be subjected to grinding in which the logs are forced against a rotating abrasive stone which separates the fibers from the log and also the wood cell matrix. In a refining process, wood chips are fed between two metal discs, with at least one disc rotating. In both cases, essentially all of the constituents of wood are retained in the pulp that is eventually produced. Such pulp contains fiber bundles, fiber fragments and whole fibers. A lack of uniformity of pulp and constituents and the presence of lignin in the pulp give it certain desirable qualities, such as yield, paper bulk and opacity as well as good printability. The pulp also has less desirable properties for some paper types, such as low strength, relatively coarse surface and a lack of durability.
Chips to be refined can be destructured and impregnated with chemicals or enzymes prior to further mechanical treatment. This can help increase pulp quality or reduce energy consumption. These methods create slightly different pulps and also vary with the species of wood, quality of the wood, processing conditions and the amount of energy applied. Various forms exist: thermomechanical pulping (TMP), refiner pulping, stone groundwood pulping, etc.
In TMP, steam is added to the chips being refined to facilitate pulping and lower electricity consumption. Steam is also produced during refining and heat recovery systems can help recoup some of the energy cost of the process. The electric motors used to operate these refiners require very large amounts of power. The TMP process generally involves several refining stages to produce a desirable pulp. However, only a small portion of the energy used in each refining stage is actually used to separate and develop the fibers. Screening is used after or between refining stages to separate adequately refined fibers from longer, coarser fibers. These tougher fibers are sent to “rejects” refiners for further development. Depending on the quality of refining, the amount of rejects needing additional refining can be and usually is significant.
Woody biomass used in these mechanical pulping processes contains cellulose, hemicelluloses, lignin and extractives in varying amounts throughout the ultrastructure of its fibers. These various components act in conjunction to give these substrates mechanical strength and resistance to degradation. By selectively removing or altering certain components, it is possible to reduce the amount of energy required to separate and refine these fibers. The patent literature describes various approaches using different enzyme mixtures. For example US Patent Publication No. 2005/0000666, of Taylor et al., describes the use of mannanase and xylanase. Certain treatments have been found to significantly impact paper strength properties which have limited their applications. U.S. Pat. No. 5,865,949, of Pere et al., describes a process using an enzyme mixture containing endo-β-glucanase (EG), a limited mannanase and cellobiohydrolase (CBH) activity which reduces the negative effects on paper strength. U.S. Pat. No. 6,099,688, of Pere et al., describes the use of isolated cellobiohydrolase to increase the amount of relative amorphousness of the cellulose within the fibers. This process is said to cause even less damage to paper properties.
SUMMARY
The invention provides a method for preparing e.g., manufacturing a wood pulp. The pulp is prepared by exposing a mechanical wood pulp to an enzymatic solution containing an endoglucanase (EG) and a cellbiohydrolase (CBH), the ratio of enzymatic activities of the EG:CBH being at least 3.
It has been found that it is possible to carry out the treatment for an amount of time that results in a reduction of energy consumption during subsequent refining of the exposed pulp in which the freeness of the pulp (CSF) is reduced by at least 10% in comparison to the freeness of the same pulp which has not been exposed to the enzymatic solution while at least maintaining the tensile strength of a handsheet produced from the subsequently refined pulp in comparison with a handsheet produced from the same pulp which has not been exposed to the enzymatic solution. By maintaining tensile strength here is meant that the tensile index for the handsheet of treated material is at least 95% of that of the handsheet from untreated material, more preferably at least 96%, 97%, 98% or 99%.
The pulp to be treated can be pulp that has been mechanically refined, once, twice or more prior to the enzymatic treatment. The pulp can be a raw wood pulp. The pulp can also be a reject pulp containing a long-fiber fraction that makes it unsuitable for e.g., papermaking without further treatment, that can benefit from the treatment prior to further processing. Here, “long-fiber fraction” refers to R14 and P14/R30. R14 are fibers retained on a 14-mesh screen and P14/R30 pass through the 14-mesh screen but are retained on a 30 mesh screen.
The reduction in energy can be 5% or more. It can be 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22% or more.
As mentioned, one possible measure of the benefit of treatment can be determined by processing the treated pulp by further refining and preparation of handsheet, and comparing properties of the handsheet with one prepared from the same pulp that has not been treated. In the case of tensile strength, such determination can be made according to TAPPI standard T 205 sp-06.
In another embodiment, the invention provides a method for producing a wood pulp, by exposing a wood pulp that has been refined at least once and having a long-fiber fraction containing wood fibers having a length of from 1 to 7 mm to an enzymatic solution. The pulp can be e.g., screened fraction of a refined pulp. The exposure time can be selected to reduce the average fiber length by between 5% and 25%. A more likely range of reduction would be between 10% and 20%, and could be about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19% or about 20%, or up to any of these amounts. This reduction in fiber length can also be accompanied by the benefit of a reduction of energy consumption in a subsequent refining step of the enzymatically treated pulp.
The enzymatic treatment can be part of a larger process such as the manufacture of cardboard, paper towels, newspaper, hygiene products, etc.
The wood pulp treated in the enzymatic step can have a CSF of greater than 650 ml and be exposed to the enzymatic solution for time sufficient to reduce the drainability to less than 150. The initial CSF can also be greater than or about 220 ml, about 250 ml, about 300 ml, about 350 ml, about 400 ml, about 450 ml, about 500 ml, about 550 ml, or about 600 ml with the drainability of the treated pulp being less than or about 160 ml, about 170 or about 180 ml.
The enzymatic solution contains at least the aforementioned EG and CBH, and preferably also contains mannanase (MAN). The activity of the EG relative to the CBH is always significantly greater i.e., the ratio of activities of the EG:CBH are at least 3:1, but can be at least any of 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, more preferably at least 10:1, 11:1 or 12:1. The activity of MAN is also greater than CBH, activity ratio MAN:CBH being at least 1.5:1, or at least any of 1.6:1, 1.7:1, 1.8:1, 1.9:1 or 2:1.
A measure of the enzymatic activities contained in a pulp treatment solution is, in practice, made relative to the substrate being treated. In the case of e.g., a fraction containing wood fibers having a length of from 1 to 7 mm, activity can be determined based on dry weight measured according to standard T 258 om-06.
The enzymatic activity of the EG is in the range of 0.5 to 25 CMCU per gm of wood substrate, but can be about any of 1, 2, 3, 4, 5, 6, 7, 8, 9, 9, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 20, 21, 22, 23, or 24 CMCU per gm of wood substrate. Dry weight is measured according to standard T 258 om-06.
The enzymatic activity of the hemicellulase, mannanase is at least 1.5 times the activity of the CBH, and is typically at least 0.05 FPU per gm of wood fiber substrate. The long-fiber fraction based on dry weight measured according to standard T 258 om-06.
The enzymatic activity of the CBH, which is always lower than the activities of the EG and MAN, as described above, is typically at least 0.05 FPU per gm of the wood fiber substrate e.g., long-fiber fraction of the wood pulp being treated, again based on dry weight measured according to standard T 258 om-06. Enzymatic activity of CBH can be from 0.05 to 10 FPU, but is preferably between 0.1 and 3 FPU/g of wood on a dry weight basis.
An embodiment of the invention includes exposing mechanical wood pulp to an enzymatic solution for a sufficient length of time such that the amount of fines in a subsequently refined pulp is increased by at least 10% in comparison to subsequently refined pulp which has not been exposed to the enzymatic solution. Fines are measured according to standard TAPPI T-261. This increase in fines can also be accompanied by the benefit of a reduction of energy consumption in a subsequent refining step of the enzymatically treated pulp.
In another embodiment, the invention includes exposing mechanical wood pulp to an enzymatic solution for a sufficient length of time such that handsheet density of a handsheet produced from said subsequently refined pulp is increased by at least 5% in comparison to the handsheet density of a handsheet produced from the same pulp which has not been exposed to the enzymatic solution. Handsheet density is determined according to standard TAPPI T 220 sp-06. This comparative increase in handsheet density can also be accompanied by the benefit of a reduction of energy consumption in a subsequent refining step of the enzymatically treated pulp.
According to another embodiment, mechanical wood pulp is exposed to the enzymatic solution for a length of time selected to preclude the change in tear index of a handsheet produced from said subsequently refined pulp to no more than a decrease of 15% in comparison to the tear index of a handsheet produced from the same pulp which has not been exposed to the enzymatic solution. By this is meant that the tear index of a handsheet can increase or be the same, but if it decreases, it decreases no more than 15% with respect to the comparative sheet. Tear index of a handsheet is determined according to standard TAPPI T 414 om-12.
In yet another embodiment, a mechanical wood pulp is exposed to an enzymatic solution for a length of time selected such that brightness of subsequently refined pulp is at least maintained in comparison to subsequently refined pulp which has not been exposed to the enzymatic solution. Brightness (ISO) is determined according to standard TAPPI T 452 om-08. This maintenance of optical brightness can also be accompanied by the benefit of a reduction of energy consumption in a subsequent refining step of the enzymatically treated pulp.
The method of the invention has been demonstrated with the softwood Black Spruce, Picea mariana . Suitable wood fibers contain between 38 and 52% by weight cellulose, between 20 and 30% by weight lignin, between 20 and 30% by weight hemicelluloses (hemicellulose typically being from 15 to 20% mannans by total weight of the wood chips and from 15 to 20% xylans by total weight of the wood chips).
The invention includes a method for producing a paper product that includes the steps of: (a) introducing mechanical wood pulp into a vessel; (b) introducing into the vessel an enzymatic solution comprising an endoglucanase (EG), a cellbiohydrolase (CBH) and a mannanase (MAN) wherein the ratio of enzymatic activity of EG:CBH is at least 3, and the ratio of enzymatic activity of MAN:CBH is at least 1.5; (c) waiting a length of time sufficient for the freeness of the pulp to be reduced to a selected level of freeness of fibers in the pulp; and (d) making the paper product with the pulp produced, the paper having a tensile strength at least as great as paper produced from the mechanical wood pulp by the same method without exposure to said enzymatic solution.
The invention includes a method of manufacturing a wood pulp that includes the step of: exposing a mechanical wood pulp to an enzymatic solution comprising an endoglucanase (EG), a cellbiohydrolase (CBH) and a mannanase (MAN) wherein the ratio of enzymatic activity of EG:CBH is at least 3, and the ratio of enzymatic activity of MAN:CBH is at least 1.5, for a sufficient amount of time to reduce energy consumption during subsequent refining of the exposed pulp in comparison to energy consumption during refining of the same pulp which has not been exposed to the enzymatic solution while at least maintaining the tensile strength of a handsheet produced from said subsequently refined pulp in comparison with a handsheet produced from the same pulp which has not been exposed to the enzymatic solution, the tensile strength being determined according to TAPPI standard T 205 sp-06.
The present invention thus relates to methods for reducing the amount of energy required to refine reject pulp by treating said pulp with a solution containing enzymes and preferably some stabilizer compounds. Stabilizer agents and surfactants containing mainly propylene glycol, glycerol, sorbitol and to a lesser degree proxel, potassium sorbate and ethoxylated fatty alcohols can be used. The enzymatic treatment can be carried out at process temperatures of from 20° C. to 80° C., for example between 40° C. and 60° C. The enzymatic treatment can be carried out at a pH of from about 2 to about 10. The treatment time can be from 30 minutes to 10 hours. Other temperatures, pHs and or times can be used.
It is possible to maintain tensile strength although some loss of tear strength of refined pulp and resultant paper products was observed.
The enzyme solution preferably possesses the following relative activities: the EG should have a 10 fold greater activity than the CBH and the mannanase should have a 2 fold greater activity than the CBH. This enzyme solution is available commercially from Novozymes® under the name Celluclast 1.5L™.
Methods of refining pulp with lower energy requirements to obtain a desirable degree of refining are set forth herein. Methods for refining the pulp wherein the refining process includes treatment of the pulp with a complex enzyme mixture are presented, wherein the resultant pulp and/or paper products have maintained tensile strength, improved optical properties and slightly reduced tear index as compared to untreated pulps or products therewith.
Pulp and paper products made therefrom having maintained tensile strength, improved optical properties and slightly reduced tear strength are provided. Pulp and papers made therefrom which require less energy to produce are provided.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are only intended to provide a further explanation of the present invention as claimed
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments illustrating the invention and establishing feasibility of various aspects thereof are described below with reference to the accompanying drawings, in which:
FIG. 1 is a graph showing the amount of sugars released per gram of oven dried pulp (ODP) into the liquor after a 1 hour enzyme hydrolysis at different dosages. Based on these results dosages (5 and 10 FPU/g ODP) were chosen for refining trials;
FIG. 2 is a bar graph showing the freeness of pulps obtained after the enzymatically treated pulps were refined under the same conditions of feed speed, plate gap and consistency;
FIG. 3 is a plot showing percent decrease in fiber length with dosage, after enzymatically treated pulps were refined;
FIG. 4 is a plot showing percent increase in fines with dosage, after enzymatically treated pulps were refined;
FIG. 5 is a plot showing handsheet density as function of enzymatic loading, of handsheets made from enzymatically treated refined pulps;
FIG. 6 is a plot showing tear strength as a function of enzymatic loading, of handsheets made from enzymatically treated refined pulps;
FIG. 7 is a plot showing tensile strength as a function of enzymatic loading, of handsheets made from enzymatically treated refined pulps; and
FIG. 8 is a plot showing brightness as a function of enzymatic loading of handsheets made from enzymatically treated refined pulps.
DETAILED DESCRIPTION
The present invention relates to a method of refining pulp, wherein the method includes the use of an enzyme mixture containing cellulases and hemicellulase. Treatment with this solution following primary defibering and selective screening prior to secondary reject or post refining can reduce the energy required to reach a given degree of refining. This enzyme mixture is to contain a significant EG activity, a marked mannanase activity and a CBH activity that is lower than the first two but not negligible.
As used herein, an endo-β-glucanase is preferably a cellulase classified as EC 3.2.1.6-endo-1,3(4)-β-glucanase. This enzyme is preferably capable of endohydrolysis of 1,3- or 1,4-linkages in β-D-glucans when the glucose residue whose reducing group is involved in the linkage to be hydrolysed is itself substituted at C-3. This hydrolysis cleaves the O-glycosyl bond of the cellulose backbone.
As used herein, a “mannanase” is preferably a hemicellulase classified as EC 3.2.1.78, and called endo-1,4-β-mannosidase. Mannanase includes β-mannanase, endo-1,4-mannanase, and galactomannanase. Mannase is preferably capable of catalyzing the hydrolysis of 1,4-β-D-mannosidic linkages in mannans, including glucomannans, galactomannans and galactoglucomannans. Mannans are polysaccharides primarily or entirely composed of D-mannose units.
As used herein, a cellobiohydrolase is preferably a cellulase classified as EC 3.2.1.91 and called cellulose 1,4-β-cellobiosidase (non-reducing end). This enzyme produces the hydrolysis of (1→4)-δ-D-glucosidic linkages in cellulose and cellotetraose, releasing cellobiose from the non-reducing ends of the chains
EG activity can be determined following the carboxymethyl cellulose (CMC) method described in Measurement of Cellulase Activities by T. K. Ghose (Pure & Appl. Chem. Vol 69, No. 2, pp. 257-268, 1987). The amount of reducing sugars released from enzymatic hydrolysis of a 2% solution of a well characterized CMC is used to determine the enzymes EG activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959).
CBH activity can be determined following the filter paper assay method described in Measurement of Cellulase Activities by T. K. Ghose (Pure & Appl. Chem. Vol 69, No. 2, pp. 257-268, 1987). The amount of reducing sugars released from enzymatic hydrolysis of Whatman No. 1 filter paper strip of known size is used to determine the enzyme's CBH activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959).
Mannanase activity can be determined following the method described by M. Ratto and K. Poutanen (Biotechnology Letters, No 9, pp-661-664, 1988). The amount of reducing sugars released from enzymatic hydrolysis of a 0.5% solution of locust bean gum is used to determine the enzymes mannanase activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959).
An enzyme solution containing EG, CBH and mannanase activities in the correct ratios is commercially available from Novozymes® under the name Celluclast 1.5L™. This solution contains between 40 mg and 50 mg of total protein per milliliter of solution. When kept at between 0° C. and 25° C., the solution is stable and its activity is maintained for about 18 months. Storage at higher temperatures will reduce this effective storage time.
The enzyme solution can vary slightly in ratio of activities which still give the desired energy reductions and paper qualities. The amount of total protein in the correct ratio should be between 0.02 kg and 10 kg per metric ton of oven dried wood. This amount of total protein can vary depending on the type of woody substrate being used, for example virgin hardwood kraft, virgin softwood kraft, recycled groundwood, refiner groundwood, pressurized refiner groundwood, thermomechanical, chemithermomechanical or a mixture thereof; or the species of wood which makes up this substrate, for example Populus sp., Acer sp., Picea sp., Abies sp., Pinus sp., Conium sp., etc.
The pulp of the present invention can be treated with one or more other components, including polymers such as anionic and non-ionic polymers, clays, other fillers, dyes, pigments, defoamers, microbiocides, pH adjusting agents such as alum or hydrochloric acid, other enzymes, and other conventional papermaking or processing additives. These additives can be added before, during or after introduction of the enzyme solution. The enzyme solution can be added, and is preferably added to the papermaking pulp before the addition of coagulants, flocculants, fillers and other conventional and non-conventional papermaking additives, including additional enzymes.
The pulp can be any conventional softwood or hardwood species used in mechanical pulp production, such as spruce, fir, hemlock, aspen, acacia, birch, beech, eucalyptus, oak and other softwood and hardwood species. The pulp can contain cellulose fibers in an aqueous medium at a concentration of at least 35% by weight based on the oven dried solids content of the pulp. The pulp can be, for example, virgin pulp (e.g. spruce, fir, pine, eucalyptus, and include virgin hardwood or virgin softwood), hardwood kraft, softwood kraft, recycled groundwood, refiner groundwood, pressurized refiner groundwood, thermomechanical, chemithermomechanical or mixtures thereof.
According to various embodiments, the papermaking system can include a primary refiner, a secondary refiner, a screen, a mixer, a latency and/or blend chest, and papermaking equipment, for example, screens. The papermaking system can also include metering devices for providing a suitable concentration of the enzyme composition or other additives to the flow of pulp. Valving, pumps, and metering equipment as known to those skilled in the art can also be used for introducing various additives described herein to the pulp.
According to one embodiment, the enzyme solution can be added to the pulp after the pulp leaves the first refiner (also known as the primary refiner) during the refining process. For example, the enzyme solution can be added before the second refiner (also known as the secondary refiner), after the second refiner, before the screen, after the screen, before the mixer, after the mixer, before the latency and/or blend chest, to the latency and/or blend chest. For example, the enzyme solution can be added after the second refiner, between the screen and the mixer, or after the mixer. Other additives as described can be added to the papermaking system as known to those skilled in the art.
The pulp can be treated with the enzyme solution when the pulp is at a temperature of from 10° C. to about 75° C., from about 30° C. to about 70° C., or from about 40° C. to about 60° C. The pulp can be at a pH of from 2 to 10, from about 4 to 7, or from 4.5 to 5.5. A treatment time can be from 10 minutes to about 10 hours, from about 30 minutes to about 5 hours or from 1 hours to 2 hours.
The enzyme treatment is carried out during the refining process, but before completion of the refining process. The enzyme treatment is carried out on “coarse pulp”. A “coarse pulp” refers to a woody material used as the raw material of the mechanical pulp, which has been subjected to at least one mechanical refining process step. The term coarse pulp therefore encompasses, e.g. once refiner or ground pulp, twice refined or ground pulp, the reject pulp and/or long fiber fractions, and combinations thereof. Preferably, the enzyme treatment is carried out on once refined or ground pulp or the reject pulp. More preferably the enzyme solution is carried out on once refined or ground pulp, a screened long fiber pulp fraction and the reject pulp.
In another embodiment, the enzyme solution can be added at the latency chest in a refining operation. As an example, the enzyme solution can be added after screening and in the feedline before the latency chest. In this embodiment, the screened pulp is directed to a latency chest prior to a reject refiner. The pulp is then refined to desired specifications before being returned to the papermaking system stream.
The introduction of the enzyme solution can be made at one or more points and the introduction can be continuous, semi-continuous, batch, or combinations thereof.
According to various embodiments, the consistency of the pulp can be less than 20%, from about 1% to 15%, or from about 4% to 10%.
A pulp processed as described herein can exhibit maintained tensile strength, while suffering some loss of tear strength. Paper products made from the pulp also maintain tensile strength while losing some tear strength. The addition of the enzyme solution creates fiber weaknesses which allow the formation of shorter fibers but also enhance fiber fibrillation which is why tear is affected while tensile strength is maintained. Fines production increases, thus lowering freeness at a given specific energy of refining SEC. The addition of the enzyme solution to coarse pulp reduces the amount of SEC needed to obtain a desired level of freeness.
A pulp produced by the methods described herein can be used in the production of paper products, including, for example, cardboard, paper towels, newspaper, and hygiene products. The methods described herein can also be suitable for textile manufacturing.
EXAMPLES
Example 1
Enzymatic Activities
The commercial enzyme product, Celluclast 1.5L™, was tested for several enzymatic activities and was found to have several different types of activities. Table 1 list all relevant and significantly measurable activities and protein concentration.
Carboxymethyl cellulase (CMC) activity, equivalent to endo-β-glucanase activity, was determined following the CMC method described in Measurement of Cellulase Activities by T. K. Ghose (Pure & Appl. Chem. Vol 69, No. 2, pp. 257-268, 1987). The amount of reducing sugars released from enzymatic hydrolysis of a 2% solution of a well characterized CMC during a 30.0 minute hydrolysis at pH 4.8 and 50° C. is used to determine the enzymes EG activity. Sugar concentration is determined by the well known 3,5-dinitrosalicylic acid (DNS) solution method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959). The addition of the DNS solution to the hydrolysis filtrate stops the reaction. The mixture was boiled for 5.0 minutes to allow for color formation. After cooling, the absorbency is measured at 540 nm and the concentration is determined against a standard curve.
Mannanase activity was determined following the method describer by M. Ratto and K. Poutanen (Biotechnology Letters, No 9, pp-661-664, 1988). The amount of reducing sugars released from enzymatic hydrolysis of a 0.5% solution of locust bean gum during a 30.0 minute hydrolysis at pH 4.8 and 50° C. is used to determine mannanase activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959) and described thoroughly above.
Filter paper activity, equivalent to CBH activity, was determined following the filter paper assay method described in Measurement of Cellulase Activities by T. K. Ghose (Pure & Appl. Chem. Vol 69, No. 2, pp. 257-268, 1987). This method uses the amount of reducing sugars released from enzymatic hydrolysis of Whatman No. 1 filter paper strip of known size during a 30.0 minute hydrolysis at pH 4.8 and 50° C. to determine the enzymes CBH activity. Sugar concentration is determined by the well known DNS method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959) and described thoroughly above.
Protein concentration was determined using the Bradford assay. Bradford assay kits purchased from Sigma-Aldrich were used. This well known method uses the binding of protein with a solution of Coomassie Blue which allows colorimetric determination of protein concentration based on a standard curve produced using bovine serum albumin. Absorbency is measured at 595 nm.
TABLE 1
Measured parameters of Celluclast 1.5L ™
Parameter
Value
Unit
Endo-β-glucanase
1860
CMC/ml
Mannanase activity
285
IU/ml
Cellobiohydrolase
150
FPU/ml
Total protein
43.4
mg/ml
Example 2
Sugars Released
The enzyme solution was added to a TMP reject pulp (5 g ODP) using the solution's filter paper activity as a dosage indicator. Several dosages (5 and 10 FPU/g ODP), chosen based on reducing sugar results, and a control were done in duplicate and measured in duplicate for a total of four data sets. Hydrolysis was carried out at a consistency of 10%, a temperature of 50° C. and a time of 1 hour. After which, the samples were filtered and the filtrate was treated using the well known 3,5-dinitrosalicylic acid (DNS) solution method described by G. L. Miller (Analytical Chem., No. 31, p. 426, 1959). The addition of the DNS solution to the hydrolysis filtrate stops the reaction. The mixture was boiled for 5.0 minutes to allow for color formation. After cooling, the absorbency is measured at 540 nm and the concentration is determined against a standard curve. This is shown in FIG. 1 from the data in Table 2.
TABLE 2
Sugars released during bench-scale Celluclast 1.5L ™ trials
Enzyme dosage
Sugars released
Standard
(FPU/g oven
into liquor
deviation
dried pulp)
(mg/g ODP)
(mg/g ODP)
0
0.54
0.01
1.0
6.13
0.06
2.0
9.79
0.11
3.0
12.74
0.16
4.0
14.15
0.19
5.0
16.62
0.03
10.0
22.31
0.05
Example 3
Freeness
The enzyme solution was added to a TMP reject pulp (200 g ODP) using the solution's filter paper activity as a dosage indicator. Two dosages (5 and 10 FPU/g ODP), chosen based on reducing sugar results, and a control were done in duplicate. Hydrolysis was carried out at a consistency of 4%, a temperature of 50° C. and a time of 1 hour. After this treatment, pulp was dewatered to 20% consistency and refined in a KRK refiner with a disc gap of 0.10 mm. Refined pulp was collected and moisture was checked prior to measuring Canadian Standard Freeness (CSF). Results are shown in the Table 3 and FIG. 2 .
TABLE 3
Freeness of pulp treated with Celluclast 1.5L ™ trials
before refining
Enzyme dosage
Standard
(FPU/g oven
Average
deviation
dried pulp)
CSF (ml)
(ml)
Control
220
14
(0 FPU/g ODP)
5
179
6
10
178
0
Example 4
Energy Savings
The enzyme solution was added to a TMP reject pulp (200 g ODP) using the solution's filter paper activity as a dosage indicator. Two dosages (5 and 10 FPU/g ODP), chosen based on reducing sugar results, and a control were done in duplicate. Hydrolysis was carried out at a consistency of 4%, a temperature of 50° C. and a time of 1 hour. After this treatment, pulp was dewatered to 20% consistency and refined in a KRK refiner with a disc gap of 0.10 mm. Energy consumption was monitored with an online monitor and networked computer. Results are shown in Table 4.
TABLE 4
Specific Energy Consumption needed to refine
pulp treated with Celluclast 1.5L ™ to
approximately 200 ml freeness
Enzyme
Meter
Net
Average
Energy
loading
reading
SEC*
SEC
Saving
(FPU/g)
(kWh)
(kWh/t)
(kWh/t)
(%)
0
0.503
1892.2
1962.2
0
0
0.531
2032.2
5.0
0.462
1687.2
1702.2
−13.5
5.0
0.468
1717.2
10.0
0.425
1502.2
1524.7
−22.3
10.0
0.434
1547.2
*No-load energy consumption (3 minutes of warm-up energy was calculated to be 0.12456 kWh) was subtracted from the meter reading to give the net energy consumption
Example 5
Fiber Properties
The enzyme solution was added to a TMP reject pulp (200 g ODP) using the solution's filter paper activity as a dosage indicator. Two dosages (5 and 10 FPU/g ODP), chosen based on reducing sugar results, and a control were done in duplicate. Hydrolysis was carried out at a consistency of 4%, a temperature of 50° C. and a time of 1 hour. After this treatment, pulp was dewatered to 20% consistency and refined in a KRK refiner with a disc gap of 0.10 mm. Energy consumption was monitored with an online monitor and networked computer. Refined pulp was collected and moisture was checked prior to testing fiber properties with a Fiber Quality Analyzer. Results are shown in Table 5 and in FIGS. 3 and 4 .
TABLE 5
Some fiber properties of pulp treated with Celluclast 1.5L ™ and
refined to approximately 200 ml freeness
Enzyme loading
Mean length
Mean length
(FPU/g oven
weighted fiber
weighted fines
dried pulp)
length (mm)
percent (%)
Control
1.202 ± 0.035
12.63 ± 0.82
(0 FPU/g ODP)
5
0.997 ± 0.030
14.29 ± 0.39
10
0.882 ± 0.024
16.43 ± 0.56
Example 6
Handsheet Properties
The enzyme solution was added to a TMP reject pulp (200 g ODP) using the solution's filter paper activity as a dosage indicator. Two dosages (5 and 10 FPU/g ODP), chosen based on reducing sugar results, and a control were done in duplicate. Hydrolysis was carried out at a consistency of 4%, a temperature of 50° C. and a time of 1 hour. After this treatment, pulp was dewatered to 20% consistency and refined in a KRK refiner with a disc gap of 0.10 mm. Energy consumption was monitored with an online monitor and networked computer. Refined pulp was collected and moisture was checked prior to preparing handsheets following TAPPI standard T 205 sp-06. Results are shown in Table 6 and in FIGS. 5 , 6 , 7 and 8 .
TABLE 6
Handsheet properties of paper made from pulp treated with Celluclast
1.5L ™ and refined to approximately 200 ml freeness
Enzyme loading
Mean Tear
Mean Tensile
Mean
(FPU/g oven
Mean density
Index
Index
Brightness
dried pulp)
(g/cm 3 )
(mN*m 2 /g)
(N*m/g)
(ISO)
Control
0.47 ± 0.02
7.71 ± 0.11
34.33 ± 0.99
47.63 ± 1.66
(0 FPU/g ODP)
5
0.52 ± 0.01
6.62 ± 0.20
33.39 ± 0.54
51.62 ± 0.22
10
0.53 ± 0.02
5.43 ± 0.17
33.12 ± 1.20
51.85 ± 0.91
All patents, applications and publications mentioned above and throughout this application are incorporated in their entirety by reference herein.
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A process using a multicomponent enzyme preparation to treat screened once refined pulps and reduces the specific energy consumption and/or increasing production while maintaining or increasing handsheet physical properties. The enzyme preparation has a major endoglucanase activity, a significant mannanase activity and a relatively small cellobiohydrolase activity. This enzyme mixture is prepared from a genetically modified strain of Trichoderma reseii.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority benefit of Taiwan application serial no. 91100553, filed Jan. 16, 2002.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a structure of a semiconductor memory device and the fabrication thereof. More particularly, the present invention relates to a structure of a non-volatile memory and the fabrication thereof.
2. Description of Related Art
Non-volatile memory is widely used to store booting information in personal computers and in various electronic apparatuses since the data stored in a non-volatile memory does not disappear when the power is turned off.
In the family of non-volatile memory, the simplest one is namely the mask read-only memory (Mask ROM). A Mask ROM uses a MOS transistor as a memory cell and is programmed by implanting ions into the channels of selected memory cells to alter their threshold voltages and thereby to control their logic states (0/1). A Mask ROM cell comprises a substrate, two bit-lines, a polysilicon word-line crossing over the bit-lines and a channel region in the substrate under the word-line and between the bit-lines. The channel region represents a logic state “0” or“1” dependent on the presence or absence of the ions implanted.
Another type of non-volatile memory is the well-known electrically erasable programmable read-only memory (E 2 PROM), which conventionally comprises a floating gate and a control gate both made from polysilicon. When an E 2 PROM is being programmed or erased, appropriate biases are applied to the control gate and to the source/region to inject charges into the floating gate or to drive out charges from the floating gate. However, if there are defects in the tunnel oxide layer under the floating gate in a conventional flash memory, a leakage easily occurs in the memory cell and the reliability of the device is thus lowered.
To solve the leakage problem of a flash memory, a nitride charge-trapping layer is recently used to replace the polysilicon floating gate in the conventional flash memory. The nitride charge-trapping layer is usually disposed between two silicon oxide layers to form an oxide/nitride/oxide (ONO) composite layer, while the memory with a nitride charge-trapping layer is known as a “nitride read-only memory (NROM)”. In a NROM, the nitride charge-trapping layer is able to trap electrons so that the injected hot electrons do not distribute evenly in the charge-trapping layer, but are localized in a region of the charge-trapping layer near the drain with a Gaussian spatial distribution. Because the injected electrons are localized, the charge-trapping region is small and is less likely to locate on the defects of the tunnel oxide layer. A leakage therefore does not easily occur in the device. Moreover, since the electrons are localized in a region of the charge-trapping layer near the drain, the NROM is capable of storing two bits in one memory-cell. This is achieved by changing the direction of the current in the channel and thus varying the generating site and the injecting region of the hot electrons. Thus, a memory cell can be configured one of the four states, in which each of the two ends of the charge-trapping layer may have one group of electrons with a Gaussian spatial distribution or have zero electron trapped in it.
However, when the non-volatile memory device is scaled down, the width of the bit-line of the non-volatile memory is also decreased. Therefore, the resistance of the bit-line becomes higher, which means that the “bit-line loading” is higher.
To lower the resistance of the bit-line, a deeper junction or a higher dopant concentration is adopted in the prior art. However, a deeper junction will cause a severer short channel effect (SCE) and a larger punch-through leakage, and the dopant concentration of the bit-line is restricted by the solid-state solubility of the dopants. Therefore, miniaturizing the non-volatile memory device is still not easy.
SUMMARY OF THE INVENTION
Accordingly, this invention provides a non-volatile memory and the fabrication thereof to lower the bit-line loading in a miniaturized memory device.
To fabricate the non-volatile memory of this invention, a planar doped region is formed in a substrate. A mask layer and a patterned photoresist layer are sequentially formed on the substrate. A plurality of trenches are formed in the substrate with the photoresist layer as a mask to divide the planar doped region into a plurality of buried bit-lines. The photoresist layer is removed and then a recovering process may be performed to recover the side-walls and the bottoms of the trenches from the damages caused by the trench etching step. The mask layer is removed. A dielectric layer is formed on the substrate and then a plurality of word-lines are formed on the dielectric layer.
This invention also provides a method for fabricating a Mask ROM. In this method, a plurality of buried bit-lines and a plurality of word-lines are fabricated by the same method described above, and a gate dielectric layer is formed under the word-lines, while a portion of the substrate under the word-lines and between the buried bit-lines serves as a plurality of coding regions. Thereafter, a coding mask not covering selected coding regions is formed over the substrate and then a coding implantation is performed with the coding mask as a mask.
This invention also provides a method for fabricating a nitride read-only memory (NROM). In this method, a plurality of buried bit-lines and a plurality of word-lines are fabricated by the same method described above, but a charge trapping layer, instead of the (gate) dielectric layer mentioned above, is formed under the word-lines.
This invention further provides a non-volatile memory, which comprises a substrate, a plurality of buried bit-lines, a plurality of word-lines, and a dielectric layer. The buried bit-lines are located in the substrate and are separated by a plurality of isolating structures. The word-lines are disposed on a portion of the substrate and the isolating structures and cross over the isolating structures and the buried bit-lines. The dielectric layer is between the substrate and the word-lines. The isolating structures may comprise trenches.
In the method of fabricating a non-volatile memory, a Mask ROM or a NROM of this invention, the recovering process is used to rearrange the distorted lattice of the substrate caused by the etching process for forming the trenches. Consequently, the defects in the channel regions are reduced and a leakage is prevented.
Since the buried bit-lines are separated by the trenches, a deeper junction can be formed to lower the resistance of the buried bit-lines and thereby to lower the bit-line loading without adversely augmenting the short channel effect and the punch-through leakage.
It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings,
FIGS. 1 A˜ 1 F illustrate the process flow of fabricating a Mask ROM according to the first preferred embodiment of this invention; and
FIGS. 2 A˜ 2 F illustrate the process flow of fabricating a NROM according to the second preferred embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
In the first embodiment of this invention, a Mask ROM structure and the fabrication thereof are described.
Refer to FIG. 1A, a substrate 100 , such as a P-type silicon substrate, is provided. The substrate 100 is partitioned into a memory region 102 and a periphery region 104 .
A sacrificial layer 106 is formed on the substrate 100 . The sacrificial layer 106 comprises, for example, silicon oxide and has a thickness, for example, from about 50 Å to about 100 Å, and is formed by a method such as chemical vapor deposition (CVD)
A patterned photoresist layer 108 is formed on the substrate 100 to cover the periphery region 104 . An ion implantation 110 is then performed to dope the substrate 100 exposed by the photoresist layer 108 to form a planar doped region 112 , wherein the implanted ions are, for example, N-type ions.
Refer to FIG. 1B, the photoresist layer 108 and the sacrificial layer 106 (FIG. 1A) are removed and then a pad oxide layer 114 and a mask layer 116 are sequentially formed on the substrate 100 . The pad oxide layer 114 has a thickness of, for example, from about 30 Å to about 60 Å and is formed by, for example, thermal oxidation or chemical vapor deposition (CVD). The mask layer 116 comprises, for example, silicon nitride and is formed by, for example, chemical vapor deposition (CVD).
A lithography process and an etching process are then performed to pattern the mask layer 116 and the pad oxide layer 114 to form a plurality of openings 118 in the mask layer 116 and the pad oxide layer 114 on the periphery region 104 .
Refer to FIG. 1C, a field oxide layer 120 is formed on the substrate 100 exposed by the opening 118 by thermal oxidation.
A patterned photoresist 122 , which covers the periphery region 104 but exposes a portion of the memory region 102 , is then formed over the substrate 100 . By using the photoresist layer 122 as a mask, the mask layer 116 , the pad oxide layer 114 and the substrate 100 are etched sequentially to form a plurality of trenches 124 . The bottom of the trench 124 is lower than that of the planar doped region 112 , so that the planar doped region 112 is divided into a plurality of buried bit-lines 126 . In additional, a portion of the bottom of one trench 124 serves as a plurality of coding regions arranged in a direction that projects out from the paper (not shown).
Refer to FIG. 1D, the patterned photoresist layer 122 is removed. A thermal oxidation is then performed to form a liner oxide layer 128 on the exposed surface of the trench 124 with the mask layer 116 as a mask, so as to decrease the defects therein caused by the etching process of the trench 124 .
Refer to FIG. 1E, the liner oxide layer 128 , the mask layer 116 and the pad oxide layer 114 are removed and then a gate dielectric layer 130 is formed on the substrate 100 . The gate dielectric layer 130 comprises, for example, silicon oxide and is formed by a method such as thermal oxidation.
A conductive layer (not shown) is then formed on the substrate 100 . The conductive layer comprises, for example, polysilicon and is formed by, for example, chemical vapor deposition (CVD) with in-situ doping. A lithography process and an etching process are performed to pattern the conductive layer into a plurality of word-lines 132 on the memory region 102 and a plurality of gates 134 on the periphery region 104 . Thereafter, a source/drain region 136 is formed in the substrate 100 beside the gate 134 on the periphery region 104 .
Refer to FIG. 1F, a coding process is performed to program the Mask ROM with the following steps. A patterned photoresist layer 138 , which does not cover a selected coding region, is formed over the substrate 100 by using a photo-mask. An ion implantation 140 is performed to implant ions into the selected coding region with the photoresist layer 138 as a mask. The subsequent back-end process is well-known by those skilled in the art and will not be described here.
In the method of the first embodiment of this invention, the distorted lattice of the substrate 100 is rearranged with a thermal oxidation process after the trench 124 is formed and after the photoresist layer 122 is removed. The defects in the channel regions thus are decreased and a leakage is prevented.
Moreover, this invention sets the coding regions at the bottom of the trench 124 and selectively implants ions therein to set the selected channels to an “Off” state during a reading operation.
Since the buried bit-lines 126 are separated by the trenches 124 , a deeper junction can be formed to lower the resistance of the buried bit-lines and thereby to lower the bit-line loading without adversely augmenting the short channel effect and the punch-through leakage.
Second Embodiment
In the second embodiment of this invention, a NROM structure and the fabrication thereof are described.
Refer to FIG. 2A, a substrate 200 , such as a P-type silicon substrate, is provided. The substrate 200 is partitioned into a memory region 202 and a periphery region 204 .
A sacrificial layer 206 is formed on the substrate 200 . The sacrificial layer 206 comprises, for example, silicon oxide and has a thickness, for example, from about 50 Å to about 100 Å, and is formed by a method such as chemical vapor deposition (CVD)
A patterned photoresist layer 208 is formed on the substrate 200 to cover the periphery region 204 . An ion implantation 210 is then performed to dope the substrate 200 that is exposed by the photoresist layer 208 to form a planar doped region 212 , wherein the implanted ions are, for example, N-type ions.
Refer to FIG. 2B, the photoresist layer 208 and the sacrificial layer 206 (FIG. 2A) are removed and then a pad oxide layer 214 and a mask layer 216 are sequentially formed on the substrate 200 . The pad oxide layer 214 has a thickness, for example, from about 30 Å to about 60 Å and is formed by a method such as thermal oxidation or chemical vapor deposition (CVD). The mask layer 216 comprises, for example, silicon nitride and is formed by, for example, chemical vapor deposition (CVD).
A lithography process and an etching process are then performed to pattern the mask layer 216 and the pad oxide layer 214 to form a plurality of openings 218 in the mask layer 216 and in the pad oxide layer 214 on the periphery region 204 .
Refer to FIG. 2C, a field oxide layer 220 is formed on the substrate 200 that is exposed by the opening 218 by thermal oxidation.
A patterned photoresist 222 , which covers the periphery region 204 but exposes a portion of the memory region 202 , is then formed over the substrate 200 . By using the photoresist layer 222 as a mask, the mask layer 216 , the pad oxide layer 214 and the substrate 200 are etched sequentially to form a plurality of trenches 224 . The bottom of the trench 224 is lower than that of the planar doped region 212 , so that the planar doped region 212 is divided into a plurality of buried bit-lines 226 .
Refer to FIG. 2D, the photoresist layer 222 is removed. A thermal oxidation is then performed to form a liner oxide layer 228 on the exposed surfaces of the trenches 224 with the mask layer 216 as a mask, so as to decrease the defects therein caused by the etching process of the trench 224 .
Refer to FIG. 2E, the liner oxide layer 228 , the mask layer 216 , and the pad oxide layer 214 are sequentially removed. A composite dielectric layer 230 (charge trapping layer) is formed on the memory region 202 and a dielectric layer 232 is formed on the periphery region 204 . The composite dielectric layer 230 comprises, for example, a silicon oxide/silicon nitride/silicon oxide (ONO) layer. The dielectric layer 232 comprises, for example, silicon oxide and is formed by a method such as thermal oxidation. The method for fabricating a composite dielectric layer 230 on the memory region 202 and a dielectric layer 232 on the periphery region 204 may comprise the following steps. A first mask layer is formed to cover the memory region 202 and then the dielectric layer 232 is formed on the substrate 200 in the periphery region 204 . The first mask layer is then removed. A second mask layer is formed to cover the periphery region 204 and then the composite dielectric layer 230 is formed on the substrate 200 in the memory region 202 . The second mask layer is then removed.
Refer to FIG. 2F, a conductive layer (not shown) is then formed on the substrate 200 . The conductive layer comprises, for example, polysilicon and is formed by, for example, chemical vapor deposition with in-situ doping. A lithography process and an etching process are performed to pattern the conductive layer into a plurality of word-lines 234 on the memory region 202 and a plurality of gates 236 on the periphery region 204 . Thereafter, a source/drain region 238 is formed in the substrate 200 beside the gate 236 on the periphery region 204 . The subsequent back-end process is well-known by those skilled in the art and will not be described here.
In the method of the second embodiment of this invention, the distorted lattice of the substrate 200 is rearranged with a thermal oxidation process after the trench 224 is formed and after the photoresist layer 222 is removed. The defects in the channel regions thus is reduced and a leakage is prevented.
Structure of the NROM
The structure of the NROM according to the second embodiment of this invention will be described below.
Refer to FIG. 2F, the non-volatile memory comprises a substrate 200 , a plurality of buried bit-lines 226 , a plurality of word-lines 234 , and a charge trapping layer 230 . The buried bit-lines 226 are located in a substrate 200 and are separated by a plurality of trenches 224 . The word-lines 234 are disposed on a portion of the substrate 200 and the trenches 224 and crosses over the trenches 224 and the buried bit-lines 226 . The charge trapping layer 230 is between the substrate 200 and the word-lines 234 .
Since the buried bit-lines 226 are separated by the trenches 224 in the NROM of this invention, a deeper junction can be formed to lower the resistance of the buried bit-lines 226 and thereby to lower the bit-line loading without worrying the short channel effect and the punch-through leakage.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention covers modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
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A method for fabricating a non-volatile memory is described. A planar doped region is formed in the substrate at first. A mask layer and a patterned photoresist layer are sequentially formed on the substrate. A plurality of trenches is formed in the substrate with the patterned photoresist layer as a mask to divide the planar doped region into a plurality of bit-lines. The patterned photoresist layer is removed and then a recovering process is performed to recover the side-walls and the bottoms of the trenches from the damages caused by the trench etching step; The mask layer is removed. A dielectric layer is formed on the substrate and then a plurality of word-lines is formed on the dielectric layer.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/164,150 filed Mar. 27, 2009, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to filters for molten metal, and more particularly to contoured molten metal filter cups.
BACKGROUND INFORMATION
[0003] Investment casting foundries utilize pouring cones as a core components of an investment casting tree, while other metalcasting foundries employ a wide variety of mold designs that include green sand, no-bake, permanent mold, and other materials in both horizontal and vertically-parted configurations. In various metalcasting techniques, there are advantages to filtering out slag and dross that form in the molten metal during pouring. Metalcasting foundries currently use different kinds of molten metal filter media, including ceramic foam filters, ceramic cellular filters, extruded lattice filters, and both fiberglass and silica mesh filter cups.
[0004] Molten metal filter cups produced from fiberglass, silica mesh or other materials have usually been designed to fit tightly against or conform as close as possible to the inner walls of the molten metal casting structures in which they are placed, such as investment casting ceramic pour cones, runner sections within a mold, and riser sleeves. The rationale behind this technique is to ensure that the cup remains stable during pouring of the molten metal. Examples of silica mesh filter cups are described in U.S. Application Publication No. 2008/0173591, which is incorporated herein by reference.
[0005] While the primary purpose of using filter cups within metal casting structures is to filter out the slag and dross, another important performance characteristic of metalcasting operations is the molten metal flow rate through the filter cups, typically referred to as “throughput”. Conventionally, the throughput of molten metal poured through filter cups or other filter media is increased or decreased by varying the size of the fabric mesh holes of the filter cups, with a larger mesh size (larger holes) providing higher throughput, and a smaller mesh size providing lower throughput. Users of ceramic filters would increase or decrease the pore size of their filter material to manipulate the throughput rate in the same manner. Unfortunately, the tradeoff for increased throughput comes at the cost of a potential reduction in filtering efficiency. While larger meshes or pore sizes permit more metal to flow through at faster rates, they also allow additional slag and dross to pass as well.
SUMMARY OF THE INVENTION
[0006] The present invention provides contoured molten metal filter cups having an interstitial flow space that is maintained between the inner-wall of a metalcasting structure such as a ceramic pouring cone, mold pattern, riser sleeve and the like, and the outer-wall of the filter cup. Examples of metal casting structures also include the contact area within or used as part of any variety of metalcasting mold patterns such as green sand, no-bake, permanent mold, horizontal and vertically parted molds, and automated pouring systems such as DISAMATIC, Hunter machines, and high and low pressure die-casting machines. The interstitial space provided by the contoured filter cups results in significantly increased molten metal throughput during casting operations, while simultaneously providing an increased level of filtering efficiency.
[0007] An aspect of the present invention is to provide a molten metal filter cup comprising an upper wall section having an outer surface structured and arranged to contact an inner surface of a molten metal casting structure, a generally conical lower wall section below the upper wall section structured and arranged to be spaced an offset distance from the inner surface of the molten metal casting structure when the outer surface of the upper wall section contacts the inner surface of the molten metal casting structure, and a bottom below the lower wall section.
[0008] Another aspect of the present invention is to provide a molten metal filter cup comprising a generally conical upper wall section, a lower wall section, a transition between the upper and lower wall sections that extends radially inwardly from a lowermost portion of the upper wall section toward an uppermost portion of the lower wall section, and a bottom below the lower wall section.
[0009] A further aspect of the present invention is to provide a molten metal filter cup comprising a generally conical upper wall section, a generally conical lower wall section, and a transition between the upper and lower wall sections that extends radially inwardly from a lowermost portion of the upper wall section toward an uppermost portion of the lower wall section.
[0010] These and other aspects of the present invention will be more apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a side sectional view of a contoured molten metal filter cup installed in a pouring cone in accordance with an embodiment of the invention.
[0012] FIG. 2 is a side sectional view showing dimensions of the filter cup of FIG. 1 .
[0013] FIG. 3 is a side sectional view of a contoured molten metal filter cup in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
[0014] In accordance with the present invention, contoured molten metal filter cups with an interstitial flow space between the filter cups and pouring cones or other metalcasting structures in which they are installed mitigate the tradeoff of throughput for filter efficiency by providing a geometry that maintains a set level of filtration efficiency while at the same time increasing the molten metal throughput of the pouring cone/filter cup unit. The interstitial flow space significantly increases the filtration area of the filter cups and increases overall filtration efficiency. The filter cups may be installed in a pouring cone or placed elsewhere within a mold pattern, such as the downsprue of an automated casting machine, e.g., a DISAMATIC, or within riser sleeves. The filter cups may be made from any known material, including silica or fiberglass mesh fabrics as well as ceramic material as is common with ceramic foam, ceramic cellular, and extruded lattice filters. For example, one type of filter cup material for use in accordance with an embodiment of the present invention comprises silica mesh fabric with a refractory coating as disclosed in U.S. Application Publication No. 2008/0173591.
[0015] FIG. 1 illustrates a contoured molten metal filter cup 10 installed in a ceramic pouring cone 20 . Although a ceramic pouring cone 20 is shown in FIG. 1 , it is to be understood that the filter cups of the present invention may be installed in various other types of molten metal casting structures. The filter cup 10 includes an upper rim 11 , a conical upper wall section 12 , a conical, inwardly offset lower wall section 14 , and a bottom 16 . The filter cup 10 includes a transition 13 between the upper wall section 12 and the lower wall section 14 , and another transition 15 between the lower wall section 14 and the bottom 16 . In the embodiment shown in FIG. 1 , the conical upper wall section 12 , conical lower wall section 14 and conical pouring cone 20 are sloped at substantially the same angle measured from a vertical axial flow direction of the filter cup 10 .
[0016] In accordance with the present invention, the filter cup 10 has an interstitial flow space 18 representing the volume between the inner surface of the pouring cone 20 and the outer surface of the lower wall section 14 . While the upper wall section 12 of the filter cup 10 contacts the inner surface of the pouring cone 20 , the lower wall section 14 is located radially inwardly of the pouring cone 20 to provide the interstitial flow space 18 .
[0017] FIG. 2 illustrates several dimensions of the filter cup 10 . The upper rim 11 has an outer diameter OD R and an inner diameter ID R . The upper wall section 12 has an outer diameter OD U measured at the lowermost portion of the upper wall section, and a height H U . The lower wall section 14 has an outer diameter OD L measured at its uppermost portion, and a height H L . The lower wall section 14 has an offset distance D representing the distance between the outer surface of the lower wall section 14 and the inner surface of the pouring cone 20 . The conical lower wall section 14 is sloped at an angle A measured from a vertical axial flow direction of the filter cup 10 . The bottom 16 has an outer diameter OD B measured at the transition 15 between the lower wall section 14 and the bottom 16 . The filter cup 10 has a thickness T.
[0018] The dimensions of the filter cup 10 shown in FIG. 2 may be selected depending upon the particular geometry of the pouring cone or other metal casting structure. For example, the outer diameter OD R of the upper rim 11 may typically be from about 4 to about 7 inches, e.g., about 5.5 inches. The inner diameter ID R of the upper rim 11 may typically be from about 2.5 to about 6 inches, e.g., about 3.25 inches. The outer diameter OD U of the upper wall section 12 may be typically from about 2 to about 5 inches, e.g., about 3 inches. The outer diameter OD L of the lower wall section 14 may typically be from about 2.2 to about 5.5 inches, e.g., about 3 inches. The height H U of the upper wall section 12 may typically be from about 0.2 to 1 inch, e.g., about 0.4 inch. The height H L of the lower wall section 14 may typically be from about 0.5 to about 4 inches, e.g., about 2 inches. The offset distance D of the lower wall section 14 may typically be from about 0.1 to about 0.5 inch, e.g., about 0.13 inch. The cone slope angle A of the lower wall section 14 may typically be from about 1 to about 30 degrees, more typically from about 5 to about 20 degrees, e.g., about 15 degrees. The slope angles of the upper wall section 12 and pouring cone 20 may be the same as, or different from, the slope angle A of the lower wall section 14 . The diameter OD B of the bottom 16 may typically be from about 1 to about 3 inches, e.g., about 1.5 or 1.6 inches. The thickness T of the filter cup 10 may be typically from about 0.01 to about 0.1 or 0.2 inch, e.g., about 0.04 inch. Although specific dimensional ranges are given above, it is to be understood that the various dimensions may be adjusted as desired, depending upon the particular casting operation and pouring cone or other metal casting structure geometry.
[0019] At the top of the pouring cone 20 and filter cup 10 , the rim 11 and the upper wall section 12 contact and remain flush against the contour and angle of the inner wall of the ceramic pouring cone 20 to provide a cup weight-bearing area. They continue down to the point where the two are separated from each other at the transition 13 . The cavity or space 18 created between the lower wall 14 of the filter cup 10 and the inner surface of the pouring cone 20 provides the interstitial flow space 18 , which starts at the end of the cup weight-bearing area (point of separation) and continues downward along the outer surface of the lower wall section 14 , following the sloping contour of the pouring cone 20 and ends at the transition 15 at the hemispherical or flat bottom 16 of the filter cup 10 .
[0020] FIG. 3 illustrates a filter cup 110 in accordance with another embodiment of the present invention, with like reference numerals designating similar elements in both FIGS. 2 and 3 . In a particular embodiment, the filter cup 110 shown in FIG. 3 may have an outer rim diameter OD R of about 5.5 inches, an inner rim diameter ID R of about 4 inches, an outer diameter OD U of the upper wall section 12 of about 3.5 to 3.7 inches, an outer diameter OD L of the lower wall section 14 of about 3.3 to 3.5 inches, an upper wall section height H U of about 0.4 inch, and a lower wall section height H L of about 1.4 inches. The diameter OD B of the bottom 16 may be about 2.7 or 2.8 inches. The filter cup thickness T and offset distance D of the interstitial flow space 18 in the embodiment shown in FIG. 3 may be similar to those of the embodiment of FIG. 2 .
[0021] To confirm the improved throughput of the present filters, tests were conducted using standard investment casting techniques to cast a stainless steel alloy (nickel chrominum Stainless Steel Alloy 625) in multiple runs of 75 pounds each. The same testing parameters and number of iterations were run and data recorded using a conventional filter cup design with no interstitial flow space in comparison with the contoured filter cup design shown in FIG. 2 . The average pour time for the conventional filter was 8 seconds, in comparison with an average pour time of 6 seconds for the filter cup design of the present invention. An average throughput increase of 25 percent was thus achieved with the contoured filter cup of the present invention.
[0022] The casting test results confirm an average increase in measured molten metal throughput of at least 20 or 25 percent. Further, the effective filtration area in the cup may be increased by over 50 percent, typically over 75 percent, as the molten metal is able to flow through the side walls and into the interstitial flow space, instead of being force-focused at the very bottom of the filter cup as in conventional designs.
[0023] Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the invention as defined in the appended claims.
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Contoured molten metal filter cups having an interstitial flow space that is maintained between the inner-wall of a molten metal pouring cone, riser sleeve or mold and the outer wall of the filter cup are disclosed. The interstitial space provided by the contoured filter cups results in significantly increased molten metal throughput during casting operations, while simultaneously providing an increased level of filtering efficiency.
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FIELD OF THE INVENTION
This invention relates to the manufacture of an aqueous solution of polyamide-epichlorohydrin resin having low levels of epichlorohydrin and related hydrolysis products, and to paper treated with such solutions. Paper so treated has improved wet and dry strength over paper that has been treated with polyamide-epichlorohydrin resin solutions that have higher amounts of free epichlorohydrin and related hydrolysis products. Furthermore, the paper product treated with aqueous solutions having low levels of free epichlorohydrin and related hydrolysis products contains smaller amounts of these chemicals that are suspected of being carcinogens and are environmental pollutants.
BACKGROUND OF THE INVENTION
Paper strengthening resins are sold commercially as aqueous solutions. Commonly such resins are thermosetting, polymeric reaction products of epichlorohydrin and a polyamide derived from a polyalkylene polyamide and certain dicarboxylic acids. U.S. Pat. No. 2,926,154 to Keim describes aqueous solutions of such resins. Typically aqueous solution of such resins contain an amine curing accelerator such as ethylenediamine or diethylenetriamine. Such compositions are disclosed in Espy U.S. Pat. No. 3,442,754. The presence of the accelerator makes it possible to thermally set the resin in a shorter time.
Commercially such aqueous solution usually contain about 10 to 35% by weight resin. Most of the remaining portion of the solution is water.
Such commercial aqueous solutions typically contain epichlilorohydrin, dichloropropanol and chloropropanediol; the latter two compounds are hydrolysis products of epichlorohydrin. These compounds are suspected carcinogens and contribute to environmental pollution during the paper making process.
A variety of references describe the removal of organohalogen compounds from water by use of various adsorbents including ion exchange resins, polymeric adsorbents, silica, alumina, clays, activated carbons, zeolites, etc. See, for example,
K. Dorfner, Ion Exchangers, Properties and Applications. (Ann Arbor Science Publishers Inc., 1972, Ann Arbor);
Ion Exchangers, K. Dorfner, Ed. (Walter de Gruyter, NY, 1991);
Amberlite® Product and Technical Bulletin, for Amberlite® IRA-93 ion exchange resin, Rohm and Haas Co., 1981.
SUMMARY OF THE INVENTION
The present invention is a process for lowering the amount of epichlorohydrin and related hydrolysis compounds that are contained in an aqueous solution of polyamide-epichlorohydrin resin, which comprises adsorbing epiclilorohydrin and related hydrolysis compounds contained in an aqueous solution of polyamide-epichlorohydrin resin by contacting the aqueous solution with an adsorbent selected from the group consisting of ion exchange resins, activated carbon, zeolites, silica, clays, and alumina.
The present invention also is a process for increasing the strength of paper and lowering the amount of epichlorohydrin and related hydrolysis compounds in paper containing polyamide-epichlorohydrin strength-enhancing resin, which comprises adsorbing epichlorohydrin and related hydrolysis compounds contained in an aqueous solution of polyamide-epiclilorohydrin resin by contacting the aqueous solution with an adsorbent selected from the group consisting of ion exchange resins, non-ionic polymeric resins, synthetic carbonaceous adsorbents, activated carbon, zeolites, silica, clays, and alumina, and then using the resulting solution as an additive in the manufacture of paper products. The resulting solution may be added to pulp as it is being fabricated into paper, or the resulting solution may be used to impregnate paper that has already been fabricated.
DETAILED DESCRIPTION
The process for forming the starting material for the present invention, i.e., the aqueous solution of polyamide-epichlorohydrin, is well-known and is described in Keim U.S. Pat. No.2,926,154. As pointed out in this patent the polyamide portion of the resin is the reaction product of a polyalkylene polyamide having two primary amine groups and at least one secondary amine group with a saturated aliphatic dicarboxylic acid. Suitable polyamines include polyethylene polyamine, polypropylene polyamine, polybutylene polyamine, etc. Suitable saturated dicarboxylic aliphatic acids are preferably those containing 3 to 6 carbon atoms, for example, malonic, succinic, glutaric and adipic.
The Keim patent also teaches reaction conditions and the preferred concentration of ingredients.
In the examples below Cascamid® C-12, a polyamide-epiclilorohydrin resin produced by Borden Inc., was the wet strength resin treated.
The levels of epichlorohydrin, dichloropropanol and chloro-propanediol were measured by capillary gas chromatography using calibrated standards.
The wet and dry strength of paper was measured on unbleached kraft paper that had been treated with an aqueous solution of 0.1% resin which was applied by a size press. 4 inch by 1 inch strips of treated paper were re-wetted in distilled water by soaking for 1 hr., lightly blotted to remove excess water and then tested in a tensile strength instrument. Wet strength is reported in pounds required to break the test sample per inch of sample width. Dry strength is similarly measured for treated sample which has not been re-wetted. Wet-to-dry strength ratio is reported as percent.
The adsorbent beds are prepared by slurrying the adsorbent with deionized water, transferring the slurry to a column containing deionized water, and allowing the water to slowly drain from the column until the top surface of the bed is just covered with water and a packed bed free of entrained air created. The bed is further backwashed with deionized water to remove air bubbles and to classify the adsorbent particles within the bed. Basic ion exchange resin particles are previously washed with sodium hydroxide followed by washing with deionized water to insure that resin particles are in the desired hydroxide form. Adsorbents such as activated carbon with contain extremely fine particles should be repeatedly decanted at the aqueous slurry stage to remove such fine particles which can cause plugging of the bed. Adsorbents beds can be regenerated by using a wash appropriate to the adsorbent which removes adsorbed epichlorohydrin and hydrolysis products. The polyamide-epichlorohydrin solution can be fed to the bed by gravity or by a pump. The polyamide-epichlorohydrin solution can be contacted with the adsorbent at temperatures from about 0 degrees C. to about 50 degrees C. (Lower temperatures limit the solution pumpability and higher temperatures cause undesirable loss of polyamide-epichlorohydrin resin properties.) Pumping pressures are limited by the particular adsorbent selected by the physical limitations of the pump and column construction. Bed size is very highly dependent on the particular specific adsorption capacity of the adsorbent bed, the level of epichlorohydrin and its hydrolysis products in the solution being treated polyamide-epichlorohydrin solution, and the level of epichlorohydrin and its hydrolysis products desired in the treated, effluent polyamide-epichlorohydrin solution.
Pumping flow rates for the polyamide-epichlorohydrin solution are dependent on the specific adsorbent chosen but typically range from 1 to 40 bed volumes/hour.
Alternatively, the polyamide-epichlorohydrin solutions can be mixed with the slurry of adsorbent, stirred to insure through contact with the adsorbent, and then the solution of treated polyamide-epichlorohydrin is separated from the adsorbent by filtration or decantation.
Adsorbents are selected from the group consisting of ion-exchange resins, non-ionic polymeric resin, synthetic carbonaceous adsorbents, activated carbon, zeolites, silica, clays, and alumina. Preferred adsorbents are selected from the group consisting of weakly basic ion exchange reins, non-ionic macroporous polymeric resins, and synthetic carbonaceous adsorbents. Most preferred adsorbents are selected from the group consisting of synthetics carbonaceous adsorbents.
Examples of such adsorbents include: Amberlite® IRA 93, a weakly basic macroporous,macroreticular resin; Amberlyst® A-21, a weakly basic macroreticular resin; Amberlite® XAD-2. -4, -7, -16, a family of non-ionic macroporous polymeric resins; Ambersorb® 563 and 572, a family ol synthetic carbonaceous resins; Darco® 4-12 mesh granular activated carbon; Norit® ROO.8 pelletized activated carbon; 13X molecular sieve (1/8" pellet); 5 Angstrom molecular sieve (1/8" pellet); 100-200 mesh silica; neutral alumina; basic alumina; Montmorillonite, K10 and KSF, layered clays.
EXAMPLES
Example 1
100 grams of Amberlite® IRA-93 resin was slurried with 200 ml of deionized water and periodically stirred for 1 hr. The water was decanted and the resin stirred with 200 me of 1 Normal HCl which was then decanted. The resin was slurried with 200 ml of water, decanted; slurried with 200 ml of 0.5 Normal NaOH, decanted; slurried with 200 ml water decanted; and the entire cycle repeated. The resin was slurried and loaded to a chromatography column with a glass frit in the bottom and a stopcock. Approximately 150 ml of Cascamid® C-12 was passed through the bed. The Cascamid® contained about 5.2 ppm of epichliorohydrin, about 10,200 ppm of dichloropropanol and 105 ppm of chloropropanediol. A treated sample contained less than 1 ppm of epichlorohydrin, less than 2 ppm of dichloropropanol and about 15.5 ppm of chloropropanediol.
Kraft paper was treated with the sample. The treated paper had a wet strength of 13.0 lb./in, a dry strength of 46.5 lb./in and a wet/dry ratio of 27.9%. A sample of kraft paper treated with the untreated Cascamid® C-12 had a wet strength of 12.5 lb./in, dry strength of 45.3 lb./in, and a wet dry ratio of 27.6%.
Example 2
A resin bed was prepared as described in Example 1 using Amberlyst® A-21.
A sample of Cascamid® containing about 7.8 ppm of epichlorohydrin, about 10,800 ppm of dichloropropanol and 114 ppm of chloropropanediol was treated with this bed. A treated sample contained less than 1 ppm of epichlorohydrin, less than 2 ppm of dichloropropanol and about 4.5 ppm of chloropropanediol. Paper treated with the untreated Cascamid® had a wet strength of 12.8 lb./in, a dry strength of 42.1 lb./in, and a wet/dry ratio of 30.4%. Paper treated with the treated sample of Cascamid® had a wet strength of 15.5 lb./in, a dry strength of 45.3 lb./in and a wet/dry ratio of 34.2%.
Example 3
A slurry was prepared from 90 g (dry weight) Arnbersorb®) 563 and 150 ml methanol, was stirred for 30 minutes until the adsorbent sank to the bottom of the mixture and was then loaded to a 1 inch diameter glass column. Excess methanol was drained and the bed was washed with 10 bed volumes of deionized water to remove methanol. The bed was further treated by water backwashing with 100% bed expansion for 30 minutes at 30 ml/minute. Bed volume was approximately 150 ml.
A 12.5% aqueous solution of polyamide paper resin, Cascamid® C-12 containing a total of 6946 ppm of epichlorohydrin, dichloropropanol and chloropropanediol was then passed through the bed at 10 ml/minute by a peristaltic pump. Fractions were collected at 100 ml intervals and analyzed for total epichlorohydrin, dichloropropanol, and chloropropanediol.
______________________________________FRACTION, ml TOTAL, ppm______________________________________100 <5200 <5300 <5400 <5500 <5600 <5700 <5800 <5900 <51000 <51100 121200 551300 2401400 6161500 15471600 2568______________________________________
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A process for lowering the amount of epichlorohydrin and related hydrolysis compounds contained in paper strength enhancing resins by treating an aqueous solution of the resin with an adsorbent.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to lignin recovery processes and, more specifically, to methods for recovering lignin through neutralization of alkaline lignin solutions. In particular, the invention relates to an electrochemical method whereby both lignin and alkali are recovered in anode and cathode chambers, respectively, of one or more electrochemical cells. The invention is ideally suited for recovering lignin from the alkaline extract of a cellulose process.
2. Background of the Invention
In the production of cellulose, considerable amounts of lignin-containing extracts are obtained which have heretofore represented a waste product. As the direct discharge of the extracts into waterways is no longer possible at the present time, the extracts have been subjected to a concentration process, and the solid materials obtained usually burned. The methods used in the process are expensive and have been employed only to obtain purified water and solids separated therefrom. The water may then be returned to the waterways. The process is not only expensive, but the lignin contained in the solids is destroyed. The extracts are usually designated waste liquors.
A method for precipitating lignin from an alkaline solution is known, whereby the solution is neutralized by the introduction of acids, but a subsequent recovery of the lye is not possible or is highly involved and expensive. Furthermore, the material precipitated in this manner is contaminated by mineral salts. Alkaline liquors may be neutralized, for example, by the introduction of carbon dioxide, and the carbonate so-formed, causticized with calcium oxide. There remains, however, a need in the art for an inexpensive method for recovering both lignin and alkali from an alkaline lignin solution.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a process whereby lignin is obtained, with a low apparative expenditure, from an alkaline lignin solution. Preferably the lignin solution is waste liquor, i.e. alkaline extract, obtained from a cellulose process in a form suitable for further processing. In the method of the invention, destruction of the lignin is avoided and, further, the possibility exists for recycling the water component and the alkali of the extract to the process for further use.
The above-stated object is attained in a process according to the invention, in which lignin solution is continuously anodically acidified by electrolysis and, in the same process, alkali is cathodically regenerated. In other words, the alkaline extract (lignin solution) is introduced into the anode chamber of a divided electrolytic cell and electrochemically acidified therein, while simultaneously, in the cathode chamber, the liquor is electrochemically concentrated. The cell is appropriately divided by an ion exchange membrane, which makes the selective transportive of cations from the anode into the cathode chamber possible. Investigations have shown that a Nafion membrane is especially suitable, both satisfying the requirements, and having a useful life. Precipitation and recovery of the liquor are effected simultaneously by the supply of the single amount of energy. The process may be carried out in a single stage or may include multiple stages. A preferred embodiment utilizes multiple stages in which anolyte and catholyte are circulated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an electrolysis cell conducting the process in a single stage, according to one embodiment of the invention.
FIG. 2 is a schematic diagram of a second embodiment of the invention utilizing a two-stage process.
FIG. 3 illustrates a preferred embodiment of the two stage process of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process of the invention is generally applicable to alkaline lignin solutions. It is used principally, however, for alkaline lignin solutions consisting of an extract or waste liquor of a cellulose process, and preferably for lignin solutions obtained from the extract of an organosolv process for the production of cellulose by the separation of the organic solvent. Sodium hydroxide is preferably used as the alkali.
It has been discovered that the process may be conducted in a single electrolysis cell, as illustrated in FIG. 1 or in multiple stages, as shown in FIGS. 2 and 3. In the single stage process, lignin solution and alkali are conducted through an electrolysis cell, which is divided by a cation exchange membrane into anode and cathode chambers. At one end of the cell, a light brown lignin foam is obtained that may be further processed by known methods to produce pure lignin.
In FIG. 1, the electrolysis cell 1 comprises a housing 2, membrane 3, anode 4 and cathode 5. The anode and cathode are in the form of metal grids which are approximately the same size and shape as the membrane. The anode 4 is preferably a coarse metal grid. The housing 2 is in the form of a flat, quadrangular block, in the center of which, the membrane 3 is inserted. The size of the membrane corresponds approximately to the magnitude of one of the lateral surfaces 6 of the housing 2. The membrane 3 divides the inside of the housing 2 into anode and cathode chambers 7 and 8, respectively. The anode 4 and the cathode 5 are arranged in chambers 7 and 8. Both are adapted in their configuration and size to the membrane 3. The cathode is located approximately in the center of the cathode chamber 8, while the anode 4 is located adjacent to the membrane 3, so that between the anode 4 and the membrane 3 there is only a relatively narrow gap 9. Power connections 10 and 11 for the anode 4 and the cathode 5 are conducted out of the housing 2.
Waste liquor, for example, from a cellulose process, which has previously been freed of methanol, is conducted to the anode chamber of cell 1 through inlet 2. In the course of the electrolysis, in the anode chamber 7, a foam of lignin and oxygen is formed which is drawn off through the outlet 13. The foam generation is indicated in the drawing by bubbles 14. Lignin foam 14 the outlet 13 is centrifuged, whereby pure lignin and a solution that may be recycled into the cellulose process, are obtained. Hydrogen generated in the process escapes through a connecting fitting 15 on the cathode chamber 8. Water, dilute alkaline liquor, or the centrifugate of the lignin foam (pH 6) are introduced through the fitting 16. Concentrated alkaline liquor is drawn off through fitting 17 from the cathode chamber.
A second embodiment of the invention is illustrated in FIG. 2. It has been found that if the process is performed in two or even three stages, the expenditure of energy is especially low. The number of stages utilized is, in fact, limited by the equipment expenditure required and the efficiency that may be obtained.
The process shown in FIG. 2 is in two stages and illustrates an application of the invention to a cellulose process. From the cellulose boiler 20, the lignin and methanol-containing extract is drawn off and freed of methanol in a methanol recovery installation 21. The methanol is then returned through line 21b to the pulping process. The extract, free of methanol, is conducted through line 21a to the first electrolysis cell 22, which essentially represents the first process stage. The extract is passed to the anode chamber 23.
In the anode chamber 23, the extract is acidified until a pH value of 9.5 is attained. From the anode chamber the extract, having this pH value, is passed continuously through line 24 to the anode chamber 25 of the second electrolysis cell 26, which forms the second process stage. In this cell 26, another electrolytic acidification, and thus foam formation, takes place. The foam is removed by means of the drainage installation 27 in the form of a lignin suspension, and is passed to a separating device 28, wherein the precipitated lignin contained in the foam is separated from the extract. The pure lignin is conveyed by conveying means 29 to further processing, while the remaining extract, comprising acidic anolyte, is routed to the cathode chamber 31, via line 30, as a near lignin-free solution.
In the cathode chamber 31, the extract is electrolytically enriched with alkali. The hydrogen generated in the process is exhausted through outlet 33. From the cathode chamber 31, the extract travels through line 32 into cathode chamber 34 of the first cell 22. Here, the extract is further enriched in alkali and passes through line 25 into a collecting vessel 36. By means of line 35a, the sodium hydroxide concentration may be regulated. From the collecting vessel 36, the extract is transported in the form of caustic liquor through line 37 and recycled to the cellulose boiler 20. Hydrogen is eliminated through line 40. The Nafion membranes present between the anode and cathode chambers are designated 38 and 39 respectively.
In the first stage 22, also referred to as the neutralization cell, neutralization is carried only to the onset of lignin precipitation in the anode chamber, which, in keeping with experience, corresponds to a pH of about 9.5. In this stage, the greater portion of the sodium hydroxide in the cathode space is recovered. In the second stage 26, also known as the flocculation cell, the anode chamber is acidified to complete precipitation of the lignin, which, according to experience, is about pH 4. Because of the low conductivity of solutions below pH 8, adequate electrolysis takes place only at higher voltages. Appreciable amounts of energy are saved by the separation into two stages.
The oxygen which develops at the anode of the second stage flocculation cell 26, forms, together with the precipitated lignin and a part of the neutralized solution, a foam similar to lignin foam 4 of the single stage embodiment. The lignin suspension so formed is removed by the separating device 28, which is preferably a flotation installation. The flotation process requires no additional energy, as the oxygen is generated by the amount of energy necessary for the electrolysis.
Electrolytically precipitating the lignin in the second stage has the advantage that the recovered lignin is not contaminated by inorganic salts.
The separating device 28 may be, for example, a centrifuge. The acidic anolyte recovered from the separating device 28 in line 30 may, instead of being routed to cathode chamber 31, as shown in FIG. 2, be recycled to cathode chamber 34 of the first process stage 22 and, after suitable regeneration, addition of methanol and enrichment in alkali, if necessary, recycled to the cellulose boiler. The regenerated extract can be used as the digestion medium, or as one of the components thereof, in the cellulose process. The processing of the alkaline extract may thus be effected in a closed circulation with no waste water leaving the process.
The electrolysis is carried out in both stages at the highest temperatures possible, below the boiling temperature, as the conductivity of the solution increases with rising temperature. The waste heat obtained during the electrolysis is sufficient to maintain this temperature, so that supplemental heating of the electrolytic cells is usually not necessary.
As the electrolytic process is a relatively gentle method, not requiring the use of additional chemicals, it is suitable in particular for obtaining pure, natural lignin, such as provided, for example, by the organosolv process according to German patent application No. P 28 55 052.
It is especially advantageous to circulate the catholyte and/or the anolyte in the first process stage, as illustrated in FIG. 3. A portion of the circulation routes is formed by the electrolytic cells themselves. The conduction of the anolytes and the catholytes, in circulation with the inclusion and exclusion of a portion of the electrolytes, improves the control of the process stage. By means of very simple control devices it is possible to obtain the neutralization desired in the first process stage in a very simple manner and with observation of exact values. The acidification of the waste liquor in the first process stage is carried, preferably, to a pH of 9.5, as in the previously described embodiment. However, this value is not absolute, but depends on conditions such as the lignin content of the waste liquor, temperature, and the like. Also as previously described, the flocculation of the lignin components occurs in the second process stage only, where it is removed by means of flotation equipment. Limiting flocculation to the second stage has the additional advantage, in this embodiment, of avoiding contamination of the circulation passages.
As shown in FIG. 3, process steps 41 and 42 are equipped with electrolytic cells 43 and 44, respectively. The flocculated electrolytes obtained in the second process stage are returned to the first stage. The first process stage 41 comprises cell 43, divided by membrane 45, and the two circulation loops 46 and 47 for the catholytes and anolytes. Process stage 42 comprises cell 44, also equipped with a membrane 48, and the flotation device 49.
The lignin-containing extract obtained in the cellulose pulping process, also designated the waste liquor, has a pH value of 14 and a lignin content of about two percent to ten percent by weight, and is conducted through line 50 to the reservoir 51. By means of a controlled system 52, 53, 59, which comprises the pH and level controller, this supply of waste liquor is regulated so that, in the reservoir, a pH value of about 9.5 is maintained. The pump 54 transports the waste liquor into the cell 43, specifically into the anode chamber 55. In the anode chamber 55, the pH of the waste liquor is lowered. The waste liquor then enters a gas separator 56, where the anode gas, mainly oxygen generated during the electrolysis, is separated. While the major part of the anolyte flows back from the gas separator 56 through line 57 into the reservoir 51, part of the lignin-containing extract or anolyte, having a pH value of about 9.5. is removed through line 58 and passes to the cell 44 of the second process stage. A valve 59, set into line 58, is controlled by a level regulator in the reservoir 51.
The liquid in the cathode chamber 62 comprises the deflocculated catholyte, which has already been enriched in sodium hydroxide in the cathode chamber 73 of cell 44, and has a pH of approximately 12. This catholyte passes through a reservoir 60 and a line 61 to the cathode chamber 62 of cell 43. From the cathode chamber 62, the catholyte travels by self-convection into the gas separator 63, from which the cathode gas, i.e. hydrogen, is removed. From gas separator 63, the catholyte is returned to reservoir 60. Here, the catholyte is circulated in the same manner as the anolyte. Part of the catholyte is removed from the gas separator through line 64. This is effected by means of a level regulator 65 and reservoir 60, and by valve 66. The pH value of the catholyte is about 14. Prior to the recycling of this low-lignin strong alkaline electrolyte into the cellulose process, the sodium hydroxide concentration must be adjusted, if necessary, by dilution with water, or the addition of sodium hydroxide.
In the first process stage 41 there are thus two circulations, the catholyte loop 46 and the anolyte loop 47, wherein the major part of the catholyte and the anolyte, respectively, is circulated. A lignin-containing extract with a pH value of 14, is introduced into the anolyte circulation prior to the neutralization cell 43. A lignin-containing extract with a pH value of about 9.5, is removed from the neutralization cell 43. In the catholyte circulation 46, an electrolyte, enriched with sodium hydroxide with a pH of 12, is introduced prior to cell 43. An electrolyte with a pH value of 14 is removed from the cell 43 and reused in the production of cellulose.
The lignin-containing extract obtained in the first stage with a pH of about 9.5, is introduced into the anolyte chamber 70 of cell 44 in the second process stage. This cell is also designated the flocculation cell. In the anolyte chamber 70, the lignin components are flocculated out with the simultaneous generation of oxygen at the anode. LIgnin slurry is separated from the acidic anolyte in separation means 71, and has a pH value of about 4. The lignin slurry obtained is subjected to known methods of washing, drying and processing, so that pure lignin is produced. The anolyte solution is returned through line 72 into the catholyte chamber 73 of cell 44. During its passage, water and sodium hydroxide may be added from a reservoir 74 to the anolyte, in order to compensate for the water losses occuring during the flotation, and to obtain properties favorable for the electrolytic process such as a minimum conductivity of the catholyte.
At the end of cell 44, as viewed in the flow direction of the catholyte, the catholyte is drawn off and conducted through line 75 to reservoir 60 of the catholyte cycle 46 of the first stage 41. Sodium hydroxide, and possibly water, may again be added to line 75. Methanol may further be added for the organosolv process to the catholyte, which is recycled to the cellulose process by way of installation 76.
The weakly acidic anolyte obtained at the end of the second process still contains several grams per liter of dissolved lignin-like substances, which are difficult to precipitate even with further reduction in pH. This, however, represents no disadvantage for the overall process, as the anolyte is recirculated and, finally, is again used in the alkaline cellulose digestion. Even in the case of repeated recirculation, there is no concentration of non-precipitatable, lignin-like substances in the deflocculated electrolytes. In other words, the lignin, in the final analysis, is recovered quantitatively.
By returning the weakly acidic anolyte to the first and/or second process step in the respective cathode chambers, it is possible to return the sodium hydroxide necessarily formed in the cathode chamber (in addition to hydrogen) from water, directly to the circulation loop. In the cell of the second stage, this catholyte may be conducted concurrently to the anolyte of the cell.
The two process stages are connected with each other by a recirculation of the electrolyte, and there are thus no waste waters to be discharged. The operation is thus a closed process wherein the targeted product, lignin, is obtained as a slurry in addition to hydrogen. While the system is closed, loss of liquid may occur and is replaced with water. Furthermore, an alkaline hydroxide may be added to the catholyte in the first and second process stages in order to achieve a certain minimum conductivity from the beginning.
The following examples illustrate the invention.
EXAMPLE 1
A single stage electrolytic cell with the configuration shown in FIG. 1 was used to obtain the following results.
The electrolysis cell had an anode and a cathode, the surface area of which amounted to 50 cm 2 each. The anode and the cathode chambers were separated by a Nafion membrane. The anode chamber was equipped at the outlet with a flotation device that comprised 300 ml. At the onset of the experiment, the anode chamber was filled with 200 ml of a lignin-containing liquor of pH 13.6. The initial filling of the catholyte consisted of 0.1 N sodium hydroxide. The cathode chamber also comprised 300 ml and was filled completely. The electrolysis was effected with 5 A=100 mA/cm 2 . The cell voltage slowly increased from 6 V to 15 V. After an electrolysis of approximately 75 minutes, the anolyte had attained a pH of about 8. The precipitation of a viscous light brown foam began and was drawn off by means of the flotation device, and processed. Fresh lignin-containing waste liquor, with approximately 60 grams per liter dissolved lignin (pH 13.6), was then introduced continuously from the bottom into the cell (approximately 100-150 ml/h). The entire electrolyte volume, again neutralized, left the cell in the lignin/oxygen foam through the flotation device. Approximately 40 grams of lignin were obtained from the foam per liter of the waste liquor.
EXAMPLE 2
In an experimental installation with a configuration according to FIG. 3, the neutralization and flocculation cells were connected in series. The neutralization cell had an anode and a cathode surface area of 18 cm 2 each. The anode and the cathode chambers were separated by a cation exchange membrane. The cathode (expanded V2A metal) was resting directly on this membrane, while the anode (platinum) was spaced at a distance of about 1 mm from the membrane. The anode reservoir comprised approximately 200 ml. The anolyte was pumped from the reservoir, by means of a hose pump, through the cell and the gas separator, and into the circulation at a rate of approximately 8 liters per hour. This corresponds to an anode chamber volume of approximately 2 ml and to a retention time in the cell of about 0.9 seconds. The catholyte moved through the gas separator by self-convection in circulation. The reservoir was thus eliminated. The pH value of the anolyte was determined by a glass electrode. The current flow in the neutralization cell amounted to 3.6 A=200 mA/cm.sup. 2. The cell voltage was approximately 10/11 V. At the start of the experiment, approximately 250 ml of a lignin-containing waste liquor of pH 13.6 was added to the reservoir and pumped in circulation under electolysis. The initial filling in the catholyte circulation was 0.1 M sodium hydroxide. After approximately 120 minutes of electrolysis, the anolyte had attained a pH value of about 10. Subsequently, in intervals of approximately three minutes, taking care that the pH was less than 9.5, 10 ml of fresh waste liquor (pH 13.6), was added to the reservoir and, simultaneously, downstream of the neutralization cell, anolyte of pH 9.5 was continuously removed at the same rate. This corresponded to a flow in the neutralization cell of about 200 ml/h. The removal thus corresponded to approximately 2.5 percent of the circulating anolyte flow. The flocculation cell had a cathode and anode surface area of approximately 20 cm 2 . The anode and the cathode chambers were separated by a cation exchange membrane. The anode chamber was opened and was provided with a flotation device. Its volume was approximately 300 ml. Electrodes were arranged at the bottom. The current flow was approximately 4 A=200 mA/cm 2 . The cell voltage was approximately 15 V. The anolyte (pH 9.5), removed from the anolyte circulation of the neutralization cell, was introduced into the flocculation cell and electrolyzed at the rate of approximately 200 ml/h. A viscous, light brown foam of lignin flocks, deflocculated anolyte (pH 5) and anode gas (oxygen) was produced and removed by means of the flotation device. The settling of this foam yielded approximately 0.5 liters of waste liquor (deflocculated, pH 5) on a per liter bases of anolyte (pH 9). Between one and two liters of a concentrated lignin-containing foam was obtained but could not be settled further, and from which approximately 40 grams of raw lignin were obtained by drying. The deflocculated waste liquor (pH 5) was again mixed continuously, following the settling of the foam and filtration, with the catholyte of the neutralization cell (approximately 100 ml/h), and sodium hydroxide (pH 14) removed continuously at the same rate. This sodium hydroxide was returned, after suitable dilution and solvent addition, to the cellulose pumping process.
EXAMPLE 3
The two stage process of FIG. 3 was again used as in the previous example. A further flocculation cell with a settling device preceding it, was connected in series after the flocculation cell, and both cells were operated at 2A. The first flocculation cell produced a foam at approximately pH 7, which settled over a period of time, into an electrolyte of pH 7. The lignin flock precipitated (about 10% of the total content) was filtered, and the anolyte conducted into the second flocculation cell. The second cell produced a foam as in the previous example. The cell voltages amounted, in the flocculation cells, to 7 and 7.5 V, respectively.
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The invention relates to a method and apparatus for recovering lignin and kali from an alkaline lignin solution. One or more electrolytic cells are used to anodically acidify the lignin and simultaneously cathodically regenerate alkali. The invention is especially advantageous for the preparation of pure lignin and alkali from the waste liquor of a cellulose process.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention falls into the field of postpress processing; it relates to an apparatus for inserting, collecting or collating two-dimensional products in accordance with the preamble of patent claim 1 and to a method for inserting, collecting or collating two-dimensional products in accordance with the preamble of patent claim 15 .
2. Discussion of Related Art
The prior art discloses installations for inserting, collecting or collating products which have a main unit with a conveyor means and a plurality of ancillary units with dedicated drives for supplying products to the conveyor means.
The ancillary units are supply conveyors, for example, and need to have their timing coordinated with respect to one another in order to ensure a desired location for the product they are supplying relative to a predefined position on the conveyor means. Since one and the same supply conveyors have to be used to deliver products of different length to the conveyor means and the distance from one ancillary unit to another ancillary unit is not always optimum in terms of timing on account of physical constraints, appropriate measures need to be taken so as nevertheless to ensure synchronized supply of products to the conveyor means. One such measure is shifting the phase of the supply conveyor, or of the supply conveyors, relative to the phase of the conveyor means. The phase is ideally 100%, that is to say that the operating cycle of the supply conveyors corresponds precisely to the operating cycle of the conveyor means. For the reasons cited above, the operating cycles of the supply conveyors need to be adjusted relative to the operating cycle of the conveyor means. Such a shift in the phase can take place only within an operating cycle of the conveyor means, however. The phase is typically calculated in a central controller or in a drive controller/control system which is associated with each ancillary unit, said central controller and said drive controllers/control systems of the ancillary units being connected to one another via a data bus. To calculate the time of supply, further signals need to be transmitted to the drive controllers/control systems of the ancillary units, which in conventional installations results in numerous signals or data needing to be interchanged between the central controller and said drive controllers/control systems of the ancillary units, said signals often being analogue signals which require appropriate individual connections. Such connecting lines and connectors are generally a possible source of problems for optimum signal transmission, for example on account of electromagnetic incompatibilities, and are therefore accordingly susceptible to interference.
EP 0917 965 B1 discloses an embodiment in which data interchange between a plurality of drive controllers and a central controller is effected exclusively via a bus system, which reduces the number of connections between main and ancillary units. Additional signals are transmitted via the drive controller which is associated with each unit and via an input/output unit, associated with each drive controller, to a bus interface, where they are transferred to the data bus. The data bus therefore firstly transmits data from a preceding setup mode and data corresponding to the analogue signals between the central controller and the individual drive controllers.
The known apparatuses are inadequate in terms of transmission speed and data integrity.
SUMMARY OF THE INVENTION
In respect of an apparatus, it is therefore an object of the present invention to allow simplified, more secure and faster data traffic for a number of drive controllers or control systems with a main drive control system.
In respect of a method, it is also an object of the present invention to simplify and increase the security and speed of data traffic for a number of drive controllers or control systems with a main drive control system.
The object on which the invention is based for the apparatus is achieved with the features of claim 1 . Further embodiments are the subject matter of dependent claims 2 to 14 .
The invention is distinguished in that data from a main drive control system and from a number of drive control systems are transferred directly to a common data bus, which dispenses with the time-consuming detour via an input/output unit, as is the case in the prior art. In addition, the direct transmission of data from the main drive control system and from each drive control system directly to the data bus reduces the probability of error for the data transmission and the error rate for the entire apparatus, since fewer components and fewer internal connections are required for transmitting these data.
In a first embodiment of the present invention, an apparatus for inserting, collecting or collating a multiplicity of flexible, two-dimensional products has a product collection unit and a multiplicity of handling units, but from now on the text will refer only to a first handling unit and a second handling unit by way of representation and to simplify the explanations.
The term products is understood to mean chiefly printed products or printer's products, and also subproducts such as inserts, postcards or advertizing product supplements. A product may be a newspaper, a magazine or a similar printer's product. In addition, the term product also covers multipart printed products which comprise at least one main product and one or more subproducts. Similarly, a subproduct may itself be multipart and may itself comprise main products and subproducts.
All the handling units are used for synchronized handling, for example for supplying and stitching products. In addition, the product collection unit has a main drive control system which is operatively connected to a main drive for the purpose of driving a conveyor means, said conveyor means usually being embodied by a collection drum or a collection belt. The first handling unit has a first drive control system which is operatively connected to a first drive. “Operatively connected” is understood to mean a control connection, which may also be indirect, however, i.e. can be routed via a plurality of components—not described in more detail here. The second handling unit has a second drive control system which is operatively connected to a second drive. The main drive control system and also the first and second drive control systems are furthermore operatively connected to one another via a first data bus. In addition, the first handling unit has a first data collector which is connected to the main drive control system and to the first drive control system via the aforementioned first data bus. Similarly, the second handling unit has a second data collector which is connected to the first drive control system and to the second drive control system via the first data bus.
Furthermore, the small number of parts or components means that the apparatus according to the invention is not so costly in comparison with the prior art and can be operated more economically on account of the low maintenance complexity. In view of the large numbers of items which are customary in postpress processing with comparable apparatuses, for example 30 000 to 40 000 copies per hour, a correspondingly large volume of data arises which needs to be processed in the controller, the main drive control system and each drive control system. With such levels of clock cycles, the error rate inherent in every component (MTBF) therefore becomes relevant and contributes to a significantly lower total error rate in comparison with the prior art.
In a further embodiment, the product collection unit has a first controller which is preferably connected to the main drive control system directly via the first data bus. Such an arrangement of local intelligence in the form of a controller can now be used specifically to relieve the load on a superordinate unit which prescribes the commands for the present apparatus. In the present case, the first controller is relieved of load specifically by the first and second drive controllers, which undertake ascertainment of the target values, that is to say phase synchronization, for their respective drives locally. In this case, the main drive control system and the first and second drive control systems preferably serve only as phase controllers, whereas the first data collector and the second data collector replace corresponding local controllers, for example conventional PLC controllers.
The first controller therefore has sufficient capacity to undertake error management, for example.
A person skilled in the art is familiar with field buses, Ethernet and Industrial Ethernet, and also particularly the extension for Real-Time Ethernet and Fast Ethernet, for data communication between individual subscribers involved in the control of a process. Examples of known field buses are CAN bus, Profibus, Modbus, DeviceNet or Interbus. The bus subscribers communicate by Ethernet using specified protocols. In addition, the demands on network capability are known in order to provide simple and inexpensive communication mechanisms and in order to link industrial devices to such a network. The need to couple drive components, for example between drive control systems, power circuits and transmitters in numerically controlled machine tools and robots is also known, these requiring a polarity of interpolating axles to be operated in sync.
Since the first data bus in the present embodiment is preferably implemented with EtherCat (Ethernet for Control Automation Technology), data interchange between the subscribers (e.g. drive control systems etc.) is assured in real time.
The real-time data transmission allows the intelligence not to be decentralized so as to cause a high level of control and alignment complexity but rather to be left centrally, but without having to dispense with the advantages of local intelligence completely. On account of the high data rate of 500 bytes per second in EtherCat, the controller does not recognize that it is not actuating the main drive and the first and second drives directly but rather that the slaves thereof (i.e. the first and second drive controllers) undertake this. The short cycle times in EtherCat are a result of the continuous processing which lead to good bandwidth utilization, since the first controller, the main drive control system, the first and second drive control systems and the first and second data collectors do not require a dedicated frame at each time.
On account of the performance capability of EtherCat, it is possible to enter in a frame not only a guide value, actual single cycle and actual fine cycle but also, by way of example, the status of the product collection unit and of all handling units, the counters thereof, threshold value, speeds and limit values.
In addition, in one particularly preferred apparatus, the main drive has an associated first sensing element for sensing a first actual value, also called actual fine cycle. Since sensing elements, like rotary encoders associated with, or incorporated in, the drive motor, are known to a person skilled in the art, a detailed description thereof is dispensed with at this juncture. The first actual value is supplied to the main drive control system via a first connection, preferably in the form of a conventional signal line.
Since even good drives are not perfect, a small error in the angle synchronism in respect of the movement brought about by the drive motor on the effective conveyor means arises for every movement made by the drive motor on account of gear backlash owing to wear, and also mathematical rounding, which is expedient for control purposes, of a decimal place in the number Π (pi). On account of the large numbers of items in postpress processing, this quickly results in multiple errors per hour, which is intolerable. For this reason, one preferred development of the present apparatus involves the conveyor means having an associated second sensing element for sensing a second actual value, also called actual single cycle. The sensing element is connected to the main drive control system via a second connection, preferably a second signal line.
In a further, preferred embodiment of the apparatus in the present invention, at least the first, but preferably also the second, handling unit is of modular design. This provides an operator of the apparatus with the opportunity, at least in the case of first and second handling stations which are of identical design specifically in terms of the interface, to exchange the first handling unit for the second handling unit, and vice versa. In addition, the flexibility of the apparatus is increased, since in the event of a faulty first handling unit it is possible for said handling unit to be quickly replaced by an identical or at least—specifically in terms of the interface—compatible handling unit without needing to accept long downtimes for the entire apparatus.
For control purposes, a further, preferred embodiment of the apparatus involves the first controller being connected to a superordinate unit via a second data bus. By way of example, the superordinate unit is a superordinate data collector which has no intelligence and merely instructs the first controller what needs to be produced in the present apparatus with what structure. By virtue of the fact that it is not the first data bus which is used for this purpose but rather a separate second data bus, it is possible to tell that improved control certainty in comparison with the prior art is achieved. This is significant when the data interchange on the first data bus collapses as a result of overload, for example, and it allows the apparatus to be switched off under control nevertheless. In an online mode of the apparatus, an upstream rotary printing machine, for example, forms a superordinate master and uses the second data bus—preferably likewise an EtherCat bus—to communicate with the first controller, which for this purpose is accordingly defined as a slave. Any production variations in the rotary printing machine are controlled by the apparatus by means of the first controller as appropriate, for which reason the conveying capacity of the conveyor means can be continuously adjusted as appropriate. In an offline mode, the speed of the conveyor means is by contrast largely constant, and the first controller forms the master.
In one particularly preferred embodiment of the apparatus, the second handling unit is an initial collection apparatus and therefore has an initial product collection unit and also a first initial handling unit and a second initial handling unit for synchronized handling, preferably for supplying products. In a similar fashion to the handling units, the terms first initial handling unit and second initial handling unit are not intended to be understood to be limiting, but rather are merely intended to be understood as representatives of any number of initial handling units for the purpose of simplified explanation.
Preferably, the initial handling units are formed by supply conveyors for supplying identical and/or different subproducts to form an initially collected stack. Whether these supply conveyors are in the form of bundle feeders or have another design is not important to the control situation described below. The initial product collection unit has a second controller instead of the second data collector, said second controller being operatively connected to the second drive via the second drive control system for the purpose of driving an initial conveyor means. The first initial handling unit has a first initial drive control system which for its part is operatively connected to a first initial drive. Moreover, the second initial handling unit has a second initial drive control system which is operatively connected to the second initial drive. The second drive control system and the first and second initial drive control systems are operatively connected to one another via a third data bus in a line structure. Since the control scheme for the initial collection apparatus is of similar design to the control scheme for the entire apparatus, the second drive accordingly has an associated third sensing element for sensing a third actual value for the second drive. This third actual value is subsequently also called the second actual fine cycle. This third sensing element is accordingly connected to the second drive control system by a third connection, preferably a third signal line. In addition, the first initial handling unit has a first initial data collector which is operatively connected to the second drive control system and to the first initial drive control system. Accordingly, the second initial handling unit has a second initial data collector which is operatively connected to the first initial drive control system and to the second subordinate drive control system.
To prevent the previously explained error, the second drive motor and the initial conveyor means driven thereby have an associated fourth sensing element between them for sensing a fourth actual value for the initial conveyor means, subsequently also called second actual single cycle. This fourth sensing element is connected to the second drive control system via a fourth connection, preferably a fourth signal line.
Control logic of this kind relieves the first controller of a substantial number of computation operations, since the second controller continues to have a slave function therefor and hence sends it only a limited number of data items in unfiltered form. The second controller also has a master function, in terms of control, for its associated initial data collectors and the initial drive controllers thereof. So as not to overload the first data bus locally and in order to avoid a long spur in the line structure of the first data bus, the data interchange is effected on a separate, second data bus.
It is also possible to connect the second data bus to the first data bus via a coupling element.
In a further embodiment of the apparatus, a data bus subscriber defined as a slave—for example the first data collector—with the first drive control system temporarily becomes a master. This dual function allows the first data collector, for example, within an area of competence which is acknowledged for it, to autonomously decide in a subfunctionality in situ whether it needs to send an adjacent slave, for example the second data collector, control data directly which overlap the guide data or guide values of the first controller. To allow such slave-to-slave communication between data bus subscribers, no slave of which has a bus master functionality, in the case of the first data bus with sequentially circulating frame traffic, the protocol chip of the bus subscriber that wishes to send data to other bus subscribers is preferably complemented by a transmission memory and possibly a reception memory.
To prevent the previously explained error between the drive motors and the conveyor means or initial conveyor means driven thereby, both the product collection unit and the initial product collection unit and also the handling units and initial handling units respectively have a dedicated actual fine cycle sensing element and a dedicated actual single cycle sensing element. These are used for the main drive control system and for the second drive control systems firstly for local readjustment in the event of an error and secondly as a basis for calculating a guide value for the phase shift in their associated handling stations, while the first and second initial drive control systems are used exclusively for locally readjusting the first or second initial drive.
In a further embodiment of the apparatus, a signal regenerator (repeater) for bridging purposes is arranged with the first drive control system, which receives the bus signals, that is to say the Ethernet/EtherCat frames, and forwards them in freshly conditioned form to the second data collector if the first drive control system fails. This makes it possible to ensure that the subscriber components which are “downstream” in the line structure, such as data collector or drive controllers, continue to be reliably supplied with data.
In a further embodiment of the apparatus, a collection drum with saddles arranged on the perimeter, but preferably with pockets, forms the conveyor means. The first handling unit is preferably a supply conveyor and the second handling unit is a delivery conveyor. In a further embodiment of the apparatus, a further handling unit forms a stitching station.
In addition, in a further embodiment of the apparatus, the collection drum has a first drum element and a second drum element which are of circularly cylindrical design in a known manner and are arranged so as to have an axially linear profile. In this case, the drum element forms the conveyor means and the second drum element forms a further conveyor means within the context of the conveyor means idea. The conveyor means and the further conveyor means are accordingly operatively connected to the main drive control system via a first main drive, and a second main drive, respectively, such that the first drum element and the second drum element can be driven on the basis of and independently of one another and can be synchronized to one another. Such collection drums with a plurality of drum elements are known to a person skilled in the art from EP 0344102 A2, EP 0672603 A1 and EP 0681979 A1. A collection drum of such design increases the flexibility of use for the operator by virtue of either one product, preferably a printed product, with five subproducts or two printed products with two subproducts each being able to be produced in the case of six supply conveyors, for example.
In a further embodiment of the apparatus, the conveyor means is formed by a conveyor belt, said conveyor belt ideally having low stretch and being dimensionally stable. Such an apparatus can be used for collecting products in stacks, for example, said products subsequently being packaged in a film bag.
In a further embodiment of the apparatus, the conveyor belt has fan-like compartments into which subproducts and/or main products are tossed or directed. Inclining the fans relative to a conveyor direction of the conveyor belt ensures that the collected products are in a preferred position, namely on a lateral wall of a compartment which forms a stop for the obliquely situated products and/or supplied subproducts.
In a further, preferred embodiment of the apparatus, the main drive and also the first and second drives are driven, in terms of power, by a respective power element, preferably an angle-synchronized frequency converter. Each of said power elements are connected, for control purposes, to their associated main drive control system or to the first or second drive controller via a respective dedicated subordinate data bus. The conscious isolation of the control signal plane from the power plane firstly increases fail-safety by means of a physical distance between signal loop and control loop and alleviates known problems, such as interference signals in the control loop on account of spikes in the power loop. The power elements are preferably used as simple actuators which ensure low-maintenance, stable operation of the apparatus.
In a further embodiment of the apparatus, the main drive control system and/or the first drive control system and/or the second drive control system are respectively connected to a plurality of power elements for the purpose of driving a plurality of drives. This means that a plurality of power elements share an associated drive control system. In a further form of the apparatus of the present invention, the subordinate data bus is routed only as far as a first power element, while a further power element is configured—in other words connected in parallel—as a slave of the first power element.
The problem on which the invention for the method is based is solved by means of the features of claim 15 . Further embodiments of the method are the subject matter of dependent claims 16 to 22 .
In a first embodiment of the present method, reference is made to the description above for the structural design of the apparatus required for this purpose. The main drive is controlled by means of a main drive control system, while the first and second drives are controlled by a first and a second drive control system. The main drive control system and the first and second drive control systems interchange data via the first data bus. The first controller also communicates with the main drive control system via the first data bus. When sending data from the main drive control system for the second drive control system, said data are written to an EtherCat frame by the first controller, and said frame is delivered to the second drive control system by the first data bus successively via the first data collector, the first drive control system and the second data collector.
To prevent the error already explained above between the main drive motors and the conveyor means driven thereby, one particularly preferred embodiment for the present method involves the first actual value for the main drive (to be precise the main drive motor thereof) and preferably also the second actual value for the conveyor means driven by the main drive being sensed and being transmitted to the main drive control system. On the basis of these data, the main drive control system compensates for local target/actual differences and therefore prevents accumulation of errors.
If a handling unit is formed by an initial collection apparatus, a similar process takes place in one particularly preferred embodiment of the method. To this end, the third actual value for the second drive (to be precise the drive motor thereof) and preferably also the fourth actual value for the initial conveyor means driven by the second initial drive are sensed and are transmitted to the second drive control system. The second drive control system compensates for local target/actual differences on the basis of these data and prevents accumulation of errors, which relieves the load on the second controller in targeted fashion.
In a further embodiment of the present method, the first data bus transmits its data transferred to it in real time and the first controller, the main drive controller, the first and second drive control systems and the first and second data collectors read in and out the data sent to them from this first data bus. In this case, data from the handling stations, or the slave subscribers thereof, are preferably read out by the first controller in order to keep the coordination complexity between all bus subscribers as low as possible.
In a further embodiment of the present method, the main drive control system produces a guide value and writes said guide value together with the first actual value and the second actual value preferably into the data bus frame of the first data bus. Guide value is understood to mean an ascertained target phase for a handling station relative to the conveyor means. By way of example, a target phase is plus 15%, which corresponds to a phase shift of 15%. The aforementioned frame is transmitted to the first drive control system via the first data collector, whereupon said drive control system ascertains a first target value therefrom for the first drive thereof. The same frame then proceeds and is transmitted to the second drive control system via the second data collector, whereupon said drive control system ascertains a second target value therefrom for the second drive thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained below with reference to figures, which merely show exemplary embodiments and in which
FIG. 1 shows a control scheme for an apparatus in line with a first embodiment of the present invention;
FIG. 2 shows a control scheme from a second embodiment, and
FIG. 3 shows a control scheme from a third embodiment.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a control scheme from a first embodiment of an apparatus 10 based on the present invention. The apparatus has three units arranged next to one another, namely a product collection unit 12 , a first handling unit 14 and a second handling unit 16 . To the right of the second handling unit 16 , one or more further handling units would be conceivable.
The product collection unit 12 has a first controller 38 which is connected to a main drive control system 18 via a first data bus 32 . The first data bus is formed by an EtherCat bus. The main drive control system 18 is connected to a power element 96 via a subordinate data bus 98 , said power element being formed by an angle-controlled frequency converter. The power element 96 is connected to a main drive 20 via a conventional power connection. The main drive 20 is connected to a conveyor means 22 for drive purposes. In addition, the product collection unit 14 has a first sensing element 40 for sensing a rotary position of the main drive 20 , or the drive motor thereof. This first sensing element is a rotary encoder, which in the present case is formed by an incremental encoder arranged directly in the main drive 20 . The first sensing element 40 is connected to the main drive control system 18 via a first connection 44 , which is in the form of a conventional signal line 44 . In addition, the product collection unit 12 has a second sensing element 46 . This second sensing element 46 is an induction sensor, which is used to sense a rotary position for the conveyor means 22 driven by the main drive 20 . The second sensing element 46 is connected to the main drive control system 18 via a second connection 50 , which is in the form of a conventional signal line 50 .
At least one of the handling units 14 , 16 in this arrangement is intended as a delivery conveyor for transporting away the collected, inserted or collated products. Since such delivery conveyors are known, they are not discussed in more detail.
The first handling unit 14 is of the same design, in control terms, as the product collection unit 12 . In this case, a first drive control system 24 corresponds to the main drive control system 18 , while a first drive control system 24 corresponds to the main drive control system 18 , a power element 96 a is of the same design as the power element 96 , a further first sensing element 40 a is of the same design as the first sensing element 40 , a further second sensing element 46 a is of the same design as the second sensing element 46 , and a first handling means 122 is arranged instead of the conveyor means 22 . Instead of the first controller 38 , however, a first data collector 34 is arranged in the first handling unit 14 .
The second handling unit 16 is of similar design to the first handling unit 14 . In this case, a second drive control system 28 corresponds to the first drive control system 24 , a power element 96 b is of the same design as the power element 96 a , a further first sensing element 40 b is of the same design as the further first sensing element 40 a , a further second sensing element 46 b is of the same design as the further second sensing element 46 a , and a second handling means 222 is arranged instead of the conveyor means 122 . Instead of the first data collector 34 , a second data collector 36 is arranged in the second handling unit 16 .
A first data bus 32 connects the first controller 38 to the main drive control system 18 , the main drive control system 18 to the first data collector 34 , the first data collector 34 to the first drive control system 24 , the first drive control system 24 to a second data collector 36 and the latter to a second drive control system 28 . Stylized continuation of the first data bus 32 to further handling stations—not shown here—is distinguished by data bus 32 . In the present case, the first controller 38 forms a master with coordination and monitoring intelligence, to which the low-intelligence bus subscribers defined as slaves, main drive control system 18 , first and second data collectors 34 , 36 , and the first and second drive control systems 24 , 28 , are hierarchically subordinate. Thus, data from the first controller 38 , which are provided for the second drive control system 28 , are successively transmitted via the main drive control system 18 , the first data collector 34 , the first drive control system 24 and the second data collector 36 to the second drive control system 28 .
For control purposes, the apparatus is actuated by a superordinate data collector 54 via a second data bus 52 . In this case, the second data bus 52 is likewise formed by an EtherCat bus. In an offline mode of the apparatus 10 , the input is made using a superordinate computation unit or using an input station—not denoted in more detail—, for example, and the first controller 38 forms the master for the bus subscribers which are subordinate to it, defined as slaves. In an online mode, a rotary printing machine typically forms the master and prescribes the clock cycle as a target value for the first controller 38 . In this case, the first controller 38 serves as a slave toward said superordinate unit 54 (e.g. the rotation) and is at the same time the master over the main drive control system 18 , which is subordinate to it, and the first and second data collectors 34 , 36 , or the first and second drive control systems 24 , 28 .
The apparatus of this kind is used for inserting, collecting or collating flexible, two-dimensional products, primarily printer's products. The insertion typically involves subproducts being transferred from a plurality of supply conveyors to a conveyor means, to which end the conveyor means is preferably in the form of an insertion drum, clamp conveyor or conveyor belt. For collection, the conveyor means is a collection drum or a linear conveyor with saddles onto which the folded subproducts are placed astride, for example. One such linear conveyor for collection is known from CH 688091 A5, for example. For collation, a linear conveyor with a circumferential conveyor belt typically forms the conveyor means, in this case, the products and/or subproducts are collated to form a stack. One such linear conveyor for collation is known from WO 03/053831 A1 or EP 1029705 1, for example. Conveyor means 22 is then accordingly also understood to mean an insertion, collection or collation apparatus, which are in the form of clamp conveyors, belt, drum or rung conveyors, for example. In one embodiment of the apparatus, the conveyor means 22 includes fan-like compartments 23 into which products and/or subproducts are tossed or directed.
A common feature of all the aforementioned apparatuses is that they have a multiplicity of handling units, which are typically in the form of supply conveyors. These supply conveyors supply the conveyor means with the respective main or subproduct in phase sync. Supply conveyors are understood to mean, by way of example, bundle feeders, transporters with claws, clamp feeders, winding feeders, and also initial collection apparatuses, which for their part may again contain initial collection apparatuses.
The synchronization between the handling units 14 , 16 and the product collection unit 12 entails a multiplicity of data items which need to be interchanged with one another. Thus, the power element 96 uses the subordinate data bus 98 to communicate with the main drive control system 18 . Similarly, the power elements 96 a and 96 b use subordinate data buses 98 a and 98 b to communicate with their associated first and second drive control systems 24 , 28 . Using EtherCat as the first data bus 32 , the data to be interchanged are entered into an Ethernet frame 100 and routed sequentially and in real time along each bus subscriber in line with the linear structure. The first controller 38 , the first and second data collectors 34 , 36 and the main drive controller 18 , the first and second drive control systems 24 , 28 can read the data intended for them from the frame and, particularly in the case of the first controller 38 , can also write them.
In parallel therewith, the first and second actual values 42 , 48 from the first and second sensing elements 40 , 46 are transferred to the main drive control system 18 via the signal lines 44 and 50 . Corresponding signals are sensed by appropriate further first sensing elements 40 a , 40 b and further second sensing elements 46 a , 46 b and are supplied to the first and second drive control systems 24 , 28 via appropriate signal lines 44 a , 44 b , 50 a , 50 b.
The main drive control system 18 ascertains a guide value 102 and transmits it with the first actual value 42 and the second actual value 48 to the first drive control system 24 in frames via the first data collector 34 . For the first drive control system 24 , the first actual value 42 and the second actual value 48 form the target values. The first drive control system 24 takes the guide value 102 , the first actual value 42 and the second actual value 48 as a basis for ascertaining a first target value 104 for the first drive 26 . Analogously, the second drive control system 28 takes the guide value 102 , the first actual value 42 and the second actual value 48 as a basis for producing a second target value 106 for the second drive 26 .
FIG. 2 shows the basic design of the control logic for parallel processing or serial processing using a further embodiment of an apparatus 10 a from the present invention. Processing is understood to mean insertion, collection or collation. Although both processing operations are subsequently explained with reference to a collection drum with a circular conveyor means 22 , the explanations below also apply mutatis mutandis to linear conveyor means such as conveyor belts.
The apparatus 10 a shown in FIG. 2 comprises a multipart conveyor means 22 with a two-part collection drum 22 , having a first drum element as the first conveyor means 22 a and a second drum element as the second conveyor means 22 b , the longitudinal axes of which are typically flush, that is to say are situated on a common straight line. Since both the basic design and the control operation largely correspond to an apparatus as shown in FIG. 1 in principle, however, only the differences from that apparatus 10 are explained below, although all elements are noted. The apparatus 10 a has a product collection unit 12 a arranged essentially centrally with a first and a second handling unit 14 , 16 , 14 ′, 16 ′, respectively, on both sides, the first and second handling units 14 ′, 16 ′ being arranged and set up, in terms of design, so as to be basically a mirror image of the first and second handling units 14 , 16 in this case. The difference between the first handling unit 14 ′ and the first handling unit 14 will be discussed in more detail at another juncture.
In contrast to the drive situation of the apparatus 10 shown in FIG. 1 , the product collection unit 12 a has two drive trains. For this reason, each of the two main drives 20 a , 20 b also has a respective associated power element 96 and 96 ′ which, as is known, can communication with the main drive control system 18 via a respective subordinate data bus 98 and 98 ′.
Since the first conveyor means 22 a is intended to be able to be operated independently of the second conveyor means 22 b , the first main drive 20 a and the second main drive 20 b are connected only to the first drum element and the second drum element, respectively. As a result, each drive train has a dedicated first and second actual value sensing unit with corresponding dedicated first and second sensing elements 40 , 40 ′, 46 , 46 ′ which then supply the ascertained values to the common main drive control system 18 via appropriate signal lines 44 , 44 ′ in a known manner. To provide a better overview, actual values 42 , 42 a , 42 a ′, 42 b , 42 b ′, 48 , 48 ′, 48 a , 48 a ′, 48 a ″, 48 b , 48 b ′ for the relevant sensing elements 46 , 46 ′, 46 a , 46 a ′, 46 a ″, 46 b , 46 W are labeled across the writing direction which is otherwise used.
An apparatus 10 a of such a design can be used to drive the first conveyor means 22 a and the second conveyor means 22 b both on the basis of and independently of one another. It goes without saying that the first conveyor means 22 a and the second conveyor means 22 b can also be driven in sync by their first main drive 20 a and second main drive 20 b . In a further embodiment—not shown here—of the apparatus 10 a , the product collection unit 12 a has an individually controlled first main drive 20 a and an individually controlled second main drive 20 b . To this end, the first main drive 20 a is connected to a first main drive control system via a power element of the same design, while the second main drive 20 b is connected to a second main drive control system via a further power element of the same design.
The first and second main drive control systems are controlled by the superordinate unit 54 preferably via the second data bus 52 and via a further data bus which corresponds to the second data bus 52 , and can accordingly communicate with them. In a further embodiment—not shown—of the apparatus 10 a , the first main drive control system corresponds to the main drive control system 18 and serves as a master for the second main drive control system, designed as a slave. In this case, the first main drive control system is connected to the superordinate unit 54 via the second data bus 52 , and the first main drive control system is connected to the second main drive control system via a further data bus.
When products are processed in parallel, the first conveyor means 22 a is typically supplied with subproducts by a first group of supply conveyors, and a first main product produced in this manner is removed, or accepted and routed away, by a first router associated with the first conveyor means 22 a . Similarly, the second conveyor means 22 b is typically supplied with subproducts by a second group of supply conveyors, and a resultant, second main product is then removed, or accepted and routed away, by a second router associated with the second conveyor means 22 b . It is clear that the first and second main products in this case may be identical or different.
When products are processed in series, the first conveyor means 22 a is typically supplied with subproducts by a first group of supply conveyors, and a first main product produced in this manner is removed, or accepted and supplied as an initial product to the second conveyor means 22 b again, by a first router associated with the first conveyor means 22 a . In the interim, the products can be labeled, for example. The second conveyor means 22 b is typically supplied with further subproducts by a second group of supply conveyors, so that ultimately a single main product is produced. This main product is then removed, or accepted and routed away, by the second router, for example.
FIG. 2 reveals that a single drive control system caters for a plurality of drives (in the present case, two first drives 26 ′, 26 ″) independently of one another. This property is also shown by way of example with reference to the first handling unit 14 ′. With regard to the design with two drive trains in the first handling unit 14 ′, the first handling unit 14 ′ corresponds to the product collection unit 12 a . Considered in control terms, however, it is of the same design as its mirror image—the first handling unit 14 . Accordingly, an apostrophe (') in FIG. 2 reflects the symmetry. In the present embodiment, a subordinate data bus 98 a ′ is routed to a power-element connection of a power element 96 a ′ and from there onward to a second power element 96 a ″. Considered in control terms, it is therefore also possible to refer to a slave mode of the second power element 96 a ″, for which the first power element 96 a ′ forms the master. Since the first drives 26 ′ and 26 ″ are actuated in the same way, sensing of a first local actual value 48 a ′ is dispensed with, but not sensing of a second local actual value 48 a ″, since this value is required for monitoring the first handling means 122 ″.
Moreover, FIG. 2 has an additional element 108 which is a wildcard for a further peripheral device 108 . The additional element 108 can be used to retrieve data from the first data memory 34 of the first handling unit 14 directly. The additional element 108 is a portable computer, a diagnosis device or an IPC (Interpace), for example.
Although FIG. 2 shows only a first and a second handling unit 14 , 14 ′, 16 , 16 ′, respectively, it is clear to a person skilled in the art that one or more further handling units may be arranged as appropriate on the left and right of the second handling units 16 , 16 ′.
FIG. 3 shows a further embodiment of the present invention using an apparatus 10 b . The control-based design of the apparatus 10 b fundamentally corresponds to the design shown in FIG. 1 . In contrast to the apparatus 10 shown in FIG. 1 , however, the apparatus 10 b has a somewhat more complex handling unit 16 ″ instead of a second handling unit 16 of simple design. Upon closer observation, it can be seen that this is a subordinate apparatus which is defined as an initial collection apparatus and has the same control logic and basically the same design as the apparatus 10 shown in FIG. 1 . To the right of the second handling unit 16 ″, a further handling unit is shown as representative of one or more further handling units. Similarly, to the right of the second initial handling unit 60 , a further initial handling unit is shown as representative of one or more further initial handling units.
In comparison with the apparatus 10 , an initial product collection unit 56 in the case of the second handling unit 16 ″ corresponds to the product collection unit 12 , a first initial handling unit 58 corresponds to the first handling unit 15 , a second initial handling unit 60 corresponds to the second handling unit 16 , a first subordinate data collector 82 corresponds to the first data collector 34 , a second drive control system 28 ″ corresponds to the second drive control system 28 , a first initial drive controller 66 corresponds to the first drive controller 24 , a second initial drive controller 70 corresponds to the second drive controller 28 , a power element 96 c together with subordinate bus 98 c corresponds to the power element 96 b together with subordinate bus 98 b , a power element 96 d together with subordinate bus 98 d corresponds to the power element 96 c with subordinate bus 98 c , a third actual value sensing element 76 corresponds to the first actual value sensing element 40 , a second actual value sensing element 86 corresponds to the second actual value sensing element 46 , etc. For the sake of a better overview, the first and second actual values 42 , 48 , 78 , 88 and the relevant local actual values 42 a , 48 a , 78 a , 78 b , 88 a , 88 b are labeled across the other reading direction.
FIG. 3 viewed together with FIG. 1 reveals that the design has been retained within the units, which is why a detailed description of the connecting lines is dispensed with on account of the functionality remaining the same.
The second drive control system 28 ″ uses a second data bus 74 to communicate with the first initial data collector 82 , the first initial drive control system 66 , the second initial data collector 84 and the second initial drive control system 70 .
Instead of a second data collector 36 defined as a slave, the initial product collection unit 56 contains a second controller 62 defined as a slave, without changing anything about the data bus connection of the first data bus 32 . In addition, the second drive control system 28 ″ has an additional bus interface for an industrial Ethernet bus in comparison with the second drive control system 28 .
To allow data traffic between the first data bus 32 and the second data bus 52 , an indicated embodiment of the apparatus 10 b has the second data bus 74 connected to the first data bus 32 via an additional data link. In this case, the connection is made not directly but rather via a coupling element 110 , however. The link is therefore shown as a dashed line.
In this embodiment with the apparatus 10 b , the initial handling units 58 , 60 are in turn defined as initial collection systems. In this case, the first and second initial data collectors 82 and 84 are accordingly replaced by a respective further controller, which in turn use a dedicated data bus (preferably again EtherCat) to communicate with their respective subordinate slaves.
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The invention relates to a device for inserting, collecting or collating a plurality of flexible, planar products, preferably printed products, wherein the device ( 10, 10 a, 10 b ) comprises a product collection unit ( 12, 12 a ), a first processing unit ( 14, 14 ′), and a second processing unit ( 16, 16′, 16 ′) for the synchronized processing, for example feeding, of products. The product collection unit ( 14, 14 ′) comprises a main drive controller ( 18 ), which is operatively connected to a main drive ( 20, 20 ′) for driving a conveying means ( 22 ). The first processing unit ( 14, 14 ′) comprises a first drive controller ( 24, 24 ′), which is operatively connected to a first drive ( 26, 26′, 26 ′), and the second processing unit ( 16, 16′, 16 ′) comprises a second drive controller ( 28, 28′, 28 ′), which is operatively connected to a second drive ( 30, 30 ′). The first processing unit ( 14, 14 ′) additionally comprises a first data collector ( 34, 34 ′), which is connected to the main drive controller ( 18 ) and to the first drive controller ( 24, 24 ′) via a first data bus ( 32, 32 ′), while the second processing unit ( 16, 16′, 16 ′) comprises a second data collector ( 36, 36 ′), which is connected to the first drive controller ( 24, 24 ′) and the second drive controller ( 28 ) via the first data bus ( 32, 32 ′).
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CROSS-REFERENCE TO RELATED APPLICATION
This document is a divisional application of parent U.S. patent application Ser. No. 07/664,668 filed March 5, 1991, entitled "PLATE TRAILER JOINTS"now U.S. Pat. No. 5,066,066.
BACKGROUND OF THE INVENTION
The present invention generally relates to van-type semi-trailers and similar cargo vehicles and containers constructed of a plurality of rectangular panels composed of thin aluminum plate or composite materials as disclosed in U.S. Pat. Nos. 4,685,721, 4,810,027, 4,904,017 and 4,940,279. The invention particularly relates to joining members for such cargo carriers, the joining members being rectilinear strips intended to join two adjacent panels in side-by-side relationship so as to form at least a portion of the wall structure of such cargo carriers.
Cargo carriers of the type disclosed in the above-noted patents have employed particularly thin rectangular panels coupled by relatively flat joining members in such a way as to form a semi-trailer, cargo vehicle, container, or other cargo carrier having a high cubic capacity. The very minimum thickness of materials has been employed to construct the walls of such a cargo carrier so as to maximize the volume of the cargo carrier for a given width. In the construction of such cargo carriers, particular care has been required in the handling of the panel members in order to protect the edges of the panel members to insure the panels are smooth and flat. Any burr, bend, or crease has the propensity to allow moisture to creep between the panel member and the joining member joining the panel to an adjacent panel thereby permitting possible damage to the cargo carrier contents. The burr, bend or crease in the plate edge have the tendency to displace the joining member outward from the edge portions of the plate. The special care handling requirements imposed during the construction of such cargo carriers contributed directly to an increased manufacturing cost of such carriers.
Other special problems of plate type cargo carriers resulted when it became desirable to include logistics tracks on the sides of such cargo carriers. The attachment of logistics tracks directly to the flat Plates is effectively prohibited since such an attachment requires holes in the plates for fasteners, which can contribute to the invasion of weather. Such holes also produce unwanted stress risers which might contribute to untimely product failure.
SUMMARY OF THE INVENTION
To overcome these and other problems associated with existing styles of joining members, the present invention conceives of a joining member for joining adjacent pairs of plates on a plate trailer comprising a rectilinear strip having an outer surface and an inner surface with parallel edges joining the outer and inner surfaces. Two rows of apertures extend between the outer and inner surfaces, one row adjacent each of the edges for receiving appropriate fasteners for fastening the joining strip to the plates to be joined together. The inner surface of the strip includes a pair of flanges positioned between the two rows of apertures with a channel of uniform depth situated between the pair of flanges.
In the first embodiment of the invention, a sealing strip is fixed in the channel, the strip having a width about equal to the distance between the pair of flanges, a length about equal to the length of the rectilinear strip and a thickness greater than the channel depth. The flanges defining the channel are situated midway between the parallel edges of the linear strip and straddle the line of adjacency between the pair of plates joined by the joining member. The sealing strip is compressed within the channel by the two plates of either side of the line of adjacency to seal the junction of the two plates.
One feature of the first embodiment of the present invention is the presence of the sealing strip Provided in the channel and situated to straddle the seam or juncture between the adjacent plates thereby maintaining a sealed barrier despite any slight flexing of the juncture during travel or operation of the plate trailer. The presence of small creases, burrs, or other imperfections in the edges straddled by the channel will generally be insufficient to cut the moisture barrier provided by the sealing strip and will not generally provide any structure which would otherwise act to displace the joining strip outward from the plate sufficiently to permit moisture to be driven past the line of fasteners into the interior of the cargo carrier.
In a preferred embodiment, the plate includes outer channels provided between the parallel edge and the row of fastener receiving apertures so as to prevent moisture from being pressure driven passed the row of fasteners. A second inner lateral channel is also provided which allows moisture to travel vertically within the joining member away from the joined seam between the two adjacent plates joined by the joining member. A small undercut on the inner edge of the second inner lateral channel allows for small amount of conformity correction to the pair of flanges defining the central channel where certain large plate errors may exist.
In a second embodiment of the present invention, the adjacent plates forming the wall are spaced apart from each other and the pair of flanges project between the pair of adjacent flanges toward a second inner strip. The inner strip includes appropriate openings aligned with said channel for receiving the desired logistics fittings. In a preferred embodiment, both the outer strip and inner strip are positioned on the outer surface of the adjacent pair of plates with the inner strip having an off-set center portion projecting between the selected pair of plates. In this embodiment, the lateral edges of the outer strip project laterally beyond the inner rectilinear strip and include a sealing means joining the outer edges of the outer rectilinear strip to the outer surface of the adjacent plates.
In another preferred embodiment of the invention, the outer rectilinear strip and the inner rectilinear strip are positioned on opposite surfaces of the selected pair of spaced adjacent plates. In this preferred embodiment, lateral channel means are provided on each side of the pair of flanges coincident with the spaced edges of the adjacent plates and sealing means is received in the lateral channels engaging the spaced edges of the pair of adjacent plates.
A feature of both embodiments is the use of a pair of rectilinear joining strips which adjoin the spaced plates with the logistics track being positioned between the pair of adjacent spaced apart plates. Such a structure has the advantage of increased strength over the use of a single joining member, yet at the same time provides for easy attachment of the desired fasteners and fittings. Further, since the fasteners and fittings are to be received in a strip which is positioned at least in part between the adjacent plates, this feature has the further advantage of reducing any projection of the logistics fittings into the cargo area thereby maximizing the cubic content of the cargo carrier.
Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of the preferred embodiments exemplifying the best modes of carrying out the invention as presently perceived. The detailed description particularly refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a plate trailer incorporating joining members in accordance with the present invention.
FIG. 2 is a sectional view taken along line 2--2 showing a joining member in accordance with the present invention in cross-section.
FIG. 3 is a detail sectional view of the joining member shown in FIG. 2 prior to assembly.
FIG. 4 is a detail sectional view of the joining member shown in FIG. 2 subsequent to assembly.
FIG. 5 is a sectional view taken along line 5--5 of FIG. 1 showing a second embodiment for joining member in accordance with the present invention.
FIG. 6 is a sectional view similar to that of FIG. 5 of yet another embodiment of a joining member in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A plate trailer 10 in accordance with the present invention is shown in perspective in FIG. 1 to generally comprise a floor 12, a roof 14, and a pair of side walls 16 and 18. The trailer body also includes a forward bulkhead 20, a suspension 22 including wheels 24, and one or more axles 26 for supporting a rearward end of the trailer 10. The trailer 10 also includes a king pin 28 for attachment to the fifth wheel of a tractor in the conventional manner and a landing gear 30 for supporting the trailer 10 when not attached to a tractor. Each side wall 16 and 18 comprises a plurality of generally flat rectangular plates 32. The plates 32 may be constructed either of a lightweight metallic material, preferably tempered aluminum alloy, or may be a composite structure employing a thin aluminum skin bonded to each side of a polymeric core of polypropylene, polyethylene, or the like. The plates 32 are joined by joining members 34 which are in the form of vertically oriented rectilinear strips shown in greater detail in FIGS. 2 and 4.
A shown in FIG. 2, the plates 32 are situated with respect to each other such that their edges define a common line of adjacency 36. The joining member 34 includes an outward facing surface 38 and an inward or plate facing surface 40. The outer surface 38 and inner surface 40 are joined by a pair of outside edges 42 and 44 defining the margins of the joining member. Two rows of fasteners 46 and 48 are provided in fastener receiving apertures in the joining member and extend through the plates 32 with one row of fasteners adjacent to each of the edges 42 and 44. The outer surface 38 includes linear depressions 50 and 52 intended to protect the heads of the fasteners 46 and 48 from any shearing action which might occur due to casual contact with an obstruction or the like.
The inside surface 40 of the joining member 34 includes outside channels 54 and 56 running the length of the strip which aid in trapping any moisture which might be pushed passed the margins 42 and 44 prior to contact with the row of fasteners 46 and 48, respectively. The outside channels 54 and 56 provide a vertical pathway for such moisture to be directed to the bottom of the trailer and thereby prevent any migration to the inside of the trailer 10.
Between the two rows of fasteners 46 and 48 are a pair of lateral channels 58 and 60 which are separated by a stem member 62 supporting a pair of flanges 64 and 66 straddling the line of adjacency 36 between the two Plates 32. As shown in greater detail in FIGS. 3 and 4, the flanges 64 and 66 are separated by a central plate-facing channel 68 of uniform depth. Each of the lateral channels 58 and 60 include undercut portions 70 and 72, respectively, which define the inside edges of the lateral channels 58 and 60 and act together to define the width of the stem Portion 62 which is illustrated to have a width less than, but about equal to the distance between the flanges 64 and 66.
A sealing strip 74 of elastomeric material is situated in the channel 68. The sealing strip 74 has a width about equal to the distance between the flanges 64 and 66, a length equal to the length of the rectilinear strip 34 and a thickness considerably greater than the depth of channel 68.
As the strip 34 is assembled to the plates 32 such that flanges 64 and 66 straddle the line of adjacency 36 between the plates 32 as shown in FIG. 4, the sealing strip 74 is compressed by contact with the outer surface 76 of the plates 32 in the immediate vicinity of the line of adjacency 36. Any minor misalignment of the plates 32 along the line of adjacency 36 is easily compensated for by the sealing strip 74. The presence of any burrs, bumps or creases in either of the plates 32 immediately adjacent to the line of adjacency 36 is also easily compensated for by the strip of sealing material 74 retained in compression on both sides of the line of adjacency 36 by the flanges 64 and 66 defining the sides of channel 68. An additional strip of sealing material (not shown) is preferably situated between the joining member 34 and the plates 32 along the two rows of fasteners 46 and 48 to prevent any moisture intrusion through the fastener receiving apertures in the plates 32.
While such a self-sealing joining member can be employed in most locations along the length of a trailer, it has been found that in certain locations it is desirable to provide a joining member which includes means for receiving logistics fasteners and fittings on an inner surface thereof. Two alternative embodiments of such a strip 78 are shown in section in FIGS. 5 and 6.
In a first embodiment shown in FIG. 5, the joining member 78 includes an outer rectilinear strip 80 fixed to the outer surface of plates 32 and an inner rectilinear strip 82 fixed to the inner surface of the plates 32 by a common set of fasteners 84 and 86 which pass through both outer and inner rectilinear strips 80 and 82 as well as the plates 32. It is important to note that the plates 32 are spaced apart from each other. The inner surface 88 of the outer rectilinear strip 80 includes a pair of flanges 90 and 92 which project between the margins of the plates 32 to contact surface 94 of inner strip 82. A channel 96 of uniform depth is provided between the two flanges 90 and 92. The channel 96 is aligned with a plurality of openings 98 in the inner rectilinear strip 82 which were adapted to receive various logistics fittings. The outer margin of each of the flanges 90 and 92 defines a lateral channel 100 and 102 into which a sealing material 104 can be placed which engages the spaced edges of the plates 32 thereby sealing the channel against any intrusion by moisture. An additional strip of sealing material (not shown) is preferably situated between the joining member 78 and the plates 32 along the two rows of fasteners 84 and 86 to prevent any moisture intrusion through the fastener receiving apertures in the plates 32.
An alternative embodiment for a joining member incorporating a logistics fittings receiving openings is shown in FIG. 6 wherein an outer rectilinear strip 106 and an inner rectilinear strip 108 are both situated on the outer surface 76 of plates 32. The inner strip 108 includes an offset central portion 110 which projects inward beyond the inner wall surface 112 of the trailer. A pair of flanges 114 and 116 of the outer longitudinal strip 106 Project into the space between the adjacent plates 32, but stop short of the inner strip central portion 110. Like flanges 90 and 92, the flanges 114 and 116 straddle a central channel 118 of essentially uniform depth which is aligned with the logistics receiving openings 98 provided in the inner linear strip 108. As in FIG. 5, the outer linear strip 106 and inner linear strip 108 are fixed to the adjacent plates 32 by a common row of fasteners 84 and 86. The lateral edges 120 and 122 of the outer lateral strip extend laterally beyond the outer limits of the inner strip 108 and are sealed to the plate outer surface 76 by sealing strips 124 and 126, respectively, which inhibit moisture from traveling into the interior of the trailer. An additional strip of sealing material (not shown) is preferably situated between the inner strip 108 and the plates 32 along the two rows of fasteners 84 and 86 to prevent any moisture intrusion through the fastener receiving apertures in the plates 32.
Although the invention has been described in detail with reference to certain illustrated preferred embodiments, variations and modifications exist within the scope and spirit of the invention as described and as defined in the following claims.
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Joining member for joining an adjacent pair of plates on a side of a cargo carrier are formed by a rectilinear strip having an inner surface including a pair of flanges positioned between two rows of aperatures straddling a channel of uniform depth. A sealing strip fixed in said channel having a width about equal to the distance between said pair of flanges, a length equal to the rectilinear strip length, and a thickness greater than the channel depth seals the line of adjacency between the pair of plates. Alternatively, an inner strip including openings alligned with said channel for receiving logistics fittings is employed where the plates are spaced apart to permit the channel defining flanges to project between the plates.
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This application is a division of application Ser. No. 08/979,230, filed on Nov. 26, 1997, now U.S. Pat. No. 6,019,801, which is a Continuation Application of Ser. No. 08/273,756, filed Jul. 12, 1994, now U.S. Pat. No. 5,837,401, which issued on Nov. 17, 1998.
BACKGROUND OF INVENTION
a) Field of the Invention
The invention concerns additives which may be used as lamination lubricating agents or are part of lamination lubricating agents. The invention also concerns compositions including these additives and which may be used in the lamination of a sheet such as lithium in order to obtain thin films, which may be used as such in the production of polymer electrolyte electrochemical cells. In addition, the invention concerns the use of the additives per se or compositions containing same to provide, by lamination, films of alkali metals or alloys thereof which may be used as anodes in electrochemical cells preferably with polymer electrolytes. The invention also concerns a process of lamination utilizing these additives or compositions containing same as lamination lubricating agents.
b) Description of Prior Art
The production of thin films of lithium having thicknesses lower that 75 micrometers and in the form of wide bands, for example 5 centimeters or more and in lengths of many tens of meters, by means of rapid and reliable processes, faces important technical difficulties which are attributable to the extreme physical and chemical properties of this metal: chemical reactivity, malleability, rapid self-welding by simple contact and strong adhesion on most solid materials, for example the usual metals.
This difficulty is confirmed by the difficulty of obtaining from suppliers of specialty metals and chemical products, thin lithium films 40 micrometers (μm) thick and less, of sufficient surface and length, having an adequate surface finish and chemical property to be used in lithium cells.
Presently, cold extrusion is used for the continuous production of sheets 75 μm and more. These thicknesses are generally adapted to the production of lithium cells utilizing liquid electrolytes. For lower thicknesses, the films obtained by extrusion are thereafter laminated between rollers made of hard materials. These processes have been described and are commercially used for the production of limited quantities of sheets of 30-75 microns. Reference will particularly be made to U.S. Pat. No. 3,721,113, inventor Hovsepian and dated Mar. 20, 1973. Many successive passes, according to the present state of the art, are required to give films 40-30 μm.
Other alternative processes have been described to give ultra-thin sheets, which are used for example in the production of polymer electrolyte cells in the form of thin films. This is the case for example of a lamination process between steel rollers which are protected by films of hard plastic which are non reactive towards lithium, such as described in U.S. Pat. No. 3,721,113, or of processes based on the coating of molten lithium on a metallic of plastic support, described in U.S. Pat. No. 4,824,746, inventors André Bélanger, et al, dated Apr. 25, 1989.
The difficulty in achieving the lamination of lithium to thicknesses which vary between 40 and 5 microns for the production of polymer electrolyte cells is mainly due to the reactivity and the adhesion of the laminated metal with the materials with which it is in contact: lamination rollers, protection plastic films, lamination additives, as well as to the bad mechanical properties of thin sheets. For examples a film of lithium 20 μm thick and 10 cm wide breaks under a drawing tension higher than 579.13 KPa which does not permit to pull on the film which exits from the laminating machine or to release it from the lamination rollers if lithium adheres somewhat thereto.
An approach which is normally used for the extensive lamination or calandering of hard metals, such as iron and nickel, is based on the use of liquid lamination additives consisting of organic solvents which may contain greases or lubricating agents. Examples include fatty acids or derivatives thereof such as for example lauric or stearic acids and alcohols, for example the compounds known under the trade marks EPAL 1012 of Ethyl Corporation U.S.A., which are mixtures of primary linear C 10 -C 12 alcohols.
For lithium and particularly for lithium intended for electrochemical cells, the use of such additives involves two major difficulties:
1) the chemical reactivity of lithium which is in contact with solvents or lubricating agents including reactive organic functions, such as organic acids and alcohols. These functions react at the surface of lithium during and after lamination and create passivation films at the surface of the metal. This is harmful for a good operation of electrochemical cells especially when the latter are intended to be rechargeable;
2) the difficulty of removing the lubricating agents or greases which are in contact with lithium after lamination. This is the case, for example, when lubricating agents which mostly consist of hydrocarbon chains are selected, because they are nearly not reactive with lithium. These compounds constitute electrical insulating materials which are harmful to the good operation of lithium electrodes made with these sheets. Such lubricating agents are not very soluble in polymer electrolytes and should therefore be removed from the surface of lithium by washing after lamination. In addition to the fact that the washing of the surface of lithium is a delicate and costly operation, it will be noted that this operation inevitably contributes to contaminate the surface of lithium, in spite of all the care which may be used to control the quality of the surface of the metal. The latter reacts indeed irreversibly with all the impurities, including water, which are present in the washing solvents, or resulting from accidental contaminations.
It can be shown that the lithium obtained after a process of lamination with an additive followed by a subsequent washing is generally more contaminated at the surface than a lithium which is laminated without additive. This phenomenon may be observed with optical means, including a simple visual inspection or by a control of the impedance of the electrochemical batteries produced with polymer electrolytes. On the other hand, lamination without solvent and without lubricating agent means low production speeds and a tendency of the fresh lithium to stick to the rollers or the protection films of the rollers; moreover, many consecutive laminations are therefore required to reach thicknesses of the sheet lower than 40 micrometers.
SUMMARY OF INVENTION
It is an object of the present invention to solve the problem of lamination or calandering of lithium films, to thicknesses between 40 and 5 μm, which can be directly used in lithium batteries made with thin films, for example polymer electrolyte batteries.
It is also an object of the invention to propose lubricating additives which are chemically compatible with lithium and which may be used in a process of lamination which does not require a subsequent washing of the surface of laminated lithium.
Another object of the invention resides in a composition consisting of a lamination lubricating agent including an appropriate solvent as well as an additive having two functions.
Another object of the invention resides in an improvement of the process of lamination of lithium in the presence of an improved lubricating agent.
Another object of the invention is to propose lamination lubricating additives enabling to produce in a single pass, extremely thin lithium, for example a thickness lower than 10 μm, at appreciable speed which may be up to 50 m/min., and even more, and with an excellent control of the surface properties: uniform surface profile and low impedance of the passivation layer when the sheets thus produced are used in an electrochemical cell.
Another object of the invention consists in the provision of a lamination lubricating agent including an additive and solvents, in which the latter are selected for their chemical compatibility with a lithium which is intended for an electrochemical cell.
As used in the present description and in the appended claims, chemical compatibility of solvent or of an additive toward lithium of an electrochemical generator means the absence of chemical reaction with lithium or also, a limited chemical reaction leading to the formation of a passivation film which is not harmful to electrochemical exchanges at the interface lithium/electrolyte of said cell.
Another object of the invention resides in the chemical formulation of a lubricating agent for use in lamination which is not volatile and is selected so that it may be kept at the surface of lithium after lamination and this without harming the good operation of the sheet of lithium (anode), when the latter is used as such in an electrochemical cell, i.e. without any previous washing step.
Another object of the invention resides in an improved process of lamination utilizing the additives according to the present invention.
The invention is based on the choice of a lubricating chemical compound of high molecular weight including at least two segments of different chemical nature: a chain or a chain segment having a lubricating function (L) as made, for example, of a hydrocarbon chain including at least 8 carbon atoms associated with a solvating chain (S), capable of ionically dissociating at least in part a metallic salt, for example of lithium, such as a chain segment of ethylene polyoxide. The solvating segment present in the lubricating additive is selected so as to confer an ionic conductivity to the lubricating additive.
A preferred but non limiting manner of inducing ionic conductivity in the lubricating additive is obtained when the laminated lithium is contacted with the electrolyte (solvating polymer+lithium salt) of the cell. The salt present in the electrolyte is then diffused in the solvating part of the additive and locally constitutes a complex conductor (solvating chain+salt).
The lubricating agent according to the invention comprises at least one sequence:
L—Y—S
where:
L designates a hydrocarbon radical, such as alkyl, alkylene, linear or cyclic or aryl-alkyl, saturated or non saturated, preferably containing more than 8 carbon atoms used as a lubricating segment which is compatible with lithium;
S designates an oligomer segment including heteroatoms such as O or N, and capable of solvating salts, for example salts of lithium and ensuring an electrolytic conductivity;
Y designates a chemical bond or a chemical group which is at least divalent joining the chains or chain segments L and S.
The solvating cell segment S may be joined to a terminal group C to constitute the sequence L—Y—S—C, C then being selected for its low reactivity with lithium.
C may for example designate a group Y′—L′, which is identical or different from group Y—L, an alkyl radical, an alkyl-aryl radical, of valence equal to or higher than 1. According to a variant, C is a polymerisable group which can be incorporated to at least one of the repetitive units which constitute the polymer electrolyte of an electrochemical cell. According to another variant, C includes a ionophoric group which is somewhat dissociable and is capable of inducing an intrinsic ionic conductivity in the additive.
Examples of polymeric solvating chains are given in the following patents: U.S. Pat. No. 4,303,748, inventors Michel Armand, et al, dated Dec. 1, 1981, and U.S. Pat. No. 4,578,326, inventors Michel Armand, et al, dated Mar. 25, 1986. Chains bases on ethylene oxide —[CH 2 —CH 2 —O] n —, propylene oxide —[CH 2 —CH 2 (CH 3 )—O] n — or on poly-(N-methyl-ethylene-imine) —[CH 2 —CH 2 —N(CH 3 )] n or their combinations are generally preferred, but other solvating functions may also be used as long as they may induce an ionic conductivity in the lubricating additive.
In the case where the hydrocarbon segment originates from a fatty acid, the bond Y preferably consists of ester (L)—CO—O—(S) or ether (L)—O—(S) groups. Y may also represent amine or amide groups.
According to a preferred embodiment of the invention, the segment may correspond to the hydrocarbon chain of a fatty acid including at least 8 and preferably from 10 to 30 carbon atoms. For example, L may consist of a hydrocarbon chain of a fatty acid such as stearic acid and Y may then be a chemical bond of the ester or ether type, or may represent a carboxylate group which originates from a fatty acid ester.
According to another preferred embodiment of the invention, the segment S may consist of polyethers or polyamines of molecular weights 150.
According to another preferred embodiment of the invention, the terminal group C may also include a chemical function capable of covalently fixing a metallic salt, for example a lithium salt.
According to another preferred embodiment of the invention, the chemical bond C may include a lithium salt which is chemically grafted by the anion or by means of one or more in saturations.
The invention also resides in a lithium film covered with a thin layer of the additive defined above, the thickness of the film being between 5 and 50 microns.
Another aspect of the invention concerns a lithium based anode prepared from a sheet of lithium covered with a thin layer of the additive defined above, the thickness of the anode being between 5 and 50 μm, which is in direct contact with a sheet including carbon or metals capable of chemically forming an alloy of lithium or an intercalating compound of lithium.
The invention also concerns a polymer electrolyte electrochemical cell including a lithium anode which is prepared as indicated above, in which a free lithium salt is present in the electrolyte so as to form, by diffusion, a complex electrolyte conductor with the chain S of the additive, and the latter may be soluble in the electrolyte.
According to another embodiment of the invention, there is provided the use of an additive or a composition as defined above for producing films of alkali metals or alloys thereof by lamination, which may be used as anodes in polymer electrolyte electrochemical cells.
The invention finally concerns a process of lamination which is intended to give thin films of alkali metals or alloys thereof, from a sheet of said metals or alloys thereof wherein the sheet is passed between working rollers with a laminating lubricating agent to laminate the sheet into thin films, characterized in that the lubricating agent includes an additive or a composition as defined above.
A particularly interesting additive is a polyoxyethylene distearate whose solvating segment corresponds to a molecular weight between about 150 and 4000.
The compositions according to the invention preferably contain 0.01 to 10% by weight of additive, more specifically about 0.2%. With respect to the solvent, it may be selected among saturated or partially saturated linear, cyclic or aromatic hydrocarbons, for example heptane, benzene, toluene, cyclohexane or a mixture thereof. It may also be selected among aprotic solvents which are compatible with lithium.
A particularly advantageous formulation consists in using a family of compounds of the type: L—Y—S—Y—L based on diesters of fatty acids, for example,
CH 3 —(CH 2 ) 16 —COO—(CH 2 —CH 2 —O) n —OOC(CH 2 ) 16 —CH 3
where n preferably varies between 3 and 100. Compounds including polyether segments of molecular weight equal to 200, 400 and 600 are commercially available from Polyscience, preferably POE 400 Aldrich No 30541-3.
The stearate segments have excellent lubricating properties and their hydrocarbon chains are inert towards lithium; in this case, the bond Y is ensured by the carboxylic group of the starting fatty acid. The terminal group C then consists of a segment Y′—L′ identical to L—Y.
It has been observed that a central polyether chain, of low molecular weight, distearate POE 200, is sufficient to give to the lubricating compounds an ionic conductivity of the order to 1×10 −5− S.cm at ambient temperature when a lithium salt such as Li(CF 3 SO 2 ) 2 NLi is added in a ratio such that the ratio O/Li is 30/1. This value is amply sufficient to ensure ionic exchanges at the lithium/electrolyte interface of an electrochemical cell taking into account the small thickness of the residual deposit of the lubricating agent after lamination.
These preferred formulations are given by way of example of possible embodiments of the invention. Other lubricating and solvating functions L and S may be used as well as other bonds Y. By way of non limiting example, reference may be made to the following articles which deal with types of solvating chains:
Polymer Electrolytes review-1, J. R. MacCallum & C. A. Vincent eds. Elsevier Applied Science London (1987);
Polymer Electrolyte, review 2, J. R. MacCallum & C. A. Vincent eds. Elsevier Applied Science London (1989);
Solid Polymer Electrolytes, F. M. Gray VCH Publisher New-York, Weinheim (1991); as well as
Surface Active Ethylene Oxide Adducts, by V. Schoenfeldt-Permagon Press, (1966).
The preparation of the additives according to the present invention is well known to one skilled in the art and needs no detailed discussion in the present context. It is sufficient to mention that any skilled chemist would have no problem to synthesize the desired additive once the solvating and lubricating chains are established and the choice of the chemical bond which is intended to be used has been made.
During lamination, it is generally preferable to dilute the lubricanting agents according to the invention in one or more solvents which are compatible with lithium and which are preferably linear, saturated or partially unsaturated, or cyclic aromatic hydrocarbons such as heptane, benzene, toluene, cyclohexane or any other pre-dehydrated aprotic organic solvent or a mixture thereof. This dilution enables to reduce to a minimum the required quantity of lubricant and to obtain optimum qualities of lithium for use in an electrochemical cell. These solvents are previously dehydrated, for example on a molecular sieve, to lower the water content below 100 ppm. The concentrations of additives may vary up to about 10% by weight for example between 0.01 and 10% by weight, preferably 0.2% by weight. The addition of the lubricanting agent in solution is carried out in a controlled manner immediately before lamination between rollers. The laminated film is dried by a continuous operation with dry air immediately at the outlet of the rollers and is thereafter wound with or without a separator film of inert plastic, preferably of propylene or polyethylene.
BRIEF DESCRIPTION OF DRAWINGS
The invention will be better understood by the annexed drawings given by way of illustration but without limitation, in which:
the single FIGURE is a schematic illustration of a laminating operation utilizing an additive according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
It will be seen that a lithium sheet 1 having a thickness of about 250 micrometers mounted on an unwinding drum (not illustrated) is passed between two working rollers 3 and 5 made of polyacetal. A pressure is applied on the two rollers in the direction indicated by arrows 7 and 9 , which is sufficient to reduce the thickness of the sheet by about 90%. At the inlet of the sheet between. the laminating rollers, a lamination lubricant 11 is poured, for example toluene, from a pouring spout 13 .
At the outlet of the two lamination rolls, the sheet of lithium is converted into a film 15 whose thickness is about 25 micrometers. On the other hand, it will be realized that the film 15 remains in adhesion on the surface of the roll 3 from the meeting point 17 between the two rollers 3 and 5 , up to a given limit point 19 on the circumference of the roller 3 forming an angle a of about 90° with the meeting point 17 .
Film 15 is thereafter wound onto a winding drum (not illustrated) with sufficient tension, determined empirically for, on the one hand, causing the film 15 to move from point 19 to be gradually brought to point 21 where the operation is continued without any other change.
Normally, at point 21 , the angle β formed will be about 45°, it being understood that this angle may vary depending on circumstances and the desired properties of the film of lithium 15 .
An advantageous way to carry out the invention is described in the patent application filed simultaneously herewith and directed to a process of lamination in a single pass, between two rollers of hard plastic. This procedure which is preferably carried out in a single pass relies on the control of the adhesion on one of the plastic rollers so as to pull the lithium according to a preferred angle and to control its inherent flatness.
Other processes of lamination utilizing metallic rollers are also possible while using these additives. Thus, the metallic rollers could be pre-coated with lubricant so as to minimize the adhesiveness. However, the concentration as well as the chemical nature of the additives according to the present invention should be adjusted as a function of the intended production speeds.
These additives are also applicable to the lamination of lithium enriched alloys such as lithium-boron or lithium-magnesium alloys or also to the lamination of other alkali metals, for example sodium and sodium-lead alloys.
The process, the compositions and the additives according to the present invention are also applicable to the preparation of lithium anodes which are used in liquid electrolyte cells as long as the residual film is conductive or soluble in the electrolyte. Similarly, the process and the additives according to the present invention may be used to chemically prepared anodes of lithium alloys or based on carbon-lithium.
Advantageously but without limitation, it is possible to use as additive according to the invention the following chemical products:
Polyoxyethylene distearates in which the solvating segment has a molecular weight (mol. st.) equivalent to 200, 400 and 600, for example distearate 400 of Aldrich No. 30541-3.
Non-ionic surfactants: BRIJ® of ICI America available at Aldrich under catalogue Nos:
85,836-6 Brij® 35
23,599-7 Brij® 58
23,600-4 Brij® 78
23,865-1 Igepal® CO-720
23,869-4 Igepal® DM-970
Other possible products are illustrated by:
Distearates (dilaurates, dipalmitates, dioleates)
of POE (200,4000 mol. wt.)
of polypropylene glycol (725, 1000, 2000, 3000)
of Pluronic® (OE-OP blocks)
of polyoxytetramethylene (poly THF) (650, 1000, 2000).
Dihexadecyl ethers of POE (200-4000 mol. weight).
Dicholesteryl carbonates of POE (200-4000).
Tristearates (laurates, palmitates, oleates) of POE, triol (200,4000) (DKS).
Monostearates (laurates, palmitates, oleates)
of BRIJ (35,58,78)
of Igepal (CO-720, DM-970).
The polymethacrylates of oligo-oxyethylene-monolaurylether.
It is often preferable to use solvents which are compatible with lithium for diluting the lubricating additive. The latter are preferably linear hydrocarbons. The concentrations of the additives may then vary between 10 to 20% P/P and less than 0.05% P/P.
The lithium produced by utilizing the additives according to the present invention may be used as such in polymer electrolyte cells. Canadian patent application No 2,068,290-6 filed on May 8, 1992 describes one way of producing a complete cell and various ways of establishing electrical contacts on the lithium sheet. In these cases, the lamination additive will be made electrolytically conductive by the diffusion of the salt of lithium from the film of electrolyte of the cell.
In certain cases, the residual layer remaining after lubrication may be more or less dissolved or dispersed in the electrolyte, for example when the latter is of low molecular weight or comprises liquid aprotic solvents.
Other characteristics and advantages of the present invention will appear from the description which follow of embodiments given by way of illustration but without limitation.
EXAMPLE 1
In this example, the determining effect of a preferred additive according to the invention on a lamination carried out during a continuous operation and in a single pass to give a lithium film less than 30 micrometers (μ), is established. The device used is the one described in FIG. 1 and the lamination is carried out in an anhydride atmosphere containing less than 1% relative humidity. The rollers are made of polyacetal and have a diameter of 20 mm; the starting lithium consists of an extruded sheet 250 micrometers (μ) thick. The solvents and the additive, if needed, are previously dehydrated on a molecular sieve in order to give a water concentration lower than 10 ppm.
As a first step, an attempt is made for laminating in a continuous operation a sheet of lithium 57 mm wide and to reduce its thickness in a single pass to 25μ. When no lubricating liquid is used during the lamination, lithium immediately adheres to the rollers and the process does not operate properly; with the addition of hexane, it is impossible to achieve lamination unless the rate of reduction of the thickness of the sheet is considerably reduced. At the best, we managed to obtain a lithium 90μ in a single pass in which the inherent flatness of the film is extremely bad. Therefore, hexane, as used in the prior art, does not possess sufficient lubricating properties to be used alone in a continuous process in a single pass to give a lithium less than 25μ.
When the lamination is carried out with a lubricating liquid consisting of toluene, added at the rate of 8 ml/min. on a extruded sheet 57 mm wide, the lamination of lithium in a continuous operation to 25μ becomes possible and a maximum speed of 5 m/min. is obtained while allowing the laminated film to adhere to the upper roller up to a quarter of its height (angle of 45°), as illustrated in FIG. 1 of the Canadian patent application mentioned above. This operation enables to perfectly control the tension applied on the free film and gives a lithium of excellent inherent flatness. Lengths of 10 to 20 meters may thus be obtained in continuous operation. By rapidly changing from toluene to hexane during the operation, there is produced an instantaneous rise in the thickness of the lithium to about 90μ and a lithium of very bad inherent flatness is obtained.
The interest of the additives according to the invention is established by utilizing an extruded lithium 250μ of 143 mm wide. The device of the previous tests was used with a solution of hexane and toluene in a ratio 9:1 containing a distearate POE 200 (mol. weight) at a concentration of 0.2% P/P. An excess of lubricating solution is added on the sheet of extruded lithium at the rate of 6 ml/min. Under these conditions, a lithium film 22μ of excellent inherent flatness is obtained in a single pass at a lamination speed of more than 20 m/min. This process which is still not optimum additionally enables to produce rolls of laminated sheets more than 300 meters long in which the thickness is constant at more or less 2μ. The following productions are highly reproducible from one test to the other and the rates of losses or interruptions of the process are negligible; more important productions are thus possible starting from longer rolls of extruded lithium or from a feed to the laminating rolls, directly from an extruder.
EXAMPLE 2
Lithium 22μ produced by utilizing the additive of example 1 is used as the anode of a lithium cell operating at 60° C. The visual aspect of lithium is excellent, the lithium is bright without any coloring, and the surface profile obtained with Dektak® (model 3030 of VEECO U.S.A.) fluctuates within 3μ. For this laboratory test, the lithium sheet is lightly applied under pressure on a thin nickel sheet to ensure current collection. The electrolyte used consists of a polymer electrolyte consisting of a copolymer of ethylene oxide and methylglycidyl ether and a lithium salt, (CF 3 SO 2 ) 2 NLi in an oxygen lithium ratio (O/Li) of 30/1. The composite cathode consists of vanadium oxide and carbon black dispersed in the polymer electrolyte and has a capacity of 5 C/cm 2 . The active surface of the battery thus constituted is 3.9 cm 2 . The initial impedance of this battery at 60° C. is 15Ω, i.e. it is equivalent to or lower than the best lithium obtained commercially. The cycling properties of this battery utilizing the lithium of example 1 are excellent after 100 cycles and the rate of utilization of the battery remains at least equivalent to similar batteries prepared with commercial lithium, or about 90% of the initial value stabilized after 10 cycles. This example confirms that the presence of the non volatile distearate of POE which remains at the surface of lithium causes no harm to the good operation of the cell. This result is explained by the electrolytic conductivity generated by the presence of the POE solvating segment of the additive and by the chemical compatibility of the battery with lithium. In an independent test, the electrolytic conductivity of this additive, when the salt content (CF 3 SO 2 ) 2 NLi is 30/1, is about 1×10 −5 S.cm.
EXAMPLE 3
In this example, we have evaluated at a temperature of 25° C. the impedance of symmetrical batteries Li°/polymer electrolyte/Li° prepared from laminated lithium without additive and also when covered with an excess of various possible lubricating materials.
The quantity of lubricating agent used per surface unit of lithium is 0.03 mg/cm 2 . This value corresponds to an excess of lubricating agent as compared to what is necessary for laminating according to example 1, however the aimed purpose is to amplify and accelerate the electrochemical effect of various additives. The impedance values are given for batteries whose active surface is 3.9 cm 2 . The electrolyte of example 1 is also used to prepare batteries which are assembled by hot pressing under vacuum.
For the various material used, the results are the following:
Impedance
1)
Distearate of POE 200 (mol. Wt.)
113 Ω
2)
Distearate of POE 600 (mol. Wt.)
113 Ω
3)
Pure stearic acid
840 Ω
4)
Pure POE of molecular wt. 500
139 Ω
The values observed confirm the influence of the POE segment on the electrolytic conductivity of the additives and enable to conclude that stearic acid often used as lubricating agent for laminating conventional metals is incompatible with lithium for use in an electrochemical cell.
EXAMPLE 4
In this example a comparison is made of the effect of various known lamination additives for their lubricating properties on the efficiency of lamination of lithium in a single pass from 250μ to about 30μ.
In order to make these comparisons, the lamination is initiated under conditions similar to those of example 1 by utilizing distearate of POE 200 as additive. When the lamination is in operation, the composition of the solution is modified by replacing the distearate POE with other additives. The effect of the addition is immediately noted by following the thickness of the laminated lithium film, its inherent flatness and its visual appearance. When the solution containing the distearate is replaced by a solution of ethyl stearate at a concentration of 0.15% P/P, the thickness of lithium rises suddenly from 40 to 90μ and with a loss of inherent flatness of the laminated lithium.
When changing to a laminating solution based on the lamination lubricant EPAL® 1012 (CO linear alcohol) of Ethyl Corporation, it is noted that the thickness of laminated lithium progressively rises beyond 65μ and that the lithium obtained become sticky at the center of the rollers while the sides become irregular (undulations).
When changing to a laminating solution based on POE 5000 in toluene, a rapid rise of the thickness of laminated lithium to 90μ with a loss of inherent flatness is noted.
These tests illustrate the importance of formulations based on stearates which act as lubricating agents and include solvating functions such as those based on POE. These preferred but non-limiting formulations are also superior to additives based on pure POE in terms of lamination process even if the electrolytic conductive properties are in this case adequate as illustrated in example 3.
EXAMPLE 5
In this example, the POE stearate is replaced by other compounds of the invention while preserving the other identical conditions. The two compounds used are: dicholesteryl-carbonate of POE 600 (mol. Wt.) and dipalmitate of POE 4000.
In the two cases, the lamination speed may be maintained and the thickness of the laminated lithium is substantially the same. In these two cases, the inherent flatness of lithium is preserved. These examples confirm the generality of the formulations which combine the solvating and lubricating functions.
EXAMPLE 6
This example describes a compound according to the invention which includes the ionophoritic group according to formula L—Y—S—C (where C comprises a dissociable metal salt enabling the additive L—Y—S—C to have an intrinsic ionic conductivity). This type of compound is important as lamination additive when the laminated lithium is intended to be used for example in cells in which the electrolyte include a salt whose anion is chemically bounded to the polymeric chain. In this case, there is no possibility for the salt of lithium to diffuse and the lubricating additive should include an ionophoretic function to prevent the formation of an insulating deposit at the surface of lithium.
A non-ionic tensio-active agent of the type BRIJ 35®, polyoxyethylene 23 lauryl ether C 12 H 25 (OCH 2 CH 2 ) 23 OH is sulphonated by the following procedure: 12 g of BRIJ 35® are dried by azeotropic distillation with benzene followed by lyophilisation. After addition of 50 ml of THF, the terminal OH groups are metallized with sodium hydride in the presence of 5 mg of triphenylmethane. The stoichiometry is determined by colorimetry, the end of the reaction being indicated by the intense red colour of the Φ 3 C anion. 1.4 g of 1,4 butane sulphone are then added. After evaporation of the solvent, the sulphonated oligomer is obtained in the form of powder. 5 g of the product thus formed in suspension in 15 ml of acetonitrile are treated with 1 ml of thionyl chloride and 20 μl of dimethylformamide. A precipitate of sodium chloride is formed in 20 mn. After filtration, the solvent and the excess of SOC 2 are evaporated under reduced pressure. The residue is solubilized in 30 ml of pyridine and added to 1.2 g of the sodium salt of bis(trifluoromethanesulfonyl)methane. After filtration, the reaction mixture is stirred in the presence of 1 g of lithium phosphate Li 3 PO 4 . A new filtration enables to separate a colourless solution which, by concentration, gives a wax. This material possesses tensio active properties of lubrication and ionic conduction.
When used under the conditions of Examples 1 and 5, this material also enables the lamination of lithium under equivalent conditions. This example is non-limiting and other equivalent materials including a more or less dissociable ionic function may also be used.
EXAMPLE 7
An extruded sheet of lithium 1 250 micrometers thick and 143 mm wide is used as starting material. The latter is mounted on an unwinding drum, passed between working rollers and the film is rolled onto a winding drum. A pressure which is sufficient to thin down the film is applied on the working rollers. These rollers are of polyacetal and have a diameter of 20 mm. The film is mounted on the apparatus between the working rollers. The pressure on the rollers is increased in order to decrease the thickness of the film by about 90%. A lubricating agent is added on the film of lithium at a rate of 6 ml/min. This lubricating agent is made of a mixture of solvents to which there is added a lamination additive, which comprises dry hexane and toluene in a ratio of 9:1 and 0.2% p/p POE 200 distearate of formula CH 3 —(CH 2 ) 16 —(COO—(CH 2 —CH 2 O) n —OOC(CH 2 ) 16 —CH 3 where n is selected so that the polyether segment has a molecular weight of 200.
The film is allowed to adhere to X ¼ of the height of the working roller so as to perfectly control the tension applied on the latter. The pressure which is exerted on the rollers is adjusted so as to obtain in a single pass a film of lithium 25 micrometers thick, homogeneous at ±2 μm and 300 meters long. It will therefore be seen that it is possible to operate in a continuous manner without reject.
This additive enables to raise the speed of lamination to 20 m/min and to obtain a thin film of lithium of excellent quality.
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These additives are represented by the following general formula:
L—Y—S
in which L designates a hydrocarbon radical which serves as lubricating segment; S designates an oligomer segment which serves as solvating segment of metallic salts and Y designates a chemical bond which joins the hydrocarbon radical and the oligomer segment. With these additives there is no more need to subsequently wash the surface of laminated lithium.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of manufacturing hollow bodies and a method of manufacturing resinous containers.
2. Description of the Related Art
For example, a washer tank, which is applied to a wiper device of a vehicle and contains a solution such as a window washer solution or the like, is generally manufactured through blow molding. Further, in the washer tank, a bracket to dispose and reliably fix the washer tank onto a vehicle body is integrally fixed to a tank main body.
However, when the bracket is positioned in the direction which is orthogonal to the parting line of a molding die, the tank cannot be manufactured through one step. Therefore, in this case, conventionally, a hollow tank main body is manufactured through blow molding and the bracket is manufactured through a separate process such as injection molding or the like. Further, the molded bracket is thermally melt-adhered (thermally press-adhered) to the tank main body in order to integrate these parts and complete the tank as a product. Alternatively, the bracket is manufactured through the separate process such as injection molding or the like as mentioned above. Thereafter, when the hollow tank main body is manufactured through blow molding, the bracket is insert molded to the tank main body so as to unite the two parts and complete the tank as a product.
In this way, conventionally, because the bracket is manufactured separately from the tank main body in the separate process such as injection molding or the like, a molding die for injection molding and the operation of manufacturing the molding die are indispensable. Moreover, the number of the processes of manufacturing washer tanks and the cost of manufacturing are increased.
Furthermore, after the bracket is integrated with the tank main body to complete the tank as a product, the quality of the product is inspected. Because a material of the bracket, which is manufactured through the separate process such as injection molding or the like as mentioned above, is different from that of the tank main body due to the difference in the manufacturing methods, the product which was determined as defective cannot be recycled without segregating the materials (e.g., the material which is obtained by grinding down the product cannot be used as the molding material of the tank main body). Consequently, such tank has disadvantages on the point of not only high cost but also resources saving (effective utilization and recycling of materials).
SUMMARY OF THE INVENTION
With the aforementioned in view, an object of the present invention is to provide a method of manufacturing hollow bodies and a method of manufacturing resinous containers in which the number of manufacturing processes is reduced, materials can be used effectively, and the cost of manufacturing can be greatly cut down.
The present invention provides a method of manufacturing hollow bodies comprising the steps of: preparing segmental molding dies which comprise a first cavity for molding hollow bodies and a second cavity for molding auxiliary parts provided at a portion other than the first cavity in at least one of the die-matching surfaces of said segmental molding dies; supplying a resin parison between said segmental molding dies; clamping the segmental molding dies to fill said second cavity with said resin parison completely blowing a compressed gas into said resin parison to expand said resin parison within the first cavity to the extent that said resin parison is pressed against the inner surface of said first cavity; discharging said compressed gas from said resin parison; and opening said segmental molding dies to take out a formed hollow body and a formed auxiliary part which are made of said resin parison.
According to the present invention described above, when the hollow bodies are molded in a blow molding process, the auxiliary parts are also molded. Therefore, the number of the processes for manufacturing hollow bodies and auxiliary parts and the cost of manufacturing can be reduced.
Moreover, the present invention provides a method of manufacturing resinous containers comprising: a preparing process in which segmental molding dies are prepared, the segmental molding dies comprising a first cavity for molding hollow bodies and a second cavity for molding auxiliary parts which is provided at a portion other than the first cavity in at least one of the die-matching surfaces of the segmental molding dies and a third cavity for holding an auxiliary part produced in said second cavity during a previous molding cycle which communicates with said first cavity; a pre-molding process in which a resin parison is supplied between said segmental molding dies, said segmental molding dies are clamped, a compressed gas is blown into said resin parison to expand said resin parison within said first cavity to the extent that said resin parison is pressed against the inner surface of said first cavity, said compressed gas is discharged from said resin parison, and said segmental molding dies are opened to take out a formed hollow body and a formed auxiliary part; and a main molding process in which said formed auxiliary part is inserted in said third cavity, the resin parison is supplied between said segmental molding dies, said segmental molding dies are clamped, a compressed gas is blown into said resin parison to expand said resin parison within said first cavity to the extent that said resin parison is pressed against the inner surface of the of the first cavity, of the segmental molding dies, the compressed gas is discharged from the resin parison, and the segmental molding dies are opened to take out a new auxiliary part and a resin container in which the inserted auxiliary part is integrated with a hollow body, wherein once the pre-molding process is implemented, the preparing process and the main molding process are repeated.
According to the present invention described above, when the hollow bodies are molded in a blow molding process, the auxiliary parts are also molded. Therefore, the number of processes required for manufacturing resinous containers can be reduced. Moreover, if the resinous containers in which the body and the auxiliary part are integrated are determined as defective at the time of inspecting the quality thereof, the material obtained by grinding down the resinous containers can be recycled as the resin parison without segregation because the materials of the bodies and the auxiliary parts are the same. Therefore, the material can be used effectively. In addition, the material obtained by grinding down the body formed in the pre-molding process can be utilized as the resin parison. The reduction of the number of manufacturing processes and effective utilization of the material result in the reduction of the manufacturing cost.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view which shows a principal process of a method of manufacturing resinous containers relating to an embodiment of the present invention.
FIG. 2 is a cross-sectional view taken along line 2--2 in FIG. 1.
FIG. 3 is a schematic view which shows the structure of a blow molding machine used in the method of manufacturing resinous containers relating to the embodiment of the present invention.
FIG. 4 is a schematic cross-sectional view which shows the structure of an auxiliary molding die of the blow molding machine used in the method of manufacturing resinous containers relating to the embodiment of the present invention.
FIGS. 5A through 5D show specific processes of the method of manufacturing resinous containers relating to the embodiment of the present invention and are perspective views of a pre-molding process.
FIGS. 6A through 6D show specific processes of the method of manufacturing resinous containers relating to the embodiment of the present invention and are perspective views of a main molding process.
FIG. 7 is a flowchart which shows a manufacturing process of the method of manufacturing resinous containers relating to the embodiment of the present invention.
FIG. 8 is a flowchart which shows a manufacturing process according to a conventional manufacturing method.
FIG. 9 is an elevational view which shows another example of an auxiliary part (auxiliary body) which is molded in the land area, which is the area other than a cavity for molding hollow bodies, of the die-matching surface of a molding die.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A manufacturing method of the present invention is basically blow molding. As resinous containers, for example, a washer tank 10 (see FIG. 6D) which is applied to a vehicle wiper device is manufactured. A tank main body 10A of the washer tank 10 can contain a solution such as a window washer solution or the like. Further, a bracket 12 for mounting the washer tank 10 at a vehicle body, which serves as an auxiliary part (auxiliary body), is fixed integrally to a side wall of the washer tank 10 (the tank main body 10A).
FIG. 3 shows schematically the structure of a blow molding machine 20 which is used at the time of manufacturing the washer tank 10.
The blow molding machine 20 includes a die head 22 and a resin parison P serving as a molding material can be extruded therefrom. A blowing device 24 is disposed directly below the die head 22. A blow pin 26 is stood upright at the blowing device 24 and blows air to the resin parison P. The resin parison P can be thereby expanded.
A pair of segmental molding dies 28 and 30 are disposed on both sides of the resin parison P which has been extruded from the die head 22. The molding die 28 is fixed to a mount 32 and the molding die 30 is fixed to a mount 34, and further, the mount 32 is fixed to the distal end portion of a pair of guide rails 36 and the mount 34 is fixed to the distal end portion of a pair of guide rails 38. The guide rails 36 are parallel to each other and are movably supported by a support 40 and the guide rails 38 are parallel to each other and are movably supported by a support 42. In this way, when the pair of guide rails 36 is moved relative to the support 40 and the pair of guide rails 38 is moved relative to the support 42, the molding dies 28 and 30 can be moved closer to or away from each other while the die-matching surfaces thereof are kept parallel.
Moreover, a hydraulic cylinder 44 is attached to the support 40 and a hydraulic cylinder 46 is attached to the support 42. An actuator rod 48 of the hydraulic cylinder 44 is connected to the mount 32 and an actuator rod 50 of the hydraulic cylinder 46 is connected to the mount 34. Accordingly, when the hydraulic cylinders 44 and 46 are operated, the mounts 32 and 34 are moved closer to or away from each other, thereby moving the molding dies 28 and 30.
The molding dies 28 and 30 will be described in detail hereinafter.
FIG. 1 shows a perspective view of a principal manufacturing process of a manufacturing method relating to the present embodiment which uses the molding dies 28 and 30. Further, FIG. 2 shows a cross-sectional view taken along line 2--2 in FIG. 1.
A cavity 52 (for molding the tank main body 10A), which corresponds to the shape of the tank main body 10A of the washer tank 10, is provided at each of the die-matching surfaces of the molding dies 28 and 30. The resin parison P is expanded within the cavity 52 and fits the engraved surfaces, which form the outline of the cavity 52, of the molding dies 28 and 30, and the tank main body 10A can be formed.
Moreover, a holding portion (cavity) 54 for accommodating the aforementioned bracket 12 at the time of insert molding is provided at the molding die 28 so that the holding portion 54 communicates with the cavity 52.
An auxiliary molding die 58 is provided in a land area 56, which is the area other than the cavity 52 in the die-matching surface, of the molding die 28 and an auxiliary molding die 60 is provided in a land area 56 of the molding die 30. The auxiliary molding dies 58 and 60 mold the bracket 12 serving as the aforementioned auxiliary part (auxiliary body), and a cavity 62 for molding an auxiliary part (hereinafter, "cavity 62"), which corresponds to the shape of the bracket 12, is provided on the surface of each of the molding dies 58 and 60. As shown in FIG. 4, the auxiliary molding die 58 is disposed so as to be movable within a mold opening 64 formed at the molding die 28 and the auxiliary molding die 60 is disposed so as to be movable within a mold opening 66 formed at the molding die 30. Further, the auxiliary molding die 58 is fixed to the distal end portion of a pair of guide rails 68 and the auxiliary molding die 60 is fixed to the distal end portion of a pair of guide rails 70. The guide rails 68 are parallel to each other and movably supported by a plate 72 fixed to the molding die 28. The guide rails 70 are parallel to each other and movably supported by a plate 74 fixed to the molding die 30. In this way, as the pair of guide rails 68 is moved relative to the plate 72 and the pair of guide rails 70 is moved relative to the plate 74, the auxiliary molding dies 58 and 60 can be moved closer to or away from each other while the die-matching surfaces thereof are kept parallel.
Further, a hydraulic cylinder 76 is attached to the plate 72 and a hydraulic cylinder 78 is attached to the plate 74. An actuator rod 80 of the hydraulic cylinder 76 is connected to the auxiliary molding die 58 and an actuator rod 82 of the hydraulic cylinder 78 is connected to the auxiliary molding die 60. Accordingly, due to the operation of the hydraulic cylinders 76 and 78, the auxiliary molding die 58 projects from the die-matching surface of the molding die 28 and the auxiliary molding die 60 projects from the die-matching surface of the molding die 30 and thereby the cavities 62 can apply pressure to the resin parison P to form the bracket 12.
Next, FIG. 5 and 6 shows a perspective view of a specific process of the method of manufacturing resinous containers relating to the present embodiment. The specific process of the manufacturing method relating to the present embodiment will be explained accordingly.
When the washer tank 10 is molded, at first, a pre-molding process is implemented. Namely, as shown in FIG. 5A, the resin parison P serving as a molding material is extruded from the die head 22. The extruded resin parison P is hanged and stretched by its own weight. Next, as shown in FIG. 5B, the hydraulic cylinders 44 and 46 are operated to clamp the molding dies 28 and 30 and the resin parison P is put therebetween. Further, compressed air is blown from the blow pin 26 into the resin parison P while the mold clamping pressure applied to the molding dies 28 and 30 is maintained. In this way, the resin parison P is expanded within the cavity 52 of the molding dies 28 and 30 and fits to the engraved surfaces, which form the outline of the cavity 52, of the molding dies 28 and 30.
Moreover, when the compressed air is blown, the hydraulic cylinders 76 and 78 are operated to move and clamp the auxiliary molding dies 58 and 60 and thereby pressure is further applied to the resin parison P within the cavity 62.
Next, air within the molding dies 28 and 30 is discharged. Further, as shown in FIG. 5C, the hydraulic cylinders 44 and 46 are operated again to open the molding dies 28 and 30. In this way, a hollow body T (tank main body 10A) and the bracket 12, which are formed integrally with the resin parison P, are molded. Moreover, as shown in FIG. 5D, only the bracket 12 is cut out from the peripheral unnecessary resin parison P and the bracket 12 is completed. The pre-molding process ends in accordance with the above description. The hollow body T (and the cut-out piece of the peripheral resin parison P) molded in this pre-molding process is recycled.
Next, a main molding process will be implemented.
In the main molding process, as shown in FIG. 6A, the bracket 12, which has been formed in the aforementioned pre-molding process, is preheated. Thereafter, the bracket 12 is inserted and held in the holding portion 54 of the molding die 28, and the resin parison P is extruded and hanged from the die head 22 as mentioned above. Next, as shown in FIG. 6B, the hydraulic cylinders 44 and 46 are operated to clamp the molding dies 28 and 30 and the resin parison P is put therebetween. Further, compressed air is blown into the resin parison P from the blow pin 26 while the mold clamping pressure applied to the molding dies 28 and 30 is maintained. In this way, the resin parison P is expanded within the cavity 52 of the molding dies 28 and 30 and fits to the engraved surfaces, which form the outline of the cavity 52, of the molding dies 28 and 30. At the same time, the bracket 12 which is held in the holding portion 54 is integrated with the parison P. Moreover, when the compressed air is blown, the hydraulic cylinders 76 and 78 are operated to clamp the auxiliary molding dies 58 and 60 and thereby pressure is further applied to the resin parison P within the cavity 62.
Next, air within the molding dies 28 and 30 is discharged. Moreover, as shown in FIG. 6C, the hydraulic cylinders 44 and 46 are operated again to open the molding dies 28 and 30. In this way, as shown in FIG. 2 as well, the washer tank 10, in which the bracket 12 is integrated with the tank main body 10A (the unnecessary resin parison P is also formed integrally therewith), and a new bracket 12 are molded. Further, as shown in FIG. 6D, the washer tank 10 and the bracket 12 are cut out from the peripheral unnecessary resin parison P. The main molding process at the first time ends in accordance with the above description.
Thereafter, as the bracket 12 which was molded through the first main molding process is used, the main molding process from the second time onward is successively and continuously performed at a plurality of times in the same way as mentioned above.
In this way, in the method of manufacturing resinous containers relating to the present embodiment, when the washer tank 10 is manufactured, the pre-molding process in which the bracket 12 serving as an auxiliary part (auxiliary body) is molded is implemented. Thereafter, the bracket 12 which has been formed through the pre-molding process is inserted and held in the molding die 28, and the tank main body 10A serving as a hollow body (main body) and a new bracket 12 are molded, and the held new bracket 12 is integrated with the tank main body 10A. In this way, the main molding process is implemented. Afterwards, the bracket 12 molded in the last main molding process is held in the molding die 28, and the main molding process is successively and continuously effected at a plurality of times.
Further, FIG. 7 shows a flowchart of the manufacturing process according to the method of manufacturing resinous containers relating to the present embodiment. On the other hand, FIG. 8 shows a flowchart of the manufacturing process according to a conventional manufacturing method. Both methods will be compared and explained.
When the washer tank 10 as mentioned above is manufactured, conventionally, as shown in FIG. 8, the bracket 12 is manufactured through injection molding, which is implemented separately from blow molding, with a resin material B. Further, the injection-molded bracket 12 is inserted and held in the holding portion of a molding die for blow molding and the hollow tank main body 10A is manufactured with a material A and integrated with the held bracket 12 through blow molding and thereby the tank 10 is completed as a product. The molded bracket 12 may be thermally melt-adhered (thermally press-adhered) to and integrated with the tank main body 10A in such a way that the tank 10 is completed as a product.
In this way, conventionally, because the bracket 12 is manufactured separately from the tank main body 10A in the separate process such as injection molding or the like, the molding die for injection molding and the manufacturing operation thereof are indispensable. Further, the number of the processes of manufacturing washer tanks and the cost of manufacturing are increased.
Furthermore, after the bracket 12 is integrated with the tank main body 10A to produce the tank 10 as a product, the quality of the product is inspected. Because the material of the bracket, which is manufactured through the separate process such as injection molding as mentioned above, is different from that of the tank main body 10A, the product which was determined as defective cannot be recycled without segregating the materials. Consequently, the cost of manufacturing is increased, and resources are not saved favorably (effective utilization and recycling of materials).
On the other hand, in accordance with the method of manufacturing resinous containers relating to the aforementioned present embodiment, the washer tank 10 and the bracket 12 are manufactured in the same (single) manufacturing line as shown in FIG. 7. Unlike the conventional manufacturing method, there is no need to manufacture the bracket 12 separately from the tank main body 10A in the separate process such as injection molding or the like. Therefore, the molding die for injection molding and the manufacturing operation thereof are not required. The number of the processes of manufacturing washer tanks and the cost of manufacturing washer tanks can be reduced.
Further, in the method of manufacturing resinous containers relating to the present embodiment, as shown in FIG. 7, the only resin material A for blow molding (i.e., the resin parison P) is used for molding the tank 10. Moreover, the washer tank 10 which was determined as defective when the quality thereof was inspected is recycled without segregation.
Namely, since the tank main body 10A and the bracket 12 are molded of the same material (the resin parison P) and faulty products can be recycled simply, the molding material (the resin parison P) is not wasted and the cost of manufacturing is reduced. Also, resources are effectively saved (effective utilization and recycling of materials).
Furthermore, in the method of manufacturing resinous containers relating to the present embodiment, the auxiliary molding dies 58 and 60 are provided at the segmental molding dies 28 and 30 which are a pair of male and female dies. When the molding dies 28 and 30 are clamped, pressure is applied to the resin parison P and a part of the resin parison P is pushed into the cavity 62 and then the bracket 12 is molded. In addition, pressure is applied again to the bracket 12 (the resin parison P within the cavity 62) by clamping the auxiliary molding dies 58 and 60. Accordingly, the product accuracy of the bracket 12 (the auxiliary part) is further improved.
In this way, in the method of manufacturing resinous containers relating to the present embodiment, the number of the manufacturing processes is reduced, materials can be effectively used, and the cost of manufacturing can be greatly reduce.
In the present embodiment, the bracket 12 for mounting the washer tank 10 at a vehicle body, which serves as an auxiliary part (auxiliary body), is molded by the auxiliary molding dies 58 and 60 (the cavities 62) provided in the land areas 56 which is the area other than the cavities 52 in the die-matching surfaces of the molding dies 28 and 30. Then, the bracket 12 is insert-molded and fixed integrally with the tank 10 (the tank main body 10A). However, the auxiliary part (auxiliary body) which is molded in the land areas 56 of the molding dies 28 and 30 is not limited to this.
For example, as shown in FIG. 9, a cap 16 which is attached to the water supply opening 14 of the tank 10 can be molded in the land area 56. Further, in this case, the cap 16 can be molded integrally and continuously with the tank main body 10A, and a connecting portion 18 which connects the cap 16 and the tank main body 10A can be used as a connecting portion for preventing the falling of a cap.
Furthermore, in the present embodiment, the bracket 12 is molded by two auxiliary molding dies 58 and 60 and the hydraulic cylinders 76 and 78 (pressure-applying mechanism). However, only any one of the auxiliary molding dies and the hydraulic cylinders (pressure-applying mechanism) may be provided.
Moreover, the cavity 62 can be provided in at least one of the land areas 56 of the molding dies 28 and 30 in place of in the die-matching surfaces of the auxiliary molding dies 58 an 60 and the auxiliary molding dies can be omitted. In this case, the bracket 12 is molded by only clamping the molding dies 28 and 30.
Furthermore, in the case in which the auxiliary molding dies 58 and 60 are provided, the clamping of the auxiliary molding dies 58 and 60 can be implemented during, before, or after the compressed air is blown.
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The present invention provides a method of manufacturing resinous containers comprising: a preparing process in which segmental molding dies are prepared, the segmental molding dies comprising a first cavity for molding hollow bodies and a second cavity for molding auxiliary parts and a third cavity for holding the auxiliary part which communicates with the first cavity; a pre-molding process in which a resin parison is supplied between the segmental molding dies, the segmental molding dies are clamped, a compressed gas is blown into the resin parison to expand the resin parison within the first cavity and to fit the resin parison to the surface which forms an outline of the first cavity, of the segmental molding dies, the compressed gas is discharged from the resin parison, and the segmental molding dies are opened to take out a formed hollow body and a formed auxiliary part; and a main molding process in which the same process as the pre-molding process is implemented except that the formed auxiliary part is inserted in the third cavity before the resin parison is supplied between the segmental molding dies and that a new auxiliary part and a resin container in which the inserted auxiliary part is integrated with a hollow body are taken out. In the present invention, when once the pre-molding process is implemented, the preparing process and the main molding process are repeated.
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RELATIONSHIP TO OTHER APPLICATIONS AND PATENTS
[0001] The present application is a Continuation-In-Part of a pending U.S. patent application Ser. No. 11/027,095, filed Dec. 30, 2004 and published Jul. 6, 2006 as US Published Patent Application 2006/0147786 A1.
[0002] This invention was made with United States Government support under Government Contract/Purchase Order No. DE-FC26-02NT41246. The Government has certain rights in this invention.
TECHNICAL FIELD
[0003] The present invention relates to fuel cells; more particularly, to solid-oxide fuel cells; and most particularly, to modular fuel cell cassette spacers for use in assembling a fuel cell stack.
BACKGROUND OF THE INVENTION
[0004] Fuel cells for combining hydrogen and oxygen to produce electricity are well known. A known class of fuel cells includes a solid-oxide electrolyte layer through which oxygen anions migrate; such fuel cells are referred to in the art as “solid-oxide” fuel cells (SOFCs).
[0005] In some applications, for example, as an auxiliary power unit (APU) for a transportation application, an SOFC is preferably fueled by “reformate” gas, which is the effluent from a catalytic liquid or gaseous hydrocarbon oxidizing reformer, also referred to herein as “fuel gas”. Reformate typically includes amounts of carbon monoxide (CO) as fuel in addition to molecular hydrogen.
[0006] A complete fuel cell stack assembly includes fuel cell subassemblies and a plurality of components known in the art as interconnects, which electrically connect the individual fuel cell subassemblies in series. Typically, the interconnects include a conductive foam or weave disposed in the fuel gas and air flow spaces adjacent the anodes and cathodes of the subassemblies.
[0007] In the prior art, a fuel cell stack is assembled typically by first laying up each of the fuel cell subassemblies in a jig, forming a plurality of repetitive modular fuel cell units known in the art, and referred to herein, as “cassettes”. Typically, a fuel cell cassette comprises a ceramic solid-oxide electrolyte layer and a cathode layer coated onto a relatively thick, structurally significant anode element. In such a prior art assembly, each of the cassettes becomes a structural and load-bearing element of the stack.
[0008] At the elevated operating temperatures of an SOFC stack, typically in the range of about 700° C. to about 1000° C., most of the components of a cassette have very little inherent mechanical strength and would collapse if not for internal spacer rings disposed within each cassette around the anode fuel gas openings, collectively comprising supply and exhaust “chimneys” within a stack. Prior art spacer rings are fabricated so that they form a solid column of metal having radial openings to allow the anode fuel gas to flow into and out of the cassette. The assembly load of a stack thus is carried through the spacer rings.
[0009] A prior art spacer ring is a sheet metal part which is stamped and formed to achieve the desired geometry. This spacer ring is difficult to form, resulting in a part that is relatively expensive even with production tooling in high volumes. Further, each cassette requires a plurality of spacer rings (typically 8), and each ring must be tack welded into place to the cassette shell, accurately and firmly, prior to cassette assembly, adding further positioning and attachment cost and complexity to the assembly operation.
[0010] What is needed in the art is an improved spacer ring that is less expensive to manufacture and less expensive to install into a cassette during assembly thereof.
[0011] It is a principal object of the present invention to reduce the cost, difficulty, and complexity of mass-manufacturing fuel cell stack assemblies.
SUMMARY OF THE INVENTION
[0012] Briefly described, a modular fuel cell cassette for use in assembling a fuel cell stack is a sheet metal assembly comprising a metal separator plate and a metal cell-mounting plate so formed that when they are joined at their perimeter edges to form the cassette, a cavity is formed between them which can contain a gas stream that feeds a fuel cell subassembly attached within the cassette to the mounting plate. Outboard of the fuel cell subassembly, the separator plate and cell-mounting plate are perforated by openings to form chimney-type manifolds for supplying fuel gas to the anode and air to the cathode, and for exhausting the corresponding gases from the stack. The fuel cell subassembly is attached to, and insulated from, the mounting plate by a dielectric seal. The mounting plate includes an opening through which one of the electrodes is accessible, preferably the cathode, and through which a conductive interconnect element extends to make contact with the outer surface of the next-adjacent cassette in a stack.
[0013] The anode openings in the mounting plate and separator plate are separated and connected by modular spacer rings such that the cassette is incompressible. The spacer rings include radial openings which allow fuel gas to flow from the anode supply chimney into the anode gas channel in the cassette and also back into the anode exhaust chimney. In accordance with the present invention, the spacer rings are formed in modules wherein all of the rings required for all of the anode supply chimneys or all of the anode exhaust chimneys of any given cassette are ganged together and include a perimeter element to which the rings are connected which automatically orients and positions the rings within the cassette during assembly thereof. The present invention eliminates the prior art need for individually positioning and spot welding each ring in place prior to assembly of a cassette. Two different structural embodiments for a spacer ring module are disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0015] FIG. 1 is an exploded isometric view of a prior art fuel cell cassette;
[0016] FIG. 2 is an isometric view of a prior art fuel cell stack comprising three cassettes as shown in FIG. 1 ;
[0017] FIG. 3 is a plan view of a prior art separation ring, as stamped from sheet stock;
[0018] FIG. 4 is a plan view of the prior art separation ring shown in FIG. 3 , folded for use in a fuel cell cassette as shown in FIG. 1 ;
[0019] FIG. 5 is a cross-sectional view taken along line 5 - 5 in FIG. 4 ;
[0020] FIG. 6 is an isometric view of a first embodiment of a spacer ring module in accordance with the invention;
[0021] FIG. 7 is an isometric view of a second embodiment of a spacer ring module in accordance with the invention;
[0022] FIG. 8 is an isometric view of the second embodiment as shown in FIG. 7 , after folding into a planar configuration for use; and
[0023] FIG. 9 is an exploded isometric view of a fuel cell stack comprising a cassette formed with spacer rings in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The invention is directed to a modular spacer ring element which may be substituted in an otherwise prior art fuel cell cassette 100 and fuel cell stack, in a greatly simplified assembly procedure. Therefore, it is useful to review here such a prior art fuel cell cassette 100 to understand how an improved modular spacer ring element 326 , 426 may be used to replace the prior art individual spacer rings 126 .
[0025] Prior art fuel cell cassette 100 is substantially as disclosed in the parent patent application referenced hereinabove and made public in US Published Patent Application No. 2006/0147786 A1, the relevant disclosures of which are incorporated herein by reference.
[0026] Referring to FIG. 1 , a prior art fuel cell cassette 100 includes a cassette housing 101 including a fuel cell mounting plate 102 and a separation plate 104 . Mounting plate 102 includes a large central electrode opening 106 for receiving a fuel cell subassembly 128 as described below. Outboard of central electrode opening 106 are cathode air inlets 108 a , cathode air outlets 110 a , fuel gas inlets 112 a , and fuel gas outlets 114 a . Separation plate 104 is provide with similar and mating air and fuel openings 108 b , 110 b , 112 b , and 114 b , respectively, said electrode and separation plate inlets and outlets defining respective supply and exhaust chimneys for air and fuel gas. Separation plate 104 is formed as a shallow tray 115 such that a cavity is created between plates 102 , 104 for receiving fuel cell components and fuel gas as described below. Preferably, the mounting and separation plates are formed as by stamping or drawing from thin sheet stock (0.1 to 1.0 mm) of a ferritic stainless steel, although other materials such as austenitic stainless steel or high temperature alloys may also be acceptable. During assembly, prior art plates 102 , 104 are joined to define a cassette housing by formation of a metallurgical bond at their edges and around each of the air inlets and outlets such that only openings 112 , 114 have access to the interior of the cassette.
[0027] Referring to FIGS. 1 and 3 - 5 , a prior art spacer ring 126 is provided within each cassette 100 for each anode fuel gas inlet 112 a,b and each anode fuel gas outlet 114 a,b . In the prior art embodiment shown here for forming prior art spacer rings 126 , a pair of rings 120 a,b having radial tabs 118 extending from rings 120 a,b are connected by a link 122 . Radial tabs 118 are folded inward and line up with one another when the two rings 120 a , 120 b are folded over at link 122 to form solid columns of metal, as shown in FIG. 4 . Link 122 provides a convenient tab for tack welding of each ring 126 to the cassette shell during assembly. The spaces between the tabs 118 form openings 124 which allow fuel gas to flow from the fuel gas inlets 112 into the anode gas channel (space contained within the cassette), and into the fuel gas outlets 114 from the anode gas channel. The folded spacer rings 126 form solid metal spacers between mounting plate 102 and separator plate 104 , thus defining and maintaining a constant spacing therebetween despite assembly and operational loads on the cassette. Prior art rings 126 are formed by stamping from sheet materials similar to those disclosed for forming the mounting plate and separator plate.
[0028] Referring to FIG. 2 , a fuel cell stack 200 is formed by literally stacking together a plurality of individual fuel cell cassettes 100 . The cassettes are bonded together outboard of central opening 106 in a pattern surrounding the air and fuel gas inlets and exhausts.
[0029] Referring now to FIGS. 6 and 9 , a first embodiment of a modular spacer ring element 326 comprises a plurality of identical individual spacer rings 326 a , 326 b , 326 c , 326 d oriented and attached via individual tethers 380 a , 380 b , 380 c , 380 d to a common rail 382 . Each spacer ring 326 a - d has radial anode fuel gas flow passages 324 formed into one surface of the ring. The flow passages 324 are separated by columnar ring segments 318 corresponding to prior art tabs 118 which are the full thickness of the ring and therefore can act as structural support columns around the anode fuel gas openings after assembly of a cassette and stack. Spacer ring element 326 can be simply placed into the cassette during the cassette assembly process. The rings are automatically positioned and oriented, and no welding is required. Rail 382 is sandwiched between the abutting edges of fuel cell mounting plate 102 and a separation plate 104 ( FIGS. 1 and 9 ), thereby securing rings 326 a - d in position. The axial faces of rings 326 a - d are sealed to the fuel cell mounting plate 102 and separation plate 104 by compression during assembly of the cassettes into a fuel cell stack.
[0030] Modular spacer ring element 326 is readily formable as a monolith in known fashion via, for example, photochemical machining, powdered metal fabrication, coining, or forging. Two such elements 326 , one for anode fuel gas supply and one for anode fuel gas exhaust, are required for each cassette 300 . Preferably, element 326 is formed by photochemical machining. Although photochemically machined parts are typically more expensive than simple stampings, a single photochemically machined element 326 is less expensive than the corresponding four stamped prior art rings 126 currently in use (in addition to the assembly savings already described).
[0031] Referring now to FIGS. 7 and 8 , a second embodiment of a modular spacer ring element 426 comprises a sub-element 426 ′ having a plurality of identical individual spacer sub-rings 426 a 1 , 426 a 2 , 426 b 1 , 426 b 2 , 426 c 1 , 426 c 2 , 426 d 1 , 426 d 2 oriented and attached via individual tethers 480 a 1 , 480 a 2 , 480 b 1 , 480 b 2 , 480 c 1 , 480 c 2 , 480 d 1 , 480 d 2 to a common rail 482 formed in two parts, 482 - 1 , 482 - 2 , and foldable at points 484 .
[0032] Second embodiment 426 as formed initially ( FIG. 7 ) is one-half the thickness of first embodiment 326 . Each spacer sub-ring 426 a 1 - d 2 has a plurality of curves defining an annular pattern of alternating inwardly- and outwardly-extending arcs 486 - 1 , 486 - 2 . Arcs 486 - 1 are angularly shifted from arcs 486 - 2 by one-quarter cycle (in the present example, by 300 ) with respect to tethers 480 such that when first rail portion 482 - 1 is folded at points 484 , defining a folding line 485 , onto second rail portion 482 - 2 , as shown in FIG. 8 , a fully formed spacer 426 is formed having the same thickness as first embodiment 326 . The annular geometry of the two rows of sub-rings is such that, when folded into superposition, radial openings 488 are formed therebetween for passage of anode fuel gas into and out of the stack chimneys. The fully-formed spacer rings 426 a - d ( FIG. 8 ) define columns 418 where the sub-rings overlap, corresponding to prior art tabs 118 which are the full thickness of the ring and therefore can act as structural support columns around the anode fuel gas openings after assembly of a cassette and stack. Spacer ring element 426 can be simply placed into the cassette during the cassette assembly process. The rings are automatically positioned and oriented, and no welding is required. Rail 482 is sandwiched between the abutting edges of fuel cell mounting plate 102 and a separation plate 104 , thereby securing rings 426 a - d in position. The axial faces of rings 426 a - d are sealed to the fuel cell mounting plate 102 and separation plate 104 by compression during assembly of the cassettes into a fuel cell stack.
[0033] It will be observed that portions 426 - 1 and 426 - 2 , shown in FIG. 7 , are not mirror images but rather inverted images; that is, portion 426 - 2 may be derived from a second portion 426 - 1 by simply turning portion 426 - 1 end-for-end. Thus, sub-element 426 ′ may be formed either by stamping as a single sheet from sheet stock, for folding as described at points 484 , or by two identical portions 426 - 1 oriented as just described for attachment at points 484 .
[0034] Modular spacer ring element 426 is readily formable in known fashion via, for example, photochemical machining, powdered metal fabrication, coining, or forging. Two such elements 426 , one for anode fuel gas supply and one for anode fuel gas exhaust, are required for each cassette 300 . Preferably, element 426 is formed by stamping and folding from sheet stock.
[0035] Referring to FIG. 9 , a portion 500 of a completed fuel cell stack in accordance with the invention comprises first and third cassettes 500 a , 500 c completed in accordance with the invention on either side of an intermediate exploded second cassette 500 b.
[0036] Second cassette 500 b includes a cassette housing 501 including a fuel cell mounting plate 502 and a separation plate 504 . Mounting plate 502 includes a large central electrode opening for receiving a cathode mesh air baffle 503 . Outboard of the central electrode opening are cathode air inlets 508 a , cathode air outlets 510 a , fuel gas inlets 512 a , and fuel gas outlets 514 a . Separation plate 504 is provide with similar and mating air and fuel openings, respectively, said electrode and separation plate inlets and outlets defining respective supply and exhaust chimneys for air and fuel gas. Separation plate 504 is formed as a shallow tray such that a cavity is created between plates 502 , 504 for receiving fuel cell components and fuel gas. A first anode modular spacer ring element 526 -A is installed adjacent anode fuel gas inlets 512 a , and a second anode modular spacer ring element 526 -B is installed adjacent anode fuel gas outlets 514 a . An anode mesh fuel baffle 505 is disposed between ring elements 526 -A, 526 -B. A contact paste layer 507 electrically connects the cathode mesh 503 to the surface of the cathode layer in mounting plate 502 . A contact paste layer 509 electrically connects the anode mesh 505 to the separator plate 504 . A fusible glass seal 511 seals cassette 500 b to cassette 500 a . (A similar glass seal is required but not shown between cassette 500 c and cassette 500 b .)
[0037] While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims.
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In a modular fuel cell cassette for forming a fuel cell stack, anode openings in the mounting plate and separator plate are separated and connected by modular spacer rings such that the cassette is incompressible at operating temperatures and compressive loads within the stack. The spacer rings are formed in modules wherein all of the rings required for all of the anode supply chimneys or all of the anode exhaust chimneys of any given cassette are ganged together and include a perimeter rail to which the rings are connected which automatically orients and positions the rings within the cassette during assembly thereof. The present invention eliminates the prior art need for individually positioning and spot welding each prior art ring in place prior to assembly of a prior art cassette. Two different structural embodiments for a spacer ring module are disclosed.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a valve which is suitable for use with a hydraulically activated device such as a rock prop employed in an underground location.
[0002] In one type of rock prop water under pressure is used to set the prop so that it is brought to an operative condition as soon as possible at the time of installation. Typically the prop is positioned between a foot wall and an opposed hanging wall. After installation, if closure of the hanging wall towards the foot wall takes place, then the pressure of water inside the prop is increased and, to accommodate the hanging wall movement, water is released from the prop at a controlled rate.
[0003] In order to set a prop in the aforementioned manner water is introduced through a filler valve into an interior of the prop. When the source of pressurised water is disconnected from the prop interior, the filler valve automatically closes. It is possible to use the filler valve as a release valve to allow water under pressure to escape from the prop interior. Alternatively, a release valve designed for the purpose, is used.
[0004] Arduous conditions exist underground. Although filters and similar mechanisms can be used to remove particulate material from water which is to be used with a prop, it is quite possible that unwanted particles can be entrained in the water which is introduced into a prop. The problems which are posed by these particles when the prop is being set can normally be overcome. However, when a prop is under pressure and closure takes place then small quantities of water must be allowed to escape at a controlled rate from the prop to cater for the closure. The presence of foreign particles in the water escaping from a prop can adversely affect the functioning of a pressure release valve. For example, if a particle is lodged between a valve member and a valve seat then the valve member would normally not be able to seal and water would escape continuously from the prop which then would not be capable of exhibiting its designed load-bearing function.
[0005] An object of the present invention is to provide a valve which, to some extent at least, addresses the aforementioned situation.
SUMMARY OF INVENTION
[0006] The invention provides a valve for use with a hydraulically activated device, wherein the valve includes a housing, a bore through the housing, the bore having an inner surface, an inlet to the bore, and an outlet from the bore, a tubular valve member which is made from a resiliently deformable material and which is located in the bore, the tubular valve member including an outer surface, a first end, an opposed second end, and a passage through the valve member from the first end to the second end, a first seal between the first end of the tubular member and an opposed section of the inner surface of the bore, a second seal between the second end of the tubular member and an opposed section of the inner surface of the bore, and a filler arrangement, connected to the housing, to introduce a gas under pressure into a volume between the first seal and the second seal and between the outer surface of the tubular valve member and part of the opposed inner surface of the bore.
[0007] The filler arrangement may comprise a one-way valve.
[0008] The inlet to the bore may be used to introduce a liquid e.g. water under pressure into an interior of the device, e.g. a prop, to which the valve is connected. The outlet may be connected to the device, i.e. the prop, opposing an opening through a wall of the prop.
[0009] A retention device, e.g. a circlip, may be positioned inside the bore to restrict movement of the tubular valve member towards the inlet.
BRIEF DESCRIPTION OF THE DRAWING
[0010] The invention is further described by way of example with reference to the accompanying drawing which illustrates from one side and in cross-section a valve according to one form of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0011] The accompanying drawing illustrates from one side and in cross-section a valve 10 according to the invention, which is connected to a wall 12 of a hydraulically activated rock prop (not shown in detail).
[0012] The valve 10 includes a housing 14 through which extends a bore 16 . The bore has an inner surface 18 , an inlet 20 and an outlet 22 . The housing is attached in any suitable way to the wall 12 , for example by means of welding 24 . The outlet 22 opposes an opening 26 in the wall so that the outlet is thereby placed in communication with an interior of the prop.
[0013] The housing 14 , in an outer surface adjacent the inlet, is formed with a circumferentially extending slot 30 , as is known in the art, so that a connection device, not shown, can be coupled to the housing. The connection device is at an end of a hose or conduit which extends from a pressurised source of water, not shown. This aspect is known in the art and therefore is not further described herein.
[0014] A tubular valve member 40 is located inside the bore 16 . The valve member is made from a resiliently deformable material e.g. polyurethane or rubber. A passage 42 extends through the tubular valve member from a first end 44 to a second end 46 .
[0015] A first seal 48 is coupled to the first end and defines a sealing interface between the inner surface 18 of the bore and the tubular valve member 40 . Similarly a second seal 52 is engaged with the second end and defines a sealing interface between the inner surface 18 and the tubular valve member.
[0016] The first seal 48 has a passage 60 which extends through the seal and an adjacent tubular spigot 62 which extends into the passage 60 . The second seal 52 is similar to the first seal and has a passage 66 which extends through the seal and an adjacent tubular spigot 64 which extends into the passage. Thus, flow of a liquid can take place through the passage 66 into the passage 42 and then into the passage 60 .
[0017] A one-way filler valve 70 is connected to a side of the housing at a location which is between the first and second ends 44 and 46 .
[0018] In use of the valve 10 a pressurised gas is introduced through the one-way filler valve 70 into a volume 72 which is defined between an outer surface of the tubular valve member 40 and an opposing part of the inner surface 18 of the bore and which is located between the first end 44 and the second end 46 of the tubular valve member. The pressure of the gas is sufficiently high to cause the tubular valve member to collapse so that the passage 42 between the first and second ends is effectively sealed.
[0019] The inlet 20 can be connected to a source of pressurised water, in the manner which has been described and water can then be passed through the inlet 20 , and through the passage 66 , in the second seal. If the incoming water has a pressure which is sufficiently high then the tubular valve member 40 is forced to move so that the passage is opened and water flows through the passage 42 in the valve member to the passage 60 , to the outlet 22 and then into the opening 26 into the interior of the prop.
[0020] If the valve 10 is disconnected from the pressurised water source the gas pressure in the volume 72 is sufficiently high to cause the valve member to collapse and immediately seal.
[0021] If the pressure inside the prop increases above a designed limit, for example if closure takes place of a hanging wall and a foot wall between which the prop is installed, then an increased pressure is exerted at the outlet of the valve member. The pressure increases as the degree of closure increases and a point is reached at which the tubular valve member is forced open to allow a quantity of water to escape through the passage 42 to the surrounding environment. As the pressure reduces inside the prop the force exerted by the pressurised gas in the volume 72 causes the tubular valve member to close, again.
[0022] A principal benefit of the invention lies in the fact that the valve member is made from a resiliently deformable material such as rubber, polyurethane or the like. These materials are exemplary only and are non-limiting. If a particle carried by water exiting the prop is in the passage 42 when the tubular valve member closes then, because of the nature of the material from which the member is made, it is possible for the material to deform and accommodate the particle. It is unlikely that the particle, in itself, will cause the sealing action of the valve member to be impaired.
[0023] If the pressure in the prop is again increased then, in the manner described, the tubular valve member is opened and water can flow from the prop. In this event it is likely that the particle previously trapped inside the passage 42 would be flushed to the surrounding environment.
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A valve includes a flexible tube in an enclosure which is filled with pressurized gas which collapses the tube and wherein a fluid, applied at either end of the tube, can open the tube if the pressure of the fluid is sufficiently high.
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FIELD OF INVENTION
The invention relates to a first stage pressure regulator for a two-stage underwater breathing apparatus, which first stage regulator is connected to a source of high pressure breathable gas, and comprises:
an inlet connected to the source of high-pressure gas and an outlet for gas having a lower pressure than the incoming gas;
a high pressure gas chamber communicating with said inlet and a low pressure gas chamber connected with said outlet;
the low pressure gas chamber communicating with the high pressure gas chamber through a regulating valve;
a balance chamber interposed between the low pressure gas chamber and a chamber communicating with the ambient or directly the ambient;
said low pressure gas chamber being sealingly separated from the balance chamber by a first movable wall;
said balance chamber being sealingly separated from the ambient exposed chamber by a second movable wall;
said first and said second movable walls being mechanically and rigidly interconnected by stem which is designed to transfer the force exerted on said movable walls;
said first movable wall being further connected by force transfer means to the closing element of the valve interposed between the high pressure gas chamber and the low pressure gas chamber;
a check valve being provided, for relieving the overpressure in the compensation chamber, between said compensation chamber and said ambient exposed chamber.
BACKGROUND OF THE INVENTION
First stage pressure regulators of the above type are known in the art. The overpressure that may build up in the balance chamber is relieved thanks to the tubular shape of the force transfer stem between the first and the second movable walls which sealingly separate the balance chamber from the low pressure gas chamber and the ambient exposed chamber respectively. A hole in the tubular wall puts in communication the inside of the tubular stem with the balance chamber, whereas a pressure relief valve is provided at the end for connection to the second movable wall which separates the balance chamber from the ambient exposed chamber, which valve is a one-way valve or a check valve whose shut-off direction corresponds to a flow direction from the ambient exposed chamber to the balance chamber.
A valve of this type is known, for example, from U.S. Pat. No. 5,097,860.
The provision of a balance chamber having means for transferring force to the regulating valve element between the high pressure gas chamber and the low pressure gas chamber, which force transfer means are two movable walls rigidly interconnected by the intermediate stem and a force transfer extension connected to the regulating valve element allows to adapt the pressure regulating valve calibration to ambient pressure conditions.
The first and the second movable walls generally consist of combinations of pistons cooperating with elastically deformable diaphragms, and elastic means are generally further provided for adjusting a certain preload on said movable walls, and operating in the same direction as the force exerted by ambient pressure.
The above construction of prior art pressure regulators has a number of drawbacks. The pressure relief valve is generally fixed to the tubular stem and requires the diaphragm to be also perforated in the area of the tubular stem. Furthermore, the pressure relief valve is very small and thence relatively expensive and makes assembly more difficult, besides being itself a construction part.
The tubular stem requires a transverse hole to be formed therein for communication of the inside tubular space with the balance chamber.
SUMMARY OF THE INVENTION
The invention has the object of improving a first stage pressure regulator as described hereinbefore, in which:
The movable wall for separating the balance chamber from the ambient exposed chamber is formed by a disk-shaped piston which is slideably and non sealingly guided along the peripheral walls of the balance chamber and by an elastically deformable diaphragm, which overlies the side of the piston facing toward the ambient exposed chamber and forms with said piston a diaphragm relief valve.
In a first variant embodiment, the diaphragm is sealingly and stably clamped at its peripheral edge, and has a relief hole in its central area, which is engaged on a coincident cylindrical or frustoconical extension of the piston projecting out of the side thereof facing toward the ambient exposed chamber.
The free end of the cylindrical or frustoconical extension possibly ends with a widened head having a diameter greater than that of the coincident through hole of the elastic diaphragm.
Advantageously, in this embodiment the elastic diaphragm has a bellows-shaped peripheral edge which is directly radially inwards from an annular peripheral lip or flange, which is designed to sealingly clamp said diaphragm.
According to an alternative embodiment, the peripheral edge of the piston which forms the movable separating wall between the balance chamber and the ambient exposed chamber is sealingly guided by the inner wall of the balance chamber, whereas said piston has at least one eccentric hole and supports a diaphragm valve on the side facing toward the ambient exposed chamber, at its central area and is free at its periphery.
In both embodiments, the diaphragm is preferably made of silicone or other highly elastic materials.
Further improvements will form the subject of the dependent claims.
The characteristics of the invention will appear more clearly from the following description of a few embodiments, which are shown without limitation in the annexed drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial cross sectional view of a first embodiment of the first stage pressure regulator according to this invention.
FIG. 2 , like FIG. 1 , shows a variant embodiment of the first stage pressure regulator according to FIG. 1 .
FIG. 3 shows, like the previous Figures, a second embodiment of the first stage pressure regulator according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
A first embodiment of the first stage pressure regulator of the present invention is shown in FIG. 1 . Such first stage comprises a substantially cylindrical body having a first high pressure gas chamber 1 which communicates with a gas source (not shown in detail) such as a bottle or the like, through an inlet 101 . A low pressure gas chamber 2 , with gas having a lower pressure than the incoming gas, has at least one, two or more outlets 102 for said low pressure gas. In the figure the outlets are in the form of threaded holes in which threaded fittings 103 of hoses or the like are sealingly tightened. A regulating valve is provided between the high pressure gas chamber 1 and the low pressure gas chamber 2 . This valve is composed of a stationary valve seat 4 and an element 5 which is mounted in such a manner as to be able to move towards and away from said valve seat. The valve element is mounted in such a manner as to slide along the axis of the passage 104 of the valve seat and has a surface exposed to the action of the high pressure gas which acts thereon in the opening direction, such sliding motion being opposed by preloadable elastic means 6 , which stably act in the closing direction of the valve element against said valve seat 4 . Pressure reduction occurs, as is known, thanks to the fact that the calibration of the elastic means and the ratio between the pressures in the two chambers causes the element to only open to such an extent and for such a time as to allow a small volume of high pressure air to pass in the low pressure gas chamber, and to expand in the low pressure gas chamber 2 .
The regulating valve element 5 extends through the passage 104 of the valve seat 4 by an actuating stem 7 in the low pressure gas chamber 2 and ends with a piston, preferably having a circular shape 8 . This piston 8 adheres by the surface opposite the control stem 7 against a first elastic diaphragm 9 , thereby forming a movable wall for separating the low pressure gas chamber 2 from a balance chamber 10 . The elastic diaphragm 9 is sealingly clamped along its outer peripheral edge. In the embodiment as shown, this occurs thanks to a threaded tubular member 11 which sealingly engages in an internally threaded bell joint 12 which peripherally delimits an annular shoulder 13 for clamping the peripheral edge of the diaphragm 9 , which is thus clamped between said shoulder 13 and the end edge of the tubular member 11 . The latter forms the peripheral shell wall of the balance chamber 10 . A second bell-shaped piston 14 adheres against the diaphragm side opposite the low pressure gas chamber 2 , and is rigidly connected by a central force transfer stem 15 to another piston 16 , which forms the other movable wall of the balance chamber 10 , that separates said balance chamber from an ambient exposed chamber 17 . In this embodiment, the piston 16 is unsealingly guided by the inner surface of the tubular member 11 which forms the inner shell wall of the balance chamber 10 , whereas the seal with the ambient exposed chamber is ensured by an elastic diaphragm 18 . The elastic diaphragm 18 is sealingly clamped along its inner peripheral edge, like the diaphragm 9 , between the externally threaded end side of the tubular member 11 and an internally threaded clamping ring 19 . Particularly the peripheral edge of the diaphragm 18 has an axial flange 118 which is engaged in an annular axial groove, formed in the thickness of the end edge of the tubular member 11 . The axial flange 118 is connected to the rest of the diaphragm 18 by an annular bellows-shaped part. The annular part for connection between the axial flange 118 and the annular bellows-shaped part 218 overlays the end edge of the tubular member 11 and is clamped between the latter and an annular radial shoulder 119 of the ring nut 19 . An axial frustoconical extension 20 extends from the central area of the side of the piston 16 facing toward the diaphragm 18 , thence toward the ambient exposed chamber 17 , which extension engages with a central through hole 318 of the elastic diaphragm 18 . The diameter of this hole substantially corresponds to the average diameter of the axial frustoconical extension 20 which acts as an a valve element, in combination with the natural elastic deformability of the diaphragm 18 and the hole 318 . The ambient exposed chamber 17 is closed from the ambient by a cap 21 , which has a plurality of apertures for communication with the ambient and overlays the ring nut 19 , while being locked in position, for example, by snap engagement means, in an engagement groove. Particularly, these means may consist of an end flange which is formed as a small radial neck at the free edge of the cap 21 , which is in snap engaging relationship with a groove formed between the end edge of the ring nut 19 for clamping the diaphragm 18 and a radial annular ridge of the tubular member 11 which is provided at an axial distance from said end edge of the ring nut 19 .
A stationary abutment 23 for an elastic member 24 , for instance a helical spring, is placed in an intermediate position in the balance chamber 10 , in an axially adjustable manner, and is interposed between said stationary abutment and the bell-shaped piston 14 . This elastic member generates an adjustable preload on the assembly formed by the bell-shaped piston 14 , the force transfer stem 15 and the piston 16 subjected to the action of ambient pressure toward the low pressure gas chamber 2 , therefore in the opening direction of the regulating valve element 5 .
Advantageously, the stationary abutment 23 for the elastic member 24 consists of a cup-shaped annular member having an external thread for engagement with an internally threaded portion of the tubular member 11 , which allows to adjust the compression of the elastic member 24 by simply tightening or loosening the abutment 23 .
The operation of this first stage pressure regulator is easily understandable from the above description. The action of high pressure gas in combination with that of the elastic means associated to the valve element 5 is combined with the variable force exerted by ambient pressure, which is in turn assisted by the action of the elastic means 24 . Ambient pressure is exerted on the piston 16 and transferred by the stem 15 to the bell-shaped piston and, thanks to the elastic diaphragm 9 , to the piston 8 and to the element 5 .
The diaphragm 18 which separates the balance chamber 10 from the ambient exposed chamber 17 and cooperates with the piston 16 and the frustoconical extension 20 thereof is an overpressure relief valve, which is designed to relieve the overpressure that may build up and actually builds up in the balance chamber 10 . Such overpressure is obviously undesired, as it alters pressure balancing settings. The operation is schematically shown in FIG. 1 . Assuming normal pressure conditions in the balance chamber 10 , the diaphragm is pushed, either naturally or under the action of ambient pressure, at its central portion against the piston 16 , therefore the central hole 318 slides along the frustoconical extension 20 in the increasing diameter direction, whereby a sealing condition is generated (see diaphragm outlined in dashed lines). When the balance chamber 10 is in overpressure conditions, the elastic diaphragm 18 bows in a direction opposite to that of the balance chamber 10 (see diaphragm outlined in full lines) and the hole 318 moves toward the apex of the frustoconical extension 20 , i.e. in the decreasing diameter direction, whereby the seal between said extension 20 and said hole 318 is released, which allows gas to escape from the balance chamber 10 to the ambient exposed chamber 17 .
Advantageously, as shown in FIG. 1 , at the center of the diaphragm between the hole 318 and the annular bellows 218 , the diaphragm may have a non flat, concave shape, e.g. in its natural rest condition, which defines, in combination with the bellows, a well-determined and repeatable rest position of the diaphragm, corresponding to the sealing position against the piston 16 and the extension 20 .
The construction of the first stage pressure regulator as described above has further advantages. The construction of the balance chamber by using substantially a tubular member 11 with a ring nut 19 for clamping the peripheral edge of the diaphragm 16 , as well as the engagement of said tubular member in a threaded bell shaped seat of the rest of the regulator body in which the low pressure gas chamber 2 and the high pressure gas chamber 1 are formed, allows easy assembly and dismantling and fast replacement of diaphragms and the other parts, such as the pistons 16 and 14 . Furthermore, this construction affords an easier adjustment of the position of the stationary abutment 23 for the elastic member 24 . It is further worth noting that there is no mechanical continuity between the piston 14 and the control stem 7 which connects the piston 16 to the valve element, and that the bell-shaped piston 14 acts as a presser on a separate piston 8 , whereto said control stem 7 is attached. Therefore, dynamic functionality is obtained and maintained thanks to the provision of two separate construction parts. This allows to safely sealingly separate the balance chamber from the low pressure gas chamber by means of the elastic diaphragm 9 which is continuous, with no apertures therein, and is stably clamped at its periphery. This is of great importance, because any water ingress in the low pressure gas chamber would be highly undesired, said low pressure gas chamber 2 being the chamber wherefrom breathable air is taken. As is apparent, the construction of the first stage pressure regulator as shown in FIG. 1 provides an advantageous improvement with respect to the use of a single piston in lieu of two separate pistons 14 and 8 , which single piston would be rigidly or integrally attached to the piston 16 and the element actuating stem 7 . In this case, seal could only be provided by peripheral gaskets of said single piston, cooperating between the latter and the inner shell wall of the balance chamber and being highly exposed to wear due to their sliding motion along said walls.
The variant of FIG. 2 essentially shows a first stage pressure regulator having exactly the same construction as that described above with reference to FIG. 1 . In FIG. 2 like parts or parts having like functions of those of FIG. 1 bear like numbers.
The substantial difference is that the free end of the frustoconical extension 20 of the piston 16 cooperating with the diaphragm 18 has a widened head 120 whose diameter is greater than the diameter of the hole 318 of the diaphragm 18 which is engaged on said extension. Such widened head has the function of preventing the diaphragm 18 from accidentally slipping off the frustoconical extension 20 in case of an abrupt overpressure relief. Here, if no widened head 120 were provided, an excessive deformation of the diaphragm might cause the diaphragm 18 to slip off the frustoconical extension 20 and, more seriously, to be radially offset with respect to said frustoconical extension 20 , whereby the diaphragm 18 might get caught at the end of said frustoconical extension when it is moved back to the rest and sealing position, and might not prevent water ingress from the ambient to the balance chamber 10 .
FIG. 3 shows yet another embodiment of the first stage pressure regulator according to this invention. Here again, the construction of said first stage is substantially identical to that of the previous figures, with the exception of the construction of the piston 16 and the diaphragm 18 . In fact, in this variant embodiment, the seal between the ambient exposed chamber 17 and the balance chamber 10 is provided directly by the piston 16 , which is sealingly guided along the inner wall of the balance chamber 10 , i.e. the tubular member 11 , thanks to annular peripheral sealing gaskets, e.g. an O-ring 116 received in a peripheral groove that is formed in the thickness of said piston 16 . The piston further has at least one through hole 216 in an eccentric position or two or more holes or a ring of through holes, which are sealingly closed by the diaphragm 16 on the side facing toward the ambient exposed chamber 17 . This diaphragm is a diaphragm element of a conventional diaphragm valve and is completely free at its periphery, whereas it is fixed to the piston 16 at its center. Fixation may occur in any manner whatever, e.g. by using a central axial pin for snap engagement in a snap hole 316 placed in coincidence with the piston 16 . Particularly, the central pin 418 and the snap hole are coaxial, whereas the through holes 216 are at radial distances therefrom which are smaller than the radius of the diaphragm 16 .
Particularly, the central pin 418 may have at least two opposite wedge-shaped teeth 518 or a ring of such wedge-shaped teeth or a radial annular conical projection, which is in elastic snap engagement with an inner annular shoulder or a ring of inner radial teeth or with corresponding inner radial teeth of the snap hole 316 in the piston 16 . The section of the teeth or the annular conical projection has a front with a smaller slope on the side facing toward the free end of the pin, to form a lead-in surface and a substantially radial and perpendicular front on the opposite side, to provide firm anchorage behind the shoulder or the inner radial teeth of the hole 316 .
This arrangement has the advantage of further simplifying construction and especially of facilitating the replacement of the diaphragm 16 , which is most exposed to the ambient, thence to deterioration.
It is worth noting that the cap 21 which delimits the ambient exposed chamber 17 from the outside, therefore the chamber 17 itself are not necessarily required, said cap only providing mechanical protection to the diaphragm 16 against any accidental damage.
Therefore, this invention shall be intended to also cover the sub-combination in which the ambient exposed chamber 17 is not provided, and is formed by the ambient itself.
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A first stage pressure regulator for a two-stage underwater breathing apparatus, comprises a second movable wall ( 16, 18 ) for separating a balance chamber ( 10 ) from an ambient exposed chamber ( 17 ) . The second movable wall is formed by a disk-shaped piston ( 16 ) which is slideably and non sealingly guided along the peripheral walls that delimit the balance chamber ( 10 ), and by an elastically deformable diaphragm ( 18 ), which overlies the side of the piston ( 16 ) facing forward the ambient exposed chamber ( 17 ) . The elastically deformable diaphragm ( 18 ) forms with said piston ( 16 ) a diaphragm type pressure relief valve ( 20, 318 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/476,225, filed May 21, 2012, which is a continuation of U.S. application Ser. No. 13/248,429, filed Sep. 29, 2011, now abandoned, which application is a continuation of U.S. Pat. No. 8,028,550, issued Oct. 4, 2011, which application is a continuation of U.S. application Ser. No. 11/470,658, filed Sep. 7, 2006, now abandoned, which claims the benefit of provisional application 60/734,728, filed on Nov. 8, 2005, all of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to laundry appliances and in particular to laundry washing machines for household use.
BACKGROUND OF THE INVENTION
[0003] U.S. Pat. No. 6,212,722 proposes an improved laundry washing machine for domestic use. This machine is of the top loading type having an outer bowl, a wash basket within the outer bowl and access to the wash basket through a top opening. A motor is provided to drive rotation of the wash basket within the outer bowl. A wash plate is provided in the lower portion of the wash basket to be rotated by the motor with the wash basket or independently of the wash basket. The patent proposes a combination of water level control, wash plate design, wash basket design and movement pattern for the wash plate which leads to an inverse toroidal movement of the laundry load during a wash phase. The sodden wash load is dragged by friction radially inward on the upper surface of the wash plate and progresses upward in the region of the centre. The sodden wash load then progresses radially outward to the wall of the wash basket and downward to the base of the wash basket. This has been found to provide an effective wash action with low water consumption.
[0004] The patent indicates that this is only achieved at water levels within a determinable band. With too much water the inverse toroidal rollover motion is not achieved because the clothes lose frictional contact with the wash plate.
[0005] The present inventors have ascertained a desire to include an effective wash mode that sacrifices a degree of water efficiency in favour of dilution of the wash solution. The inventors consider this to be particularly desirable in the case of heavily soiled laundry items or laundry items having insoluble soiling, such as muddy, sandy or grass covered sports clothes, and in the case of laundry subject to dye leakage.
[0006] The inventors consider that the laundry machine described in U.S. Pat. No. 6,212,722 is only partially effective in this regard. At higher water levels in which the machine cannot perform the inverse toroidal rollover pattern the inventors consider the machine is likely to provide a less effective wash action. The effect of inverse toroidal wash action by dragging is only available at low water levels, and there is a middle water level at which no rollover occurs. Where the laundry load does not rollover wash action of clothing against the wash plate is limited to a small fraction of the load and wash performance suffers.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a laundry machine which goes some way toward overcoming the above disadvantages or which will at least provide the public with a useful choice.
[0008] In a first aspect, the invention may broadly be said to consist in a laundry machine comprising a cabinet, a wash tub supported within the cabinet, a motor suspended beneath the wash tub, a wash basket rotatably supported within the wash tub and drivingly connected to the motor, and a wash plate disposed in the bottom of the wash basket and defining an outer periphery. The wash plate comprises a central hub encircled by the outer periphery, a plurality of vanes extending substantially radially from the central hub toward the outer periphery. The vanes comprise a continuously increasing width as they extend radially away from the hub, a pair of side walls diverging as they extend away from the hub, an outer portion terminating at the outer periphery, a shoulder extending from the hub and transitioning into the outer portion, wherein the shoulder is located above the outer portion and both the outer portion and shoulder have a convex cross section. Further, the wash plate is rotatably supported in the wash basket and drivingly connected to the motor to oscillate the wash plate such that the cloth items directly above the wash plate are frictionally dragged in an oscillatory manner and the cloth items rollover within the wash basket along an inverse toroidal rollover path.
[0009] This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a cutaway perspective view of a laundry machine according to a preferred embodiment of the present invention.
[0011] FIG. 2 is a block diagram of a control system for a laundry washing machine.
[0012] FIG. 3 is a perspective view of the wash basket base moulding according to the machine of FIG. 1 .
[0013] FIG. 3 b is a perspective view of another embodiment of a wash basket base moulding according to the present invention.
[0014] FIG. 4 is a perspective view from above of the wash plate according to a preferred embodiment of the present invention.
[0015] FIG. 4 b is a perspective view from above of the wash plate according to present invention as shown in 3 b.
[0016] FIG. 5 is a cross-sectional side elevation of the wash plate of FIG. 4 .
[0017] FIG. 6 is a plan view of the wash plate of FIG. 4 .
[0018] FIG. 7 is a plan view of a section of wash plate including arcuate apertures.
[0019] FIG. 8 is a graph of rotational speed versus time, illustrating elements of a wash plate drive profile for exciting toroidal rollover.
DETAILED DESCRIPTION
[0020] The present invention relates to improvements and adaptations on the wash system described in U.S. Pat. No. 6,212,722. The contents of that patent are incorporated herein by reference.
[0021] A laundry machine incorporating improvements and adaptations of the present application is illustrated in FIG. 1 . The laundry machine includes a cabinet 100 with a lid 102 and a user console 104 . A controller 106 is located within the body of the user console. The controller 106 includes a power supply and a programmed microcontroller. The power supply receives power from the mains supply and supplies power to the microcontroller, to a power supply bridge for the electric motor and to ancillary devices within the machine such as a pump and valves. Delivery of power to the motor 114 and the ancillary devices is at the control of microcontroller. The microcontroller receives inputs from a user interface on console 104 .
[0022] A tub 120 is supported within the cabinet. The tub is preferably suspended from the upper edge of the cabinet. The tub may alternatively be supported from below or from the sides of the cabinet. A wash or drain pump is fitted to the lower portion of the tub. The pump is preferably located at a sump portion of the tub.
[0023] A wash basket 122 is supported for rotation within the tub. Opening the lid 102 provides user access to an upper open end of the wash basket.
[0024] A wash plate 124 is mounted in the lower portion of the wash basket.
[0025] The improvements and adaptations of the present invention are preferably implemented in a laundry machine of a direct drive type. However, other drive systems involving for example gearbox or belts may alternatively be used.
[0026] A motor 114 below the tub directly drives a shaft 128 . The shaft 128 extends through the lower face of the tub, where it is supported in a pair of bearings 130 . Seals prevent water escaping the tub at the interface between the tub and shaft.
[0027] The wash basket 122 is mounted on the shaft within the tub. The wash basket may typically comprise a base 132 and a perforated cylindrical skin 134 . The perforated cylindrical skin extends up from the base to define an open ended drum. The wash basket may include a balance ring at the upper edge of the cylindrical skin.
[0028] The wash plate 124 is also fitted to the shaft, within the wash basket 122 .
[0029] An arrangement is provided to enable the motor 114 to selectively drive either the wash plate 124 independently of the wash basket 122 , or drive the wash basket 122 . In driving the wash basket the motor may also drive the wash plate. Various mechanisms have been proposed to accomplish this selective drive. A number of variations including twin concentric shafts and a selectable clutch to connect the motor with either or both shafts are noted in the prior art and may be applied.
[0030] Alternatively a floating clutch of a type previously described in U.S. Pat. No. 5,353,613 may be used. The machine illustrated in FIG. 1 makes use of such a floating clutch. The wash basket 122 is slidably mounted on the drive shaft 128 . The wash plate 124 is fixed to rotate with the upper end of the drive shaft. The wash basket 122 includes float chambers 140 on the underside of the wash basket base member. The wash basket is allowed to rotate on the shaft. A vertically inter-engaging clutch 142 is provided between the wash basket 122 and wash plate 144 or between the wash basket 122 and shaft 128 . A first clutch member having upwardly facing engagements may be provided in conjunction with the wash plate or a spline on the shaft. A downwardly facing clutch member is provided in conjunction with the wash basket. With the wash basket in an upper or raised position the upwardly facing and downwardly facing clutch members are not engaged and the wash basket is free to rotate on the shaft. With the wash basket in a lower position the members are not engaged. In use the wash basket will be disengaged from the shaft when sufficient water has been added to the tub for the wash basket to float to its raised position. The amount of water required before the wash basket floats depends on the weight of laundry in the wash basket. In the floated condition the shaft will drive the wash plate but will not directly drive the wash basket. In the lower condition the shaft will drive the wash plate and wash basket together.
[0031] The controller is part of a control system for coordinating the operations of the laundry machine. The control system is illustrated in the block diagram of FIG. 2 . The controller includes a microcontroller 800 . The microcontroller may include a micro computer and ancillary logic circuits and interfaces. The micro controller receives user input commands on user interface 802 . The user interface may include, for example, a plurality of touch controls such as switches or buttons, or may include a touch screen, or may include rotary or linear selection devices. The micro controller may include a display device 804 to provide feedback to a user. The display device may comprise a plurality of indicators, such as lights or LEDs, or may include a screen display. The display device 804 and the user interface 802 may be mounted to a single module incorporating the micro controller.
[0032] The micro controller receives power from a power supply 806 . The micro controller also controls power switches 808 applying power from supply 806 to drive motor 810 . The micro controller controls further power switches 812 applying power from supply 806 to a pump 814 . The micro controller also controls a power switch 830 applying power to a cold water inlet valve 832 and a power switch 834 applying power to hot water inlet valve 836 .
[0033] The micro controller preferably receives feedback from position sensors 816 associated with the motor. These sensors may for example be a set of digital Hall sensors, sensing changes in rotor position, or may be any suitable encoder. Alternatively rotor position and movement may be sensed from motor drive current or EMF induced in unenergised motor windings.
[0034] The micro controller also preferably receives input from a water level sensor 818 , which detects the level of water in the tub of the machine, and from a temperature sensor 820 which detects the temperature of water being supplied to the wash tub.
[0035] The present application presents several adaptations that enhance the operation of a wash system attempting to induce inverse toroidal rollover by frictional dragging or by fluid mechanics. These adaptations enhance the ability to generate inverse toroidal rollover wash pattern at low water levels and help extend the water levels at which this wash pattern can be maintained. A number of these adaptations involve the shape and configuration of elements of the wash plate. In particular they involve the form of the upper surface of the wash plate, including the presence and location of apertures through the wash plate. Other adaptations involve the shape and size of buffers arrayed on the base of the spin tub around the periphery of the wash plate. An additional aspect involves control methods for helping establish and maintain the inverse toroidal rollover pattern and for beneficially extending the range of operation of the inverse toroidal rollover to higher water levels.
[0036] Exemplary wash plates are illustrated in FIGS. 4 to 6 . FIGS. 3-5 illustrate one exemplary wash plate and FIGS. 3B and 4B illustrate a second exemplary wash plate. As shown in FIGS. 4 and 4B , the wash plate rises from a generally circular periphery 400 to a raised central hub 402 . The upper surface of the wash plate is broadly divided into alternating sectors. The alternating sectors comprise raised sectors 404 , or vanes, and intermediate lower sectors 406 . The lower sectors 406 are in the general form of a shallow cone with increasing gradient toward the hub 402 , so as to be outwardly concave in radial cross-section. This can generally be seen in FIG. 5 . In the outer region of the wash plate the low sectors 406 have a generally shallow gradient. In the region closest to the hub 402 the low sectors 406 of the wash plate have a higher gradient.
[0037] Each vane 404 has a form devised to enhance initiation and maintenance of inverse toroidal rollover by encouraging the inward dragging of laundry items by friction that are in contact with the upper surface of the wash plate. This enhanced form includes three major features. It is believed that each of these features independently offers an improvement over prior forms. The cumulative improvement offered by these features enables the appliance to maintain inverse toroidal rollover at higher water levels.
[0038] Each vane includes a divergent form wherein the width of the vane increases moving from the hub to the periphery of the wash plate. Further, each vane includes steep side walls 410 adjacent the neighbouring low sectors of the wash plate.
[0039] The upper face of an outer portion 412 of each vane is generally flat and the vane slopes down towards its outer periphery 414 to the level of the circular periphery 400 of the wash plate.
[0040] Each steep side surface 410 of each vane is outwardly concave. That is, the side surfaces of each vane diverge more rapidly as the vane extends toward the outer periphery 400 of the wash plate. Furthermore the opposing side surfaces 410 of adjacent vanes, facing toward one another across the low sector 406 between them, are each concave relative to the other and relative to a radius extending from the centre of the wash plate. The outermost portion of each side wall hooks toward the adjacent vane so as to be inclined in advance of a radial plane of the wash plate. The inventors have found that such side surfaces 410 aid in dragging the cloth items inward to the centre of the wash plate.
[0041] Rapid oscillation of the wash plate provides a centrifugal pumping action inducing radially outward water flow. Such radial flow above the wash plate may inhibit inward movement of the laundry items and is detrimental to establishing the inverse toroidal rollover pattern. The shape of the side surfaces 410 also counteract the centrifugal pumping action of the wash plate as it is oscillated. The inventors have found that the side surfaces 410 aid in achieving inverse toroidal roll-over at all water levels.
[0042] In the region of the vane 404 nearer the hub 402 a ridge or shoulder 420 rises from the general outer portion 412 of each vane. The ridge or shoulder 420 has side faces 422 rising to a ridge. The side faces of the shoulder 420 are less steep than the steep side faces 410 . When the wash plate is oscillated the angled side faces 422 of the shoulder 420 push on the laundry items near the hub 402 so as to impart a vertical component of force on them. Laundry items near the centre of the wash plate are then thrust upward, which aids inverse toroidal motion.
[0043] Preferably there are a plurality of such vanes 404 , for example 3, 4, 5 or 6 such vanes. Most preferably there are 3 or 4 such vanes.
[0044] Preferably the relative proportion of vane to plan area of the wash plate, is between 0.33 and 0.66.
[0045] The shape and size of the wash plate, including shoulder area, along with basket capacity, and drive profiles used by the controller, can impact motor temperatures. Accordingly these factors need to be balanced according to the overall machine requirements.
[0046] The inventors have found that by providing apertures 430 through the wash plate, radial outward water flow is induced below the wash plate by the shape of the underside of the vanes 404 , and that this reduces or compensates for induced outward flow above the wash plate. To enhance outward flow under the wash plate the underside of the wash plate may include a plurality of spaced radial ribs 432 .
[0047] The base of the wash basket preferably includes an annular series of flow channels extending from the upper side of the base through to the lower side of the base. These channels 304 can be seen in FIG. 3 . Fluid may flow from apertures 430 and through these flow channels to the region below the wash basket, between the wash basket and outer tub. This fluid may flow from there out to the wall of the outer tub, upward between the wall of the outer tub and the cylindrical wall of the wash basket and then inward through the perforations of the wash basket. The water flow carries lint into the space between the wash basket and the tub. This lint becomes caught up on the outside of the spin basket and tends not to re-enter the spin basket. The lint is then removed in the drain operation subsequent to the wash cycle or is extracted by a lint filter in a recirculation system.
[0048] Furthermore, the apertures 430 through the wash plate are preferably provided adjacent each steep side wall 410 of each vane as shown is FIG. 4 , or between each steep side wall 410 as shown in FIG. 4B . It is believed that the suction effect generated by the pumping action under the wash plate draws laundry items against the upper surface of the wash plate in these regions directly adjacent the side walls 410 of the vanes. This enhances contact of the laundry items with the side walls 410 . It is believed that this contact promotes the inverse toroidal rollover wash pattern. The inventors consider that this effect is useful in promoting maintenance of the inverse toroidal rollover wash pattern with higher water levels, where laundry items otherwise tend to float out of contact with the wash plate.
[0049] The apertures 430 may comprise small groupings or arrays of circular or shaped holes adjacent the side walls of the vane, or alternatively may comprise one or more elongate slots through the wash plate in the region adjacent the vane. FIG. 7 illustrates an example wash plate including arrays of short curved slots 700 , or arcuate holes, in place of circular holes. Sufficient apertures may be provided in the regions of the low sectors adjacent the side walls, and may therefore be excluded from regions of the low sectors that are not close to the side walls of the vane.
[0050] To enhance the dragging effect of the laundry over the surface of the oscillating wash plate the inventors consider it advantageous for the spin basket to resist movement relative to laundry in the lower portion of the spin basket. For this purpose a series of tall buffers was proposed in U.S. Pat. No. 6,212,722. The present inventors now believe that smaller buffers that do not interact with laundry that is well above the level of the wash plate are preferable. A spin basket base member 300 including an annular series of buffers 302 of preferred form is illustrated in FIGS. 3 and 3B . The base member includes a hub portion 308 and a periphery 306 . With the wash plate in place the periphery 306 of the base member 300 encloses the space between the outer edge of the wash plate and the cylindrical wall of the wash basket. As seen in FIG. 3 the preferred buffers have a very low profile. Each buffer extends radially inward from the side wall of the spin basket. Each buffer preferably has a height of less than 3 cm, relative to the surrounding surface of the base member. Each buffer has a flattened shape, being several times wider that its height. Each buffer tapers as it extends in toward the wash plate.
[0051] The washer is capable of washing in two modes, a high efficiency mode and a traditional deep fill mode. In high efficiency mode the water to clothes ratio is typically less than 10 litres/kg. The traditional deep fill wash typically uses over 15 litres/kg. The two modes each have their benefits. The high efficiency mode uses less water and the more concentrated detergent solution gives excellent soil removal results for soluble soils. The traditional mode uses more water but is better at removing insoluble soils, such as sand and grass.
[0052] Wash performance in both modes requires achieving sufficient turnover of the clothes. In the high efficiency mode, higher contact with the wash plate due to lower water level means a marriage between plate shape and plate movement can readily create the inverse toroidal motion.
[0053] The preferred controller applies an initial wash plate drive profile to initiate the inverse toroidal motion. The initial drive profile is characterised by higher angular velocity and longer stroke length to start the clothes movement. This movement is subsequently maintained by a maintenance drive profile with lower angular velocity and stroke length. Many drive systems are possible for controlling wash plate drive profiles. One example is described in U.S. Pat. No. 5,398,298.
[0054] The initial drive profile is varied according to load size. The profile is more vigorous for larger load sizes. The load size is determined from the amount of water required to float the wash basket. The controller chooses the profile from the bowl float level.
[0055] Preferably the maintenance drive profile is also varied according to load size. Again the profile is more vigorous for larger load sizes.
[0056] By way of example in the preferred embodiment of the present invention the preferred controller can adaptively adjust the drive profile from stroke to stroke to try and maintain a drive profile of certain measured characteristics. An example drive profile is illustrated in FIG. 8 . The idealised profile is represented by the solid line. The profile achieved using the control methods described in U.S. Pat. No. 5,398,298 is illustrated by the dot-dash line. The profile includes a ramp where the wash plate speed increases approximately linearly. This ramp is followed by a plateau period. After the plateau period, the wash plate and motor coast to a stop. The stroke is then repeated in the reverse direction. The measured characteristics are plateau speed (w), ramp time and plateau time. A more vigorous profile is characterised by greater energy input. In the measured characteristics this may be indicated by higher target plateau speed and reduced target ramp time while maintaining an overall stroke duration or angular stroke length.
[0057] For example in a test machine the inventors have found the following values for the measured characteristics to provide acceptable results:
[0000]
SMALL LOADS
Initial Profile
Maintenance Profile
Load
Plateau
Plateau
Size
Speed
Ramp Time
Time
Speed
Ramp Time
Time
1 kg
85
332
500
77
321
400
2 kg
89
299
500
80
299
400
3 kg
95
255
500
86
270
400
[0000]
MEDIUM LOADS
Initial Profile
Maintenance Profile
Ramp
Plateau
Plateau
Load Size
Speed
Time
Time
Speed
Ramp Time
Time
3 kg
91
270
375
87
294
275
3.7 kg
96
255
400
91
284
300
5.0 kg
105
248
412
99
277
325
[0000]
LARGE LOADS
Initial Profile
Maintenance Profile
Ramp
Plateau
Plateau
Load Size
Speed
Time
Time
Speed
Ramp Time
Time
5.5 kg
120
228
462
108
262
362
6.5 kg
128
216
488
113
257
375
7.0 kg
130
208
500
116
252
387
[0058] The preferred controller operates an adaptive control where the rate of increase in an applied motor voltage, a point of cutting off this rate of increase, and a period of subsequent steady voltage, are each varied from stroke to stroke based on feedback of the resulting measured characteristics of previous strokes. These adjustments may be made in accordance with the methods set out in U.S. Pat. No. 5,398,298.
[0059] Acceptable wash performance is considered a compromise between achieving regular inverse toroidal turnover of a wash load within the spin basket and wear and tear associated with wash profiles that are too vigorous (and speeds that are too high) or entanglement (angular strokes that are too long).
[0060] In the preferred implementation each of the target measured characteristics for the initial profile is set according to the size of the wash load. The target measured characteristics are also set for the maintenance profile according to the load size. The size of the wash load may be measured in a number of ways known to persons skilled in the art. In the implementation preferred by the inventors the size of the wash load is determined from the level of water in the tub, measured by a water level sensor of any known type, at the water level when the spin basket floats and becomes disconnected from the motor drive shaft. This disconnection may be ascertained by monitoring changes in motor performance which indicate that the motor is no longer directly driving rotation of the spin basket.
[0061] The inventors have ascertained that these target characteristics of their preferred initial drive profiles and maintenance drive profiles can each be modelled as a curve or series of curves. Accordingly, preferred values for use by the microcontroller may be read from lookup tables or derived from appropriate formulae.
[0062] In the traditional deep fill mode there is less contact with the plate. The inverse toroidal laundry movement is started at a low water level preferably the same level as the high efficiency mode using the initial drive profile. However, rather than backing off into the maintenance profile once the inverse toroidal motion is established, for the traditional wash, the controller continues the vigorous profile while continuing to add water.
[0063] To initiate inverse toroidal motion the initial drive profile is preferably applied for from one to three minutes. The maintenance profile is generally sufficient to maintain the inverse toroidal motion once the motion has been established. This reduced vigour profile is more suitable for general wash action on the laundry load without excessive wear.
[0064] However the inverse toroidal motion may be lost, for example due to unusual load distribution or entanglement of laundry items. Accordingly, in the preferred embodiment of the invention the initial, or a similar vigorous profile, is applied for short periods intermittently in the wash cycle.
[0065] The preferred laundry washing machine implementing the present invention includes the capacity to circulate wash liquor from the lower portion of the wash tub to pour or spray the wash liquor onto the laundry load from a location above the laundry load. For example a conduit may lead from the lower portion of the tub to a spray nozzle overhanging the wash basket at the upper edge of the tub. A lower end of the conduit may be supplied with wash liquor from the lower portion of the tub by a pump. The pump may be a separate recirculating pump, or may be the drain pump, with a diverter valve selectively supplying wash liquor to a drain hose, or to the recirculation conduit.
[0066] In the case of this preferred laundry device it is preferred that the inverse toroidal rollover wash pattern is established after an initial period of circulating wash liquor without agitation.
[0067] This period may include the period prior to there being sufficient wash liquid to establish inverse toroidal rollover. For example, in the most preferred machine including floating disconnection between the spin basket and drive shaft, circulation can occur in the period before disconnection. The period of circulation without agitation may go on beyond this initial float period.
[0068] According to a further aspect of the present invention, in a preferred machine with recirculation of wash liquor, the recirculation may be activated during the inverse toroidal rollover wash pattern. The recirculation may be active during establishment of rollover or during maintenance of rollover. In some circumstances the inventors prefer to intermittently activate recirculation during maintenance of toroidal rollover. They consider that this draws water from generally below the wash load and applies this wash liquor to generally above the wash load. This encourages contact between the laundry items and the wash plate. This may be particularly effective in conjunction with the apertures through the wash plate, as this circulation liquid is drawn from wash liquid beneath the spin basket, and this liquid has generally passed through the apertures of the wash plate. The inventors further consider that this may be particularly beneficial in the case of increased water levels, where transfer of wash liquid from below to above the laundry will discourage or counteract floating.
[0069] The curving steep side walls and raised shoulders of the wash plate vanes create enough inward and then upward movement to keep the inverse toroidal motion going even when there is reduced contact between the clothes and the wash plate.
[0070] In summary, wash plate and drive profile design have created a wash system that means both high efficiency and traditional washing modes are possible in the one machine.
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A laundry machine configured to supply a first amount of water to the wash tub wherein a wash plate can be oscillated such that clothes items directly above and in contact with the impeller are frictionally dragged in a oscillatory manner with the wash chamber while continuing to oscillate said wash plate, an additional supply of water is added to said wash tub such that as cloth items lost frictional engagement with the wash plate, the cloth items continue to move along an inverse toroidal rollover path at higher water levels.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of International Patent Application No. PCT/CN2014/086168 with an international filing date of Sep. 9, 2014, designating the United States, now pending, the contents of which are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P.C., Attn.: Dr. Matthias Scholl Esq., 245 First Street, 18th Floor, Cambridge, Mass. 02142.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The invention relates to a method of 5G/WLAN vertical handover (VHO) based on fuzzy logic control.
[0004] Description of the Related Art
[0005] Nowadays, with large-scale deployment of 4G (Fourth-generation Mobile Communication) network and release of 4G licenses, 5G network (Fifth-generation Mobile Communication) research has gradually come into focus.
[0006] There are three technical roadmaps for 5G network: LTE/LTE-A advanced evolution, next-generation WLAN, and revolutionary new technologies. Considering the existing networks, equipment and resources, 5G network is most likely to constantly evolve based on the existing network architectures and towards flattening expansion and enhancement. Through dense deployment and synergic integration of cellular networks having different coverage, network capacity and access transmission speed can be improved, thus, spectral efficiency per unit area and QoS (Quality of Service) can be increased.
[0007] Although a 5G system can provide high coverage and good continuity, there still exist dead zones; meanwhile, with increased number of users and hence interference, cell coverage area will be reduced, resulting in insufficient capacity in hotspots. Whereas WLAN can provide seamless coverage in enterprises, homes and hotspots. As a complement to 5G, WLAN can be advantageously utilized to address indoor networking requirements in hotspots, so that mobile communication network can be improved.
[0008] Traditional handover (HO) decision-making is based on a unique reference metric—RSS (received signal strength), however, VHO in 5G/WLAN heterogeneous networks requires more metrics for decision-making, leading to more complicated HO decision algorithm and difficulties in mathematical modeling.
SUMMARY OF THE INVENTION
[0009] In view of the above-described problems, it is one objective of the invention to provide a method of 5G/WLAN vertical handover (VHO) based on fuzzy logic control. The method evaluates three factors, namely, received signal strength of a mobile node (MN), network bandwidth and degree of user's preference in synthesis to select an optimal network to which HO is performed.
[0010] In the method of 5G/WLAN vertical handover (VHO) based on the fuzzy logic control of the invention, by building a fuzzy logic controller on a MN, and through synthesis-evaluation of the MN's state with a fuzzy logic control system according to different input information and different number of determination factors, HO is performed on the user terminal to the most suitable access network. Specifically, the method comprises the following steps:
[0011] 1) obtaining, by a mobile node (MN), dynamic access-network information from a database of access network discovery and selection function (ANDSF), wherein the dynamic access-network information is obtained from interaction of ANDSF with HSS (home subscriber register) through a newly added interface S0 between ANDSF and HSS;
[0012] 2) from the obtained dynamic access-network information, sorting out and selecting an RSS, an available bandwidth, and a degree of user's preference for WLAN as performance parameters, and monitoring a real-time status of networks;
[0013] 3) when the real-time status of the networks satisfies mandatory user-defined rules, executing a typical handover (HO) directly according to the user-defined rules; when the real-time status of the networks does not satisfy mandatory user-defined rules, triggering a VHO-decision procedure based on a fuzz logic mode:
[0014] 3.1) inputting real-time collected performance parameters into a fuzzification module for fuzzification processing: defining domains ranging from 0 to 1 for the RSS, the available bandwidth, and the degree of UF, respectively, defining three fuzzy subsets over each of the domains, and converting input exact values into fuzzy variable values represented by membership functions;
[0015] 3.2) performing, by a fuzzification inference module, multi-aspect evaluation of the three fuzzy subsets according to “If . . . Then . . . ” fuzzy rules to obtain an aggregation of fuzzy-decision outputs; and
[0016] 3.3) converting, by a defuzzification module, the aggregation of fuzzy-decision outputs into a certain numeric value according to a defuzzification formula, and comparing the certain numeric value with a previously obtained threshold, determining to which candidate access network the handover is to be performed to accomplish one-time of HO procedure; and
[0017] 4) conducting adjustment and control, by the MN, by dynamically updating access-network information, changing rules and varying membership functions, thus accomplishing multi-times of HO.
[0018] In a class of this embodiment, the RSS, available bandwidth, and degree of UF are respectively defined as a domain ranging from 0 to 1, with three fuzzy subsets defined over the domains respectively: for RSS, “0” in the domain indicates that the received signal strength at the receiver end is less than or equal to the minimum threshold, “1” in the domain indicates that the received signal strength is greater than or equal to the maximum threshold, and “0.5” is for the rest cases; for available bandwidth, “0” indicates that the available bandwidth is less than or equal to Min(i), “1” indicates that the available bandwidth is greater than or equal to Max(i), and “0.5” is for the rest cases; and for degree of UF, “0” indicates that the WLAN is not to be chosen by the user in any cases, “1” indicates that the WLAN is favored by the user, and “0.5” indicates a normal degree of favor.
[0019] In a class of this embodiment, the defuzzification module converts the fuzzy outputs into a certain numeric value according to a defuzzification formula, and the defuzzification process employs a center-of-gravity approach and generates an output as follows:
[0000]
out
=
∑
?
?
(
output
j
∏
?
?
u
ij
)
∑
?
?
(
∑
?
?
u
ij
)
?
indicates text missing or illegible when filed
[0020] where, output j is an output of a jth rule, u ij is an ith degree of membership of the jth rule.
[0021] The invention proposes an integrated 5G/WLAN network architecture. Base on Nanocell architecture proposed by China Mobile, integration and interoperability between 5G network and WLAN can be achieved by increasing network entities in access networks. The integration of 5G network and WLAN is a development trend of the next-generation mobile communication, and the key for solving the integration problem is to achieve a seamless VHO between the two heterogeneous networks (i.e. 5G/WLAN) and at the same time keep uninterrupted service on an MN during intercell HO and guarantee quality of service.
[0022] The VHO procedure of the invention comprises three stages:
[0023] 1) collection of needed information for HO: all dynamic access-network information is collected to determine whether intercell HO is required.
[0024] 2) HO decision: it is divided into HO initiation and network selection. The two substages indicate that an HO is initiated at an appropriate time and a most suitable access network is selected according to a decision algorithm.
[0025] 3) HO execution: it refers to channel change, resource allocation, etc., during changing from one network to another network.
[0026] Advantages of the method of 5G/WLAN vertical handover (VHO) based on the fuzzy logic control according to embodiments of the invention are summarized as follows:
[0027] The main idea of the method of the invention is to achieve control of a system, to which a mathematical model is hard to develop, through imitation of human's logic thoughts. Application of a fuzz-logic based control algorithm to a VHO decision can satisfyingly solve the HO decision-making problem in a multi-network coverage scenario. 5G network research is still in its infancy, whereas WLAN is constantly evolving forward, such as high efficient WLAN (HEW), hence there is great uncertainty in integration of the both networks, therefore, when an MN is located in a common coverage area of the two networks, an inter-network HO may occur. The fuzzy-logic based VHO algorithm is advantageous in that it can deal with such uncertain information, and thus can solve aforementioned technical problems, that is, difficulties in development of a mathematical model and complicated HO decision.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The invention is described hereinbelow with reference to the accompanying drawings, in which:
[0029] FIG. 1 illustrates an integrated 5G/WLAN network architecture and deployment of ANDSF;
[0030] FIG. 2 depicts a 5G/WLAN VHO scenario in accordance with the one embodiment of the invention;
[0031] FIG. 3A illustrates a membership function of RSS in accordance with one embodiment of the invention;
[0032] FIG. 3B illustrates a membership function of an available bandwidth in accordance with one embodiment of the invention;
[0033] FIG. 3C illustrates a membership function of a degree of user's preference for WLAN in accordance with one embodiment of the invention;
[0034] FIG. 4 is a schematic block diagram of a fuzzy-logic-controller based system provided by the method in accordance with the one embodiment of the invention; and
[0035] FIG. 5 is a flowchart of the fuzzy-logic-control based VHO-decision mechanism in accordance with the one embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0036] For further illustrating the invention, experiments detailing a method of 5G/WLAN vertical handover based on fuzzy logic control are described below. It should be noted that the following examples are intended to describe and not to limit the invention.
[0037] As shown in FIG. 1 , the invention is applicable for a VHO scenario in integrated 5G/WLAN networks, and the integrated network architecture enables an MN to easily obtain dynamic access-network information and is composed of three parts: an EPC (Evolved Packet Core) core network, an access part (WAG, Wireless Access Gateway) of a traditional WLAN, and a newly added network element (NE). Among them, architectures and networking techniques for access control of the EPC core network and WLAN follow the architectures and functionality of the existing systems.
[0038] Below, the functions of the newly added NE will be described.
[0039] IW5 AP (integration of WLAN/5G, hereinafter referred to as IW5) provides cellular-network access to a terminal, and communicates with the terminal through the air interface Uu. It also provides WLAN access, and communicates with the terminal through a WLAN module. IW5 APs can be aggregated by a local aggregator.
[0040] Local GW, which is an optional function of the IW5 AP, can route forward a user's data through a local network and access IP resources cached in the local network, thus reducing the amount of IP packets to be transmitted to the core network and reducing load of the core network. Content storage and delivery capability will sink to the access network, and feed contents based on analysis of users' demands, thus enhancing user's experience in business.
[0041] IW5 GW performs mutual authentication between AP devices; Signaling messages and data at the S1 interface and messages between AP and network management system are encrypted by IPSec; In the case that a large number of IW5 Aps exist, an integration gateway can perform aggregation in the signaling plane at the S1 interface according to configurations, thus reducing signaling load of Mobility Management Entity (MME).
[0042] IW5 MS, which is used to manage IW5 AP and IW5 GW, has its parameters configured upon AP's start-up, and implements AP performance management (interactive load information) during operation. AP has a list, and MS is responsible for establishing and maintaining the list, MS also collects relevant information and compares the information with the existing information in the list (to prevent a rogue access point). The management server is also responsible for dominating and coordinating a handover procedure, thus preventing reliance on access of an AP to dominate a handover procedure.
[0043] When a MN moves at a constant speed in 5G/WLAN integrated networks as shown in FIG. 1 , as the MN exits 5G network and enters into a hotspot area of WLAN, VHO between the heterogeneous networks will occur; whether and when to perform HO is determined according to the collected performance parameters. Of course, how to obtain these performances is one problem that should be firstly solved.
[0044] In order to enable the network to send access-network information to the MN, for the terminal to implement network discovery and selection, ANDSF has been introduced and discussed in detail in the standards “3GPP TS 24.312 (Release 10)”. The standards “3GPP Release 12/13” still use the concept “ANDSF”, and it can be used for integration and interoperability of 5G and WLAN networks. The invention provides an approach for dynamically updating the access-network-information database of ANDSF, wherein an S0 interface is added between ANDSF and HS S to enable ANDSF to obtain user information within a certain area under current coverage.
[0045] UE interacts with ANDSF through the S14 interface. The S14 interface transmits three types of network-discovery-and-selection policies, namely, ISMP (Inter-System Mobility Policy), AND (Access Network Discovery) information and ISRP (Inter-System Routing Policy). ANDSF has pre-stored access-network information collected in a certain geographic area in its access-network database; when the MN requests access-network information from ANDSF, ANDSF returns static information which cannot be guaranteed in reliability (for example, due to failure of some access points, or access points being no longer suitable for new user's access due to too many users and too much load), the MN needs to scan the obtained access networks to acquire useful information, resulting in increased handover latency and increased power consumption of the user's device. Considering the above factors, it is necessary to dynamically update the information in the database of ANDSF, and the invention proposes a novel approach for that.
[0046] Firstly, ANDSF dynamically updates its access network information database, then, based on the acquired information, evaluates availability ratings of the access networks; the specific procedure is as follows:
[0047] 1) based on a preset cycle period, upon expiration of the period, firstly ANDSF queries HSS through the S0 interface for user information in the area covered by the current access network, and chooses one available MN as the source of information;
[0048] 2) ANDSF sends access-network information query requests through the S14 interface to the chosen MN;
[0049] 3) after receiving the access network information query request, and according to the type of the access network, the MN opens a physical interface to scan the access networks, to acquire current availability information of the access networks, such as, accessibility and load information of the access networks, etc.;
[0050] 4) the MN sends the access-network availability information back to ANDSF, and according to the information, ANDSF evaluates availability ratings of the access networks and starts timing of the next cycle period. In this way, ANDSF can obtain dynamic information of candidate access networks in a certain area, such as network link quality, bandwidth, battery level, mobility speed and user preferences, etc.
[0051] As shown in FIG. 2 , FIG. 2 depicts a VHO scenario under common coverage of 5G and WLAN in accordance with the invention. In the future, there will be tremendous coverage of 5G network, therefore, assuming that a MN is always within a coverage area of 5G network and 5G network signals always exist, the MN can successfully execute HO from WLAN to 5G network at any time, thus the VHO decision problem becomes an issue whether a user in 5G network needs handover to WLAN. When a user moves in 5G/WLAN mixed networks, he will move across multiple WLANs; as he enters a WLAN, a MN may choose WLAN to access services, also may not choose WLAN but keep using 5G network to access services; as the user exits WLAN, he must select 5G network to access services.
[0052] FIGS. 3A-3C shows diagrams of membership functions for the Qos-related influencing factors adopted in the invention, in which Qos is determined by multi-aspect factors: RSS, bandwidth, cost, power consumption and other-aspect factors, each factor has different Qos-influencing index. For simplicity, only two variables—RSS and bandwidth—and degree of UF for WLAN are selected as factors to be considered in HO decision.
[0053] Firstly, a fuzzy logic approach is utilized for information fuzzification processing: the RSS, available bandwidth, and degree of UF are respectively defined as a domain ranging from 0 to 1. starting_input(i) denotes an initial value of an HO variable i, and input(i) denotes the converted value of starting_input(i) in the domain. Min(i) represents the minimum threshold of the variable i, and for RSS, only when the initial input value is greater than the minimum threshold, can a fuzzy-logic based VHO procedure be triggered; For available bandwidth, it represents the minimum access bandwidth that can be received by users; For degree of UF for WLAN, it represents dislike of WLAN. For all the three input variables, Max(i) represents the opposite of what Min(i) represents. For RSS, “0” in the domain indicates that the received signal strength at the receiver end is less than or equal to the minimum threshold, “1” in the domain indicates that the received signal strength is greater than or equal to the maximum threshold, and “0.5” is for the rest cases. For available bandwidth, “0” indicates that the available bandwidth is less than or equal to Min(i), “1” indicates that the available bandwidth is greater than or equal to Max(i), and “0.5” is for the rest cases; For degree of UF, “0” indicates that the WLAN is not to be chosen by the user in any cases, “1” indicates that the WLAN is favored by the user and will choose WLAN as long as a WLAN exists and can provide minimum quality of service, and “0.5” indicates a normal degree of favor. For a numeric value between the minimum and the maximum value, it is converted into the domain by using the following Equation:
[0000]
input
(
i
)
=
starting_input
(
i
)
-
Min
(
i
)
Max
(
i
)
-
Min
(
i
)
(
1
)
[0054] where i represents RSS, available bandwidth, and degree of UF.
[0055] Then, depending on membership functions for the respective input parameters, the three input parameters are mapped into three fuzzy logic variables respectively, and each of the fuzzy logic variables (decision parameters) are converted into one fuzzy subset and input into a fuzzy inference module, in which the three fuzzy subsets are Low, Medium, High; Narrow, Middle, Wide; and Dislike, Normal, Like.
[0056] FIG. 4 is a schematic block diagram of a fuzzy-logic-controller based system provided by the invention, in which each fuzzy logic controller is composed of three basic parts: a fuzzification module, a fuzzy inference module and a defuzzification module. Firstly, a fuzzy logic approach is utilized by the fuzzification module for information fuzzification processing: the RSS, available bandwidth, and degree of UF are respectively defined as a domain ranging from 0 to 1, with three fuzzy subsets defined over the domains respectively: for RSS, the three fuzzy subsets are Low, Medium, High; for available bandwidth, likewise, the system also defines three fuzzy subsets: Narrow, Middle, Wide; For degree of UF for WLAN, the three fuzzy subsets are defined as Dislike, Normal, Like, and membership functions used for the three subsets are derived from empiric values, so, an input exact value is converted into a fuzzy variable value represented by membership function.
[0057] The fuzzy inference module performs multi-aspect evaluation of the input fuzzy subsets according to “If . . . Then . . . ” fuzzy rules, and thus obtains an aggregation of fuzzy-decision outputs. Because the invention defines three fuzzy variables and three different fuzzy sets “low”, “medium” and “high”, the number of fuzzy rules is up to 33=27. The invention employs a Sugeno-type fuzzy control system, which determines the fuzzy-rule outputs as a certain numeric value. The larger the numeric value is, the higher degree of membership to the current AP the MN has; the smaller the numeric value is, the lower degree of membership the MN has. The invention classifies the 27 rules into 9 cases, and the specific fuzzy rules are described as below:
[0058] If RSS=L and B=W and Favor=L, then output is 1,
[0059] If RSS=L and B=M and Favor=L, then output is 2,
[0060] . . .
[0061] If RSS=H and B=N and Favor=D, then output is 9.
[0062] The defuzzification module converts the fuzzy outputs into a certain numeric value according to a defuzzification formula, since the fuzzy-rule inferred outputs are fuzzy quantities. There are many defuzzification approaches, and the invention employs a center-of-gravity defuzzification approach, and the defuzzification formula is as follows:
[0000]
out
=
∑
?
?
(
output
j
∏
?
?
u
ij
)
∑
?
?
(
∑
?
?
u
ij
)
(
2
)
?
indicates text missing or illegible when filed
[0063] where, output j is an output of a jth rule, u ij is an ith degree of membership of the jth rule.
[0064] As shown in FIG. 5 , the fuzz-logic based 5G/WLAN VHO method according to the invention specifically comprises the following steps:
[0065] 1) A MN obtains dynamic access-network information from database of ANDSF, and the information is not prestored static information but new dynamic information obtained from interaction of HSS with ANDSF through a newly added interface S0 between ANDSF and HSS;
[0066] 2) If all of received signal strength, available bandwidth, QoS, distance, costs, battery level and moving speed, etc. are taken as evaluation metrics, the proposed handover algorithm would be of high degree of complexity, resulting in increased system load, slowed processing speed and hence increased hardware requirements; therefore, the choice of input parameters is particularly important. So far, there is still no literature which brings up quantitative analysis on choice of parameters.
[0067] System performance parameters directly related to RSS (received signal strength) include: SNR (Signal to Noise Ratio at receiver end), SIR (Signal to Interference power Ratio) and SINR (Signal to Interference Noise power Ratio), etc. Typically, a larger RSS indicates a higher SNR or the like parameter. Considering that RSS has encompassed considerations of SNR and other above-mentioned parameters, RSS should be adopted as a decision metric.
[0068] Call blocking rate and outage probability of a communication system are important indicators of the system performance Some studies on VHO algorithms also adopt call blocking rate as one of the main considerations. In a cellular network, insufficient available bandwidth of a system is the main reason for occurrence of call blocking rate and outage probability. In WLAN, when number of users is large whereas system bandwidth resources are scarce, competition mechanism in MAC (Media Access Control) layer will cause blocking of users' calls, business interruption and call delay, etc. Since system available bandwidth fully reflects current traffic load of system with respect to total capacity of system, it to some extent determines magnitude of call blocking rate and outage probability of the system. Therefore, in VHO algorithm design, if system available bandwidth is adopted as one of input parameters, then it has encompassed considerations of call blocking probability and outage probability and other like parameters.
[0069] In the future, there will be tremendous coverage of 5G network, therefore, assuming that a MN is always within a coverage area of 5G network and 5G network signals always exist, the MN can successfully execute HO from WLAN to 5G network at any time, thus the VHO decision problem becomes an issue whether a user in 5G network needs handover to WLAN. In some cases, even when a user is in a coverage area of WLAN and at the same time the WLAN can provide good quality of service, the user however may not want to choose WLAN. There are a variety of reasons for that: the user may not want to cause loss of data packets in HO procedure, or the user dislikes the time delay brought by HO procedure, or the user dislikes the security issue brought by HO procedure, or the user himself has no particular favor for WLAN, etc.; in a word, a user has right not to select WLAN, as long as the original network meets their current needs. Therefore, the degree of UF for WLAN must be adopted as a factor to be considered in HO decision.
[0070] In consequence, the invention selects, from the dynamic information obtained by the approach described above, three variables, namely, received signal strength, available bandwidth and degree of UF for WLAN, for fuzzification processing.
[0071] 3) The VHO-decision procedure firstly detects whether there are mandatory user-defined rules (in the case of a time critical service where RSS is below the threshold), if it is true, then a typical HO is executed directly according to the user-defined rules, otherwise the VHO-decision procedure enters into a fuzz-logic based mode;
[0072] 4) The real-time collected performance parameters are input into a fuzzification module for information fuzzification processing: the RSS, available bandwidth, and degree of UF are respectively defined as a domain ranging from 0 to 1, with three fuzzy subsets defined over the domains respectively, so as to convert input exact values into fuzzy variable values represented by membership functions;
[0073] 5) A fuzzification inference module performs multi-aspect evaluation of the input fuzzy subsets according to “If . . . Then . . . ” fuzzy rules, and thus obtains an aggregation of fuzzy-decision outputs;
[0074] 6) A defuzzification module converts the aggregation of fuzzy-decision outputs into a certain numeric value according to a defuzzification formula, in which a Sugeno-type fuzzy control system is utilized to output a certain numeric value, and according to the certain numeric value, determines whether HO is performed to candidate access network or staying in the original network. If the output out is less than 0.4, indicating that at this time it is best for the MN to select 5G network; If the output out is greater than 0.6, indicating that at this time it is best for the MN to select WLAN; If the output out is between 0.4 and 0.6, the MN stays in the original network, and with such mechanisms, HO frequency can be reduced, thus avoiding ping-pong HO effect which would otherwise deteriorate HO performance;
[0075] 7) The MN conducts adjustment and control by dynamically updating access-network information, changing rules and varying membership functions, thus accomplishing multi-times of HO.
[0076] Unless otherwise indicated, the numerical ranges involved in the invention include the end values. While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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A method of 5G/WLAN vertical handover based on fuzzy logic control, the method including: 1) obtaining, by a mobile node, dynamic access-network information from a database of access network discovery and selection function; 2) from the obtained dynamic access-network information, sorting out and selecting an RSS, an available bandwidth, and a degree of user's preference for WLAN as performance parameters, and monitoring a real-time status of networks; 3) when the real-time status of the networks satisfies mandatory user-defined rules, executing a typical handover directly according to the user-defined rules; when the real-time status of the networks does not satisfy mandatory user-defined rules, triggering a vertical handover-decision procedure based on a fuzz logic mode; and 4) conducting adjustment and control, by the MN, by dynamically updating access-network information, changing rules and varying membership functions.
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This is a continuation of application Ser. No. 439,210, filed Nov. 3, 1982 now U.S. Pat. No. 4,627,001 issued Dec. 2, 1986.
CROSS REFERENCE
Reference is made to a microfiche appendix containing 16 microfiche and 750 total frames.
BACKGROUND OF THE INVENTION
The invention relates to editing voice data.
SUMMARY OF THE INVENTION
The invention features a system for processing information having continuous signal acquiring means for acquiring a continuously varying electrical signal corresponding to voice message, digitizing means for digitizing said continuously varying electrical signal, to produce discrete voice data corresponding to the audible quality of said voice message, discrete data acquiring means for acquiring discrete data corresponding to alphanumeric characters, discrete signal acquiring means for acquiring discrete signals including editing and control commands, memory for storing data in discrete form, display means for creating visible display, and a processor, all being operatively interconected by control leads and data transfer channels, with an operating program for said processor being stored in said memory such that said processor controls the operation of said system so as to: store said discrete voice data in said memory concurrently with acquiring voice message, store said character data in said memory concurrently with entry of characters, establish a sequence record in said memory indicating a unified order of voice message and character data, display visibly a sequence of voice token marks and character marks, each token mark representing a predetermined increment of acquired voice message and each character mark corresponding to one of said entered characters, said displayed sequence corresponding to the sequence in said record, and revise, responsive to entered editing commands, said sequence record to reflect editing changes in the order of voice and character data.
The invention may additionally feature an operating program such that said processor additionally controls the operation of said system so as to: respond to predetermined discrete signals acquired concurrently with acquiring voice message, to indicate in the sequence record the point when each said predetermined discrete signals was acquired; display in said visible display a distinguishable indication of when each such concurrently acquired signal was acquired with respect to other elements of the voice data; establish in memory a pointer defining a pointer position in the sequence of data, display a visible mark in said display corresponding to said pointer position; move, responsive to input signals acquired, said defined pointer position in said sequence and correspondingly in said display; generate, responsive to input signals acquired, a continuously varying audio signal corresponding to said discrete voice data stored in memory, such generating starting at a point in said voice data sequence corresponding to said defined pointer position as then defined and following the order as then defined in said sequence record; and advance said pointer through said voice message data correspondingly to the progress of generation of audio signal. The invention may also feature circuitry for sensing audio acquisition activity and in absence of activity suppressing storing of voice message data in said memory.
The invention provides an author with a visible, graphic picture of the structure of his dictation with indications which he may insert of paragraph or other functional divisions. It permits an author to edit his dictation with great flexability: moving, deleting, inserting, and playing back while the display presentation helps him keep track of the editing and pin point where to make editing revisions. The invention also permits the author to enter from a keyboard interpolated notes and instructions into his dictated record.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system in which the invention is implemented;
FIG. 2 is a display in the system of FIG. 1 showing the user interface of the invention.
DETAILED DESCRIPTION
Voice data editing system 10 according to the invention includes connections 12 for acquiring and delivering a continuously varying electrical signal corresponding to voice message. An acquired signal may be derived from a microphone 50, or a telephone line 52 operating through interfacing circuitry 54 as shown by way of illustration in the Figure, or in other ways. The delivered signal may be used to drive a speaker 56 as illustrated or in other ways. Connections 12 are connected to analog-digital converter 14, which converts in either direction. Converter 14 in turn connects to serial-parallel converter 30 operating in both direction. Audio sensor 28 is connected to connections 12 and functions to emit a control signal distinguishing when there is activity on the voice acquision channel. Also included in system 10 are visible display unit 31 which may advantageously include a CRT screen, and keyboard unit 16, which has a section 18 for entry of alphanumeric characters and a section 20 for entering editing and control signals.
System 10 also includes processor 26, which may be model Z-80 manufactured by Zilog and memory 22 for storing data in bit form and which has a section 24 which contains an operating program stored therein. All the elements of the system described above are interconnected through data bus 58, address bus 60, and control leads 62, as indicated in the Figure. All of the elements of system 10 described above are conventional commercially available items and the manner of interconnecting them is well known to those skilled in the word processing art.
The voice editor operating program stored in memory, in conjunction with the processor 26, controls the operation of the system in performing all of the voice editor functions. As an author using the system speaks into a microphone the voice message acquired by the system as an analog signal is digitized and entered into memory in discrete form. At the same time a representation of the voice message using a series of voice tokens 90 each representing one second of voice message is generated and displayed on the CRT. During voice pauses, entry of data is suppressed to avoid waste of memory capacity. Concurrently with dictating, the author may enter break signals at the keyboard which generate memory pointers indicating when in the data record the entry was made, and causing succeeding voice tokens to be displayed starting with the next display line, simulating a paragraph break. At the same time a marginal number is generated to permit easy identification of the break. The author may also with a keyboard-entered signal interrupt dictation and enter from the keyboard alphanumeric text. This text is entered into memory and displayed (92) on the CRT display.
The system operating under the control of the program maintains a record indicating a unified sequence of voice data, textual data, and break indications. Initially the order of this sequence is the temporal order in which the data is acquired by the system. The system also generates a memory pointer indicating a pointer position in the data sequence. A cursor mark (94) is displayed in the display at a corresponding position. The author can manipulate this linked pointer and cursor mark to designate any particular point in the unified data sequence. Using the cursor and keyboard editing signals including "insert", "delete", "replace", "move", and "copy", the author can effect all these editing functions, applying them indiscrimately as to whether the data is voice, textual or marks. The presentation in the display reflects all editing changes as they are made. The author can also, using the cursor and keyboard entered signals, cause playback of the voice message to any connected audio device.
A more detailed description of the program operation is given below and the program is set forth in the referenced appendix.
A voice editor operating program is stored in memory 22 and in conjunction with the processor 26 controls the operation of the system in performing all of the voice editor functions. The voice editor program makes use of a routine queue, and subroutines called by the voice editor are first thrown onto the routine queue, and subsequently executed when the processor gets around to it. With such a queue, an interrupt handler queues up a subroutine to deal with the interrupt, and then immediately reenables interrupts and returns. The subroutines get entered on the queue and are handled by the processor at its leisure. A routine queue module contains subroutines to manipulate the voice editor routine queue. They are:
RTN$QUE$INIT: Initializes the routine queue.
RTN$QUE$PUSH: Pushes a procedure address and an address parameter onto the routine queue.
RTN$QUE$RUN: Checks to see if a procedure/parameter pair is on the queue. If there is, it will call the procedure, passing it the single address parameter.
The main line voice editor program is quite simple because of the voice editor routine queue. The voice editor main line performs two functions: (1) It calls an initialization routine, voice$editor$init, to initialize all of the data structures and hardware io devices used by the voice editor. (2) It then loops forever, calling RTN$QUE$RUN to execute any subroutines on the routine queue. If the user indicates that he wants to exit the voice editor, for instance, the procedure EXIT$EDITOR is pushed onto the routine queue. The processor calls this routine as soon as it can, causing the voice editor to return to the calling application.
From the above discussion, it can be seen that once the voice editor is entered and it initializes variables and hardware, it just loops waiting for something to appear on the routine queue. Interrupt proceedures are used to put something on that queue. Interrupt procedures are run when a hardware interrupt occurs. When this happens, the processor disables interrupts, pushes the current program counter on the stack, and vectors to a procedure to handle the interrupt.
The voice editor runs in Z80 interrupt mode 2 and recieves interrupts from the following devices, listed in order of interrupt priority:
1. CTC channel 0 Block Count--this channel produces an interrupt when the audio hardware has just completed recording or playing a buffer of digitized audio.
2. CTC channel 1 Phone Ring--this channel produces an interrupt each time the telephone rings.
3. CTC channel 2 Keystroke--the voice editor programs this channel to interrupt every time a keystroke is received.
4. CTC channel 3 Timer--the voice editor programs this channel to interrupt every 10 ms (0.10 seconds).
The address of the interrupt handlers for the above devices are located in an interrupt vector table in memory. When any one of the above devices generates an interrupt, the corresponding address in the interrupt vector table is called.
The voice editor interrupt handers are found in two modules, the interrupt module and the io handlers module.
The interrupt module is just a bunch of assembly level routines, one for each interrupting device. They all save the registers on the stack, call a PLM procedure, and then restore the registers, enable interrupts and return. The handlers are:
audio: CTC channel 0 handler, calls PLM procedure AUDIO$INTERUPT.
ring: CTC channel 1 handler, calls PLM procedure RING$INTERUPT.
KEYHNDLR: CTC channel 2 handler, performs an IN (00) to get entered keystroke, saves this in variable RAWKEY, calls PLM procedure GOT$KEY.
timer: CTC channel 3 handler, calls PLM procedure TEN$MS$TIMER.
The io handlers module contains PLM procedures that do most of the interrupt handling. It also contains a few other miscellaneous routines. The interrupt routines are briefly described below:
RING$INTERUPT: Pushes a procedure onto the routine queue that will display the message `Your phone is ringing, please press TAB`.
GOT$KEY: Typically just pushes procedure KEY$DISPATCH onto the routine queue. KEY$DISPATCH actual handles the keystroke.
TEN$MS$TIMER: Calls other PLM procedures which causes periodic checks on certain conditions.
Almost all voice editor functions are initiated when the user presses a keystroke. The voice editor uses a table-driven mechanism for deciding which procedure to call in response to a given keystroke.
The workstation keys are divided up into 16 different classes. Each class is assigned a number from 0 to 15. No key can appear in more than one class. The class numbers and keys in each class are listed below.
______________________________________Class Number Description Keys______________________________________1 record key class INSERT2 stop key class STOP3 play/stop key class Space Bar, (HOME)4 cursor class North Cursor, East Cursor, South Cursor, West Cursor.5 go to class GO TO PAGE6 number class 0 through 97 text class A-Z, a-z, comma, period, ! # $%¢&*()- = + ] [ ; : ' " ?8 back space class Backspace Key9 mark class RETURN, NOTE10 renumber class11 edit class DELETE, REPLC, MOVE, COPY12 execute class EXECUTE13 cancel class CANCEL14 help key class COMMAND, (HELP)15 phone key class TAB0 invalid key class All other keys______________________________________
There is a translation table that converts raw hardware key is in sector into the corresponding class number (0-15). This table zero of the file `VOICE.CLASSTBL`. Sector one of this file contains the standard pre-WISCII keystroke translation table. It is important to note that the class table is shift-independent. Both CANCEL and SHIFT CANCEL are in the cancel class (13) for instance. This doesn't affect upper and lower case test characters, though, as both are in the text class (7).
The editor is divided into different operating states. The keys may have different meanings depending on the value of the current state , so for state a procedure table is defined. These procedure tables are called state tables. The state tables are defined in the state table module.
The voice editor state tables contain indexes into a large table of procedures. This table can be found in the routine table module containing 36 entries.
When first entering the editor, the main state is the current operating state. As new operating states come into effect, the old states, along with an index of the current prompt on the screen, are pushed onto a state stack. Let's say that while in the main state, the user presses the DELETE key. The main state is pushed onto the state stack and the segment definition state now becomes the current state. The prompt "Delete What?" appears on the screen.
Now assume the user presses the GO TO PAGE key. The segment definition state is pushed onto the stack, and the prompt is also pushed onto the state stack. The new state is the go to state. The prompt "Go to where" appears on the screen. The user types in a number, and presses EXECUTE. A procedure to go to the number is called.
At this point the segment definition state and the prompt is popped off the stack. The prompt "Delete What?" is again displayed on the screen. The user keys EXECUTE, and a procedure is called to delete the highlited portion of the voice file. The main state is then popped off the stack, and we are back to our original operating state.
In addition to the state tables themselves, the state table module also contains procedures to manipulate the state stack. These procedures are:
INIT$STATE: Initialize the state stack.
NEW$STATE: Pushes the old state onto the stack, makes the specified state the current state.
POP$STATE: Pops a state off of the stack, making it the current state.
The state table module also contains a routine that, given a class number, will return the address of the procedure that corresponds to that class for the current state:
ROUTINE$ADDR: Given a class, this procedure looks up in the current state table the address of the procedure that corresponds to that class.
The decision to call a particular procedure is summarized thus:
(1) Keystroke interupt
(2) KEYHNDLR saves registers, putss hardware key code in variable RAWKEY, calls GOT$KEY.
(3) GOT$KEY performs the following:
(a) if a fatal error has occured, exit.
(b) if SHIFT$PAGE was typed, perform a dump.
(c) if we haven't processed the previous key yet, discard this one.
(d) push address of procedure KEY$DISPATCH along with parameter RAW$KEY on the routine queue.
(4) KEY$DISPATCH is popped off routine queue and executed, performing the following:
(a) translate keystroke using translation table.
(b) using class table, get class number for this key
(c) If the high bit off the class number is zero, click on this keystroke.
(d) clear any error messages
(e) With the exception of RETURN and play/stop class, stop the audio
(f) Call ROUTINE$ADDR, passing it the class, to get the address of the procedure we should dispatch to.
(g) Push this procedure address and the translated keystroke onto the routine queue.
(5) The proper routine along with the translated keystroke are popped off the routine queue and run.
Further procedures can be roughly divided into two parts. There are low level modules for each data structure that perform operations on that structure. Typical lower level modules are the file index (audio index, mark table, note table), audio functions, and the screen.
The second part are the high level routines. These procedures are typically called by the keystroke dispatch mechanism (there addresses are in the routine table) and themselves call the lower level routines that do most of the work. Hence they can be thought of as an interface between the keystroke handling routines and the low-level workhorse procedures.
The user interface module (V:voice.rrr.plm.ve.userint) contains high level audio, section marking, and renumbering procedures:
PLAY$STOP: Called whenever a key in the play/stop class is entered. If the audio is currently stopped, it moves the cursor to the beginning of the next audio sector and starts playing. If the audio is currently playing or recording, it stops the audio.
INSERT$MARK: Called when a key in the mark class is entered. If a section mark was entered, figures out it's exact position on the screen and calls the appropriate window module routine to enter it. If the note key was pressed, it checks to see if the cursor is currently on a note. If not, it creates one. In either case, text mode is entered.
RENUMBER: Called when a key in the renumber class is pressed. The editor is put in the renumber state and the prompt "Renumber Marks?" is displayed.
REN$EXECUTE: Called when EXECUTE is pressed while in the renumber state. Calls a mark table procedure to renumber the marks, redisplays the screen, and pops the previous state off the stack.
REN$CANCEL: Called when CANCEL is press while in the renumber state. Pops the previous state off the stack.
The backspace module implements the backspace function. Pressing the backspace key causes the cursor to back up five seconds and play for five seconds. Pressing N times causes the cursor to back up N * 5 seconds and play for the same amount of time. During playback, pressing any key other than backspace stops playback, completely canceling the backspace function. When the backspace key is pressed, there is 350 milliseconds before starting to play. This is so the user has time to repeatedly press the backspace key before playback starts. The backspace module uses three variables to accomplish these functions:
bs$mode TRUE if we are backspacing, FALSE other wise.
bs$time The cursor time when the user first pressed BACKSPACE. No matter how many times it is pressed, we will play up to but not beyond this position.
bs$play$cnt A counter decremented by the ten$ms$timer. Used the count the 350 ms waiting time.
The backspace function exports the following procedures:
BS: Called when the backspace key is pressed. If first time pressed, set bs$mode to TRUE and remember bs$time. Initialize bs$wait$time to 350 ms.
BS$WAIT$COUNTER: Called every 10 ms by TEN$MS$TIMER. This procedure decrements bs$wait$time, and after 350 ms have elapsed, it pushes a procedure onto the routine queue that will play from the current cursor position to bs$time.
BS$KEY$CHECK: Called by KEY$DISPATCH, this procedure cancels backspace mode if a key other than backspace is entered.
The cursor module is has all of the high level cursor functions. Again, these procedures are just interfaces between the key dispatching and the screen routines that actually move the cursor around the screen.
CURSOR$RTN: Called in most states when a key in the cursor class is pressed. It just calls one of four screen routines, depending on which cursor key was pressed.
GO$TO$RTN: Called when the the GO TO PAGE key is pressed. It pushes the old state on to the stack and causes the current state to be the `go to` state. It displays the "Go to Where?" prompt and moves the cursor to just after the prompt. Note that at message file translation time, this prompt should be right justified.
GO$TO$EXIT: This procedure is called when CANCEL is pressed while in the GO$TO$STATE. It repositions the cursor back in the audio/mark portion of the screen and pops the previous state of the stack.
GO$TO$CURSOR: Called when one of the cursor keys is pressed while in the `go to` state. It calls one of four screen routines depending on which cursor key was entered. It then calls GO$TO$EXIT to return to the previous state.
GO$TO$ACCEPT$NUM: Called when a key in the number class is typed while in the `go to` state. This procedure displays the number on the screen just after the prompt, and updates the cursor position.
GO$TO$EXECUTE: Called when EXECUTE is pressed while in the GO$TO$STATE. If there is a number on the screen, it converted from ASCII to binary and a screen routine is called to position the cursor underneath the appropriate mark. It then calls GO$TO$EXIT to return to the previous state.
The text entry module contains routines for entering text notes while in the test mode. The following variables are used:
text$buffer (60): buffer for holding the text note while entering it.
tindex: current position (0-59) in the text buffer.
tcursor: current screen position of the cursor
note$index: index into the note table of the text note currently being worked on.
first: A flag, TRUE if the note being entered was just created. If it was, then if CANCEL is pressed, we will delete this note. If it is an old note being modified, then pressing CANCEL will just restore the note to its original form.
The following routines are exported:
TEXT$SET$FIRST: Called by INSERT$MARK to tell the text entry module that this note was just entered.
TEXT$MODE$ENTER: Called by INSERT$MARK when the NOTE key is pressed. Pushes old state, sets up new `text` state. Displays prompt "Enter Text". Grabs note from note table, puts it in text buffer.
TXT$CANCEL: Called when CANCEL is pressed while in the `text` state. If we have been entering a new note, this note is deleted. Otherwise we discard the text buffer, and redisplay the screen with the old note intact. Restores previous state.
TEXT$EXECUTE: Called when EXECUTE is pressed while in the `text` state. Replaces the old note with the contents of the text buffer. Restores previous state. TEXT$CURSOR: Called when a cursor key is pressed while in the `text` state. Moves the cursor forward or backward. Displays error message if North Cursor or South Cursor is pressed.
TXT$BACK$SPACE: Called when the backspace key is pressed while in the `text` state. Moves cursor back one position, then erases the character it is under.
TXT$ENTRY: Called when a key in the text, number, or play/stop class is pressed. Enters the character into the text buffer and onto the screen and advances the cursor one position.
TEXT: Called when a text key is hit in while in the `main` state. If the cursor is on a note, it enters text mode and enters the struck key into the text buffer and onto the screen. If the cursor is not over a note, it displays the message "Move Cursor".
The edit module provides an interface between the key dispatch mechanism and the lower level screen in file index rountines that actually perform the manipulations on the file.
The edit module keeps track of what parts of the file are being edited. A point structure is used to located positions in the file. This structure is of the form:
______________________________________ point structure ( time address, index byte)______________________________________
where time is the elapsed time into the file, and index is the mark index of the current, or if there is no mark at this position, the next mark in the file.
The following point structures are used to keep track of positions while editing:
begpoint: the begining of a segment to delete/move/copy
endpoint: then end of a segment to delete/move/copy
destpoint: the destination point for a move/copy.
To delete a portion of the file, the segment between begpoint and endpoint (inclusive) is removed from the file:
To move or copy a portion of the file, the segment between begpoint and endpoint (inclusive) is moved or copied to destpoint:
When inserting into the file, destpoint gets the insertion point. The current end of file in begpoint, recording is started at the end of the file:
When the user presses STOP, the program performs a move as described above, moving the segment delimited by (begpoint, endpoint) to destpoint.
To replace a segment of the file, three additional point structures are used:
rbegpoint: contains the beginning of the segment to delete.
rendpoint: contains the end of the segment to delete.
rbegpoint: contains the beginning of the segment to insert.
The replace procedure works as follows: Initially we define the segment to replace between begpoint and endpoint. After the segment is defined, we copy begpoint to rdestpoint, endpoint to rendpoint, and set the rbegpoint to the end of file. We then go through the standard insert procedure, recording at the end of the file. As with insert, when STOP is keyed, the new material, segment (begpoint, endpoint), is moved to the insertion point, destpoint, completing the insert. During the replace, the user can insert, play, move the cursor keys, and enter section marks and text notes. All inserts are performed in the normal way, using begpoint, endpoint, and destpoint. Of course, all inserts are restricted to beyond rbegpoint.
If the user presses CANCEL, the replace is canceled by reseting the end of voice file time to rbegpoint, restoring the file to it's original form.
If the user presses EXECUTE, the replace is executed by first deleting the segment (rdestpoint, rendpoint) and then assigning rdestpoint to destpoint, and the end of file to endpoint and then performing the insert by using a normal move of the segment (begpoint, endpoint) to destpoint.
The audio functions module contains routines to play and record into voice files. It makes use of a companion module, the io module which contains data structures and procedures to manipulate the buffers and queue requests to the master.
When playing or recording, audio data must be buffered so that playing or recording is not interrupted by waiting for a buffer write or read to complete. The audio workstation software is designed use at least two buffers, but more may be used as space allows. Currently, the audio workstation uses 6 audio buffers.
The voice editor uses buffers that are from one to 16 sectors in length. These buffers are page aligned in memory. Each buffer corresponds to an audio block in the voice file. The io module contain structures called info structures, that manage the audio buffers. The io module contain a io request queue, which is used to queue up RCBs. The ten ms timer checks this queue every 10 ms. If something is on it, the timer procedure itself will pop the request off the queue and present it to the master.
The io request queue uses the following data structures:
queue: an array of addresses, this is the io request queue.
top: index of the top of the queue
bottom: index of the bottom of the queue
count: the number of elements in the queue
The following routines manipulate the queue.
IO$PUSH: Push the address of an RCB onto the io request queue.
POP$AND$SEND If there is anything on the queue and the SCA is clear, pop the RCB address off the queue and put it in the SCA. This procedure is called whenever we first push something on the queue (try to pop it off immediately). It is also called every 10 ms by the TEN$MS$TIMER procedure.
Because the voice editor only inserts recorded data, it does not overstrike, recording always starts at the end of the file. Inserted data is recorded at the end of the file and then moved to the insertion point.
To record, the following steps are performed:
(1) start with the 6th info structure.
(a) fill in the first buffer address
(b) fill in the buffer size
(c) if we are recording into the last block in the file, set the stop flag.
(2) give the hardware the address of the first buffer
(3) tell the hardware to start recording.
(4) Perform this procedure:
(a) tell the hardware the size of the buffer it is currently recording into.
(b) Queue up a write request for the preceding buffer, if this is not the first buffer.
(c) If stop flag is set for this buffer, stop.
(d) Check to see that any past write request for this buffer have completed, if not, stop the audio until the request has completed.
(e) Fill in the RCB for this buffer.
(f) Increment variables so that we are ready to process next buffer.
After hardware finishes recording into the first buffer, a block count interrupt is generated (CTC channel 0). When this occurs, the procedure AUDIO$INTERUPT is called. This procedure checks to see if play or record mode is in effect, and calls a play or record interrupt procedure. Step (4), above, is the record interrupt procedure, RECORD$INTERUPT. As recording progresses, it gets called every time a buffer completes.
Playback is similar to record. We perform some initialization, and then tell the hardware to start playing. Immediately we call the PLAY$INTERUPT routine. As each buffer is played out, PLAY$INTERUPT is called again to prepare the next buffer for playback and queue up a request to read another buffer from the disk.
When recording, the sample rate is always set to the literal SMP$RATE, which defines the sampling rate. During playback, however, the sample rate can be changed. Every 10 ms, the procedure SET$RATE is called by the TEN$MS$TIMER procedure. This procedure calls a routine to convert the current setting of the speed control to the appropriate sample rate. The hardware is then given the value of this sample rate.
The voice editor screen is divided up into two sections, the status portion and the audio/mark portion. The status portion consists of the first two lines and the last line of the screen. This area is used for displaying prompts, the cursor time, length, etc. The audio/mark portion, which consists of lines 3 through 21, is used to display the contents of the voice file, i.e. the audio blocks, text notes, and section marks.
The display module controls the status portion of the screen. In addition, all MENUPACK procedures are found in this module. It contains procedures to initialize menupack, display the cursor time, audio mode, help reminder, phone mode, title, prompts, length, and error messages.
The window module contain the routines to display and update the audio/mark portion of the screen. This module is assisted by the following modules:
______________________________________convert (V:voice.rrr.plm.ve.convert) Positional structure conversion routinestime (V:voice.rrr.plm.ve.time) Time-position conversion routinesline (V:voice.rrr.plm.ve.line) Line structure implementationregion (V:voice.rrr.plm.ve.region) Editing indexes finderscroll (V:voice.rrr.plm.ve.scroll) Low level window manipulations______________________________________
The voice file consists of a header, mark table, note table, sector map and block map. The following modules contain routine to access the voice file:
______________________________________fileindx (V:voice.rrr.plm.ve.fileindx) File index implementationeditindx (V:voice.rrr.plm.ve.editindx) File index editing operationsmark (V:voice.rrr.plm.ve.mark) Mark table implementationnote (V:voice.rrr.plm.ve.note) Note table implementationvoicegrm (V:voice.rrr.plm.ve.voicegrm) Voice file create, initialize and clean up routinesextend (V:voice.rrr.plm.ve.extend) Voice file extend and truncate routinesfatal Fatal error, ABEND handler______________________________________
The Error Module contains procedures for ABENDs, fatal errors and non fatal errors. A flag, DUMPFLAG, set in the link, is used to determine whether an error will result in a dump or not. If DUMPFLAG is 0FFh, then dumps are enabled. If it is 0, then dumps are disabled.
The exported procedures are:
NON$FATAL$ERROR: Dump if flag set, display VE error: XXX, where XXX is a passed in error number. These error numbers are defined in (V:voice.rrr.lit.ve.ERR). Also display 16 byte data portion (typically an RCB) if passed as a parameter.
INFORM$ERROR: Display non-VE error message, after any key is hit, return to calling application. Non VE error messages are just the standard errors such as "Move Cursor" that are displayed on the lower portion of the screen. These are defined in (V:voice rrr.lit.ve.MERROR).
FATAL$ERROR: Identical to NON$FATAL$ERROR except that this is non recoverable. After the user presses any key, the editor returns to the caller.
The voice editor recovery mechanism will recover from workstation power failures or inavertant IPLs during the recording proccess. The voice editor makes use of some common data structures, and three modules contain implementations of and routines to manipulate these structures.
The routine queue uses these procedures:
QUE$INIT: This procedure defines a queue. The user specifies the address of the queue, the size of the queue, the size of each element in the queue and a pointer to a structure which holds all of the salient features of the queue. This structure identifies the queue. It must be passed as a parameter to the push and pop routines described below.
QUE$PUSH: This procedure pushes an element onto a specified queue.
QUE$POP: This procedure pops an element off the head of a specified queue.
The stack module (V:voice.rrr.plm.ve.stack) is an implementation of a stack with push and pop routines. The state table module stack uses procedures from the stack module to implement the state stack. Unlike the queue module, the stack module routines can only operate on a single stack, defined in the module as follows:
stack (12): byte The space reserved for the stack.
sp: The stack pointer.
Two routines manipulate the stack:
PUSH: Push an element onto the the stack.
POP: Pops an element off of the stack.
The bit map module (V:voice.rrr.plm.ve.bit) can set, clr, and test bits in a user specified bit map. The map cannot be larger than 256 bytes. The mark table uses a bit map to determine the number of the next section mark to create. The file index editing module uses a bit map to order all free blocks in the index so that file extends are performed optimally. The bit map module contains the following procedures:
BIT$SET: Sets a bit in a bit map.
BIT$CLR: Clears a bit in a bit map.
BIT$TEST: Tests a bit to see if it is set or cleared.
All of the PLM INPUT and OUTPUT statements for the voice editor are contained in the audio hardware control module (V:voice.rrr.plm.ve.audioctl). This module contains small procedures that act as an interface between the hardware and the bulk of the voice editor PLM code.
The set interrupt mode module (V:voice.rrr.z80.ve.setimode) contains two procedures, one to set up the workstation for interrupt mode 2 and the other to reset it back to interrupt mode 0. The PLM routines, INIT$WORKSTATION and RESET$WORKSTATION, found in the audio hardware control module, call the two routines in the set interrupt mode module. The very first bytes of this module contain the interrupt vector tables for the CTC and PIO. These tables must reside on a factor-of-eight boundary in memory, so care must be taken in the link map.to see that this is done.
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In a system for editing documents having text and voice components, portions of a document are selected by cursor control to display text characters and associated voice symbols or tokens representing the voice component position and time-length.
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BACKGROUND OF THE INVENTION
The present invention resides in the removal of chlorate from caustic solutions with iron and the consecutive recovery of said iron in metal form.
The removal of unwanted excess chlorate in sodium hydroxide solutions obtained from the diaphragm electrolysis of brine is carried out by using reducing agents, a number of which have been described, including iron. Thus, U.S. Pat. No. 2,404,453 discloses the reduction of chlorate in sodium hydroxide solutions containing about 50 percent NaOH using iron in comminuted form (chips or turnings), said iron particles being coupled with a more noble metal such as copper. Also, U.S. Pat. No. 2,403,789 discloses the purifying of 30-60 percent NaOH solution from excess chlorate by means of iron powder or filings. In such processes, the iron dissolves in the caustic forming Fe +2 and Fe 3+ ions and simultaneously reducing the chlorate to chloride.
The dissolved iron which is then present as an impurity in the caustic solution as the result of the removal of chlorate should thereafter be eliminated by means involving, for example, oxidation, precipitation or electrolytic reduction. Thus, the cathodic removal of iron and other metal ions has been disclosed in the following publications: U.S. Pat. No. 3,244,605 and French Pat. No. 1,505,466. According to the prior art, the caustic solution containing the iron to be removed (and possibly other metal impurities) is subjected to electrolysis whereby the iron deposits as a metallic coating on the cathode of the electrolytic cell. However, it has not been reported that such electrolytically deposited iron can be re-used for again reducing the chlorate content of a yet untreated caustic solution.
SUMMARY OF THE INVENTION
It is an object of the present invention to use electrolytically reduced iron for removing chlorate from caustic solutions obtained by the diaphragm process.
A further object of the invention is to decrease the chlorate content of caustic solutions containing from 300 to 1000 ppm ClO 3 - down to acceptable levels of a few ppm.
Another object of the invention is to provide economical and practical means for achieving the above task using iron as the reducing material.
Another object of the invention is to remove the iron impurity from caustic solutions in which it is present as the result of the removal of ClO 3 - .
Still another object of the invention is to recover the dissolved iron having been used for the reduction of the chlorate by cathodic reduction into its elemental form and to re-use said recovered iron for further reducing the chlorate of a still untreated portion of the caustic solution, this operation being very economical since overall consumption of iron is then strongly minimized.
Said objects which will become apparent hereinbelow are achieved by the process for removing unwanted chlorate from caustic solutions by the reduction of said chlorate with metallic iron which comprises using electrodeposited iron as the reducing agent.
The invention also resides in a process for removing unwanted chlorate from a caustic solution by dissolution therein of metallic iron and simultaneous reduction of said chlorate by said iron and consecutively electrolytically removing said iron from the chlorate free solution which comprises
(A) contacting said solution of caustic to be purified with the iron metal in a form appropriate for its easy dissolving in the solution and consequent reducing of the ClO 3 - to chloride, then
(B) contacting the resulting solution containing dissolved iron with at least one conductive substrate, the latter being suitably adapted and polarized for electrolytically precipitating the iron in a form suitable for subsequently reducing chlorate as under (A) above, thus causing said iron to deposit thereon in pulverulent metallic form, thus providing a solution substantially free from iron and ClO 3 - ions,
(C) separating said purified portion of the solution and
(D) periodically using said substrates when sufficiently coated with said metallic iron to treat a yet untreated portion of the caustic solution as under (A) above and periodically, after consumption of said available deposited iron, re-using said substrates for recovering said dissolved iron as under (B) above.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The conditions required for carrying out the process of the invention are not critical. However, preferably step (A) is carried out at temperature above room temperature, preferably at about 100° C., with or without agitation. The contacting time depends on the temperature and can be conducted over a period of time from 1 to 20 hours, this time also depending on the ratio of available iron to the caustic to be treated. Such ratio is also not critical provided, naturally, that the available iron be at least stoichiometrically sufficient for reducing the chlorate to be removed. In practice, it has been found that when nearly 100 percent of the original chlorate has disappeared, that is when there remains from 5 to 15 ppm of ClO 3 - , the amount of dissolved iron is from 400 to 600 ppm. Therefore, the amount of iron to be used is somewhat dependent on the total amount of chlorate originally present in the caustic solution to be purified. However, in practice it is always advantageous to use a large excess of metal iron since its physical bulk relative to the solution is not a problem and, actually, no more than the quantity required for effecting the required reduction needs to be dissolved. Therefore, the amount of iron to be used, and its physical arrangement within the solution will be easily determined by the skilled practitioner, this being also dependent on whether the practical implementation relates to a batch or a continuous process.
The parameters for carrying out step (B) of the above described process are also not critical. It is indeed very fortunate that the electrodeposition of iron under that strongly alkaline conditions prevailing within concentrated caustic solutions will provide that form of metallic iron which is suitable for reducing the chlorate. Thus, not depending on the nature of the conductive substrate used as the cathode, the iron will deposit in porous spongy form particularly suited for being easily re-dissolved because its "sintered" or agglomerated structure allows a very large surface of metal to be contacted by the solution. Practically, electrodes of porous graphite or metal mesh, e.g. iron or nickel are suitable. Current densitites of from 0.1 to 10 A/dm 2 (amperes per decimeter 2 ) and temperatures of from room temperature to 80° C. are suitable for recovering the iron according to step (B) above in a form adequate for being re-used according to step (A). Preferably, the solution is agitated or circulated during said recovery. The counter electrodes (anodes) must naturally not dissolve in the caustic solution by oxidation and are preferably made of noble metals or anodes having a substrate coated with a noble metal or a noble metal oxide such as, for example, a titanium core coated with a noble metal oxide. In practice, platinized expanded titanium is suitable. It should be remarked that, even in cases where electrolytic recovery conditions of the iron are such that they provide homogeneous, inherently non-porous deposits, the porous nature of the cathodically polarized substrates will ensure that a sufficient amount of internal discontinuities exist within the coated layer for still having the iron in highly divided form.
There are, of course, many possible embodiments for physically implementing the invention. For instance, in a first embodiment, the solution to be treated is introduced in a conventional glass or polytetrafluoroethylene (PTFE) laboratory container and contacted at a moderately elevated temperature of from 80° to 100° C. with a plate of nickel mesh covered by electrolytically plated iron in pulverulent form. The solution is periodically analyzed by conventional means for chlorate and iron and when the initial chlorate of from 400-500 ppm has been decreased by 90 to 95 percent, the temperature is lowered to about 50° C. and an anode plate is immersed into the liquid and electrolysis is carried out against the iron clad plate until practically all iron has been plated out and redeposited thereon. Conditions for achieving this are those described in technical literature, namely for instance the references mentioned hereintofore. Then, when the iron content has been reduced to nearly zero (practically a few ppm) the electrolysis is stopped and the purified solution is poured out and replaced by a new portion of untreated caustic. The temperature is raised again and the whole process is repeated thus avoiding undue losses of iron. It has been found that during the iron recovery step, other heavy metals which may be present in the solution, e.g. Ni, Co, Mn, Pb, are also plated out which constitutes a further advantage of the invention. During the dissolution stage, some of these metals will stay inert and, as a consequence, the substrate will get progressively enriched in such plated metals other than iron in the course of repetition of the successive dissolution and plating cycles. Therefore, there will come a time when the substrate is over-enriched and the plate will have to be taken out and replaced. However, this is not a dead-loss since such metals other than iron can then be recovered from the plate.
The annexed FIGURE is a schematic representation of an exemplary system for continuously purifying caustic solution from unwanted chlorate using iron in a closed cycle.
The system comprises an inlet conduit 1 for the unpurified caustic and a general outlet conduit 2 for the purified solution. The impure caustic solution can be directed at will from conduit 1 through a two-way valve 3 to a first cell A or to a second cell B, the inlet conduits to these cells being controlled by two-way valves 4 and 5. Therefore, the solution can also flow at will from cell A to cell B, or vice-versa, through conduit 6. Whichever way, the solution, after flowing through cells A and B will leave through one of the valves 4 or 5, the latter having been properly adjusted for the desired purpose, and will finally flow out of the general outlet conduit 2 after having passed through a two-way control valve 7. It is easily seen that, in order to properly provide the desired flow direction throughout, the various valves must be linked together by conventional means not represented here for the sake of simplicity but which will operate so as to simultaneously actuate the various valves in order to either direct the caustic solution from the inlet conduit to cell A, to cell B, and to the outlet conduit or from the inlet conduit to cell B, to cell A and to the outlet conduit.
Each of the cells contains one plate covered with electrolytically reduced iron, respectively 8a and 8b, and a plate, respectively 9a and 9b, made of an electrochemically inert material, e.g. platinized titanium or titanium covered with a noble metal oxide, these plates being connectable at will to a suitable DC generator not represented here.
Under operating conditions, the present system will function as follows: In a first mode, the valves will be adjusted so that the path of the caustic solution is directed from cell A to cell B; the plates of cell A will stay unpolarized whereas plate 8b of cell B will be made negative to plate 9b by means of the above-mentioned generator. Thus, the caustic solution flowing along plate 8a of cell A will become purified from excess chlorate by contacting the iron deposited on said plate but will simultaneously be loaded with iron. Then the iron containing caustic solution will flow through cell B whereby the iron will deposit electrolytically on plate 8b. After some time, the iron supply on plate 8a will be depleted and plate 8b will be fully plated; then, in a second mode, the valves will be re-adjusted to provide the solution flow from cell B to cell A, the b plates will be disconnected and the a plates will be polarized as described above in the case of the first mode for the b plates. The whole process is then allowed to continue, the only operation being to periodically switch back from the second to the first mode and vice-versa.
Of course, the process can be operated semi-continuously, the valves being fully closed and operation being carried out on a finite portion of the caustic, then opened to allow the content of one cell to flow to the other cell while re-filling the one cell with an untreated solution and emptying the other cell from the purified portion, such sequence being repeated until exhaustion of the iron on the reducing plate of the one cell. Then, the series of sequences will be continued after reversing the order of the cells as described above for the fully continuous embodiment.
In the present embodiment, the materials used for making the conduits, the valves and the cells can be any resins inert to concentrated caustic solutions and resisting moderately elevated temperatures. As such, polyolefins, melamine-formaldehyde and polytetrafluoroethylene (PTFE) can be contemplated. Otherwise, metals such as monel, stainless steel or bronze can also be used.
The invention is further illustrated in more detail by the following examples.
EXAMPLE 1
First phase
A 20 cm 2 sintered iron electrode plate, prepared by manually depositing a 4 mm layer of iron powder (50-80 μm particles) on a 0.5 mm ironplate, then sintering 1 hour at 900° C. under nitrogen plus 5 percent H 2 , was introduced into a 400 ml PTFE cylindrical container provided with agitation and reflux condenser. 250ml of a 35 percent sodium hydroxide containing 445 ppm chlorate was introduced into the container and heated to 110° C. The reaction was allowed to proceed under moderate agitation, samples of the solution being removed at intervals for analysis. Table I, below, shows the results of said analysis performed by known methods described hereinafter. Such results indicate that most of the ClO 3 - was removed after about 6 hours reaction time.
TABLE I______________________________________Time, hrs ClO.sub.3.sup.-, ppm Fe, ppm ClO.sub.3.sup.-, removal,______________________________________ %0 445 0 01/2 445 3.5 01 410 32 8 11/2 374 57 16 21/4 240 139 463 160 238 644 72 480 856 18 530 96______________________________________
Second phase
Thereafter, a 20 cm 2 platinized anode was introduced into the container and adjusted parallel to the iron plate at about 5 cm thereof. Then the solution was electrolyzed at 80° C. under 4 A/cm 2 for a day after which the iron level was found to be 12 ppm (about 98 percent removal).
The container was refilled with chlorate contaminated caustic and the process was repeated with essentially the same results. The whole cycle including phase one followed by phase two was repeated several times with no significant change in behavior of the reducing aand recovery conditions.
The analytical methods used were the following:
Chlorates
An amount of solution corresponding to approximately 60 mg of NaClO 3 was measured exactly and introduced into a 10 ml volumetric flask, then 3 ml of concentrated H 2 SO 4 (98%) were carefully introduced from a 3 ml safety pipette by making the tip of the pipette touch the inside wall of the upper stem of the flask and releasing the acid slowly. The solution was cooled to room temperature, 0.020 grams of FeSO 4 (NH 4 ) 2 SO 4 .6H 2 O (MOHR's salt), were added, the solution was levelled to the mark with distilled water and mixed thoroughly. A reagent blank was prepared in the same manner. Then, the absorbances (vs H 2 O) of the reagent blank and the sample solution were measured at 301 mμ in a 1 cm silica cell. The reagent blank was stable for at lest one hour and its absorption only accounted to about 0.060 of an absorbance unit. The chlorate content was calculated from: ##EQU1## Iron
10 ml of the sample, 10 ml of concentrated hydrochloric acid, 1 ml of hydrogen peroxide and 10 ml of ammonium thiocyanate were introduced into a 100 ml volumetric flask. After dilution to volume, a spectrophometric measurement was performed at 470 mμ. As this method is very sensitive (works in the range of 1 to 10 mg/l), it was necessary to choose an adequate volume of sample in the measurable concentration range.
EXAMPLE 2
A 25 cm 2 nickel grid plate, 40 mesh, (pore openings =≈500 μm) was immersed for several minutes in 2 N HCl, then rinsed in distilled water. Then it was used to de-ironize at 50° C., 600 ml of 50 percent sodium hydroxide under 4 A/dm 2 . The electrolysis was carried out for 21/2 days, after which the iron removal was 99 percent.
Then the iron plated nickel grid was used to reduce the chlorate content of 200 ml of a 50 percent untreated caustic solution containing 500 ppm of ClO 3 - for 5 hours at 100° C. exactly as described in phase 1 of Example 1. After that period, the chlorate was 99 percent removed and the iron content was 650 ppm. Then the iron was removed as described in phase 2 of Example 1 and the whole cycle was repeated several times with no significant change in the behavior of the plates and the reagents.
EXAMPLE 3
A sintered iron plate similar to that used in Example 1 was used as described in said Example for treating chlorated (550 ppm) 50 percent sodium hydroxide solution. Every twelve hours, the cell was emtied, the de-chlorated solution was put aside and a fresh portion of caustic was put to work for a new 12 hours period without changing the iron plate. After a total of 5 lit. of caustic had been treated, the iron was about fully consumed and the plate became inoperative.
Then, the iron contaminated de-chlorated solution was poured into a 10 lit. PTFE tank and subjected to electrolysis at 50° C. using a platinized titanium anode and the above iron stripped plate as the cathode. During electrolysis, the solution was kept under moderate agitation. After about 80 percent of the iron was plated out, the iron clad cathode was removed and re-used to de-chlorate untreated portions of caustic with subsequent removal of iron as described in Example 1. This plate provided the same service as the plate of Example 1.
EXAMPLE 4
A stainless steel tank was filled with 2.5 lit. of a 45 percent NaOH solution containing 375 ppm of chlorate and reduction was carried out at 100° C. under slight agitation with a 125 cm 2 sintered iron plate. The results are shown in Table II below.
TABLE II______________________________________Time, hrs ClO.sub.3.sup.-, % removal Fe, ppm______________________________________0 0 02 16 743 33 1724 49 2985 62 31415 98 450______________________________________
Then the solution was put into a 5 liter cylindrical PTFE cell and electrolyzed under agitation with a 58.6 cm 2 vitreous carbon cathode and a 50 cm 2 platinized expanded titanium anode. The current density was about 2 A/dm 2 and temperature 110° C. The results are shown in Table III.
TABLE III______________________________________Time, hrs Fe, ppm Iron recovered, %______________________________________0 450 011/4 154 6623/4 23 9542/3 18 966 5 99______________________________________
The process of iron recovery was repeated four times using fresh iron containing solutions but still using the same plate as the cathode. Thereafter such iron clad plate was used in a series of chlorate purification and iron removal cycles as described in the previous Examples with equally good results.
EXAMPLE 5
The set up of Example 1 was used but with the difference that during phase 1 (ClO 3 - removal) an iron sheet electrode was immersed in the cell, and a DC generator was connected to that electrode (cathode) and to the sintered iron plate (anode).
Then, the reduction of chlorate was carried out in the same conditions as for Example 1, but with the addition of a small current between the sintered iron anode (0.1 A/dm 2 ) and the other electrode in order to speed up iron dissolution. The results are shown in Table IV and indicate that the removal of chlorate is somewhat accelerated compared to operating without current.
TABLE IV______________________________________Time, hrs ClO.sub.3.sup.- , ppm ClO.sub.3.sup.- , % removal Fe, ppm______________________________________0 400 11 861/2 325 27 1611 277 38 234 11/2 210 53 1892 165 63 167 21/2 108 76 2344 not measurable ˜100 500______________________________________
Thereafter the sintered iron electrode was used to perform iron recovery as described in Example 1. The above two-phase cycle could be repeated several time with no significant changes to the results obtained.
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A process for removing chlorate from a caustic solution by the reduction of the chlorate with metallic iron. The process is particularly distinguished by the steps of contacting the caustic solution with iron to reduce the chlorate to chloride, contacting the caustic solution containing dissolved iron therein with a conductive substrate to electrolytically precipitate the iron on the substrate, thus providing a caustic solution which is substantially free from iron and chlorate ions, separating the purified portion of the caustic solution, and periodically using the iron coated substrate for treating an untreated portion of the caustic solution to reduce the chlorate to chloride, and periodically reusing the iron depleted substrate, for recovering dissolved iron from the caustic solution. The process of this invention decreases the chlorate content of caustic solutions to an acceptable level of a few ppm and also recovers dissolved iron on an iron depleted substrate for reuse and further reduction of chlorate of an untreated portion of the caustic solution.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to a solar heating device for heating water. More specifically, the present invention relates to arrays of lenses configured for concentrating solar rays into a plurality of focal points disposed on the surfaces of water conducting tubes to enhance the water heating capacity of the device.
BACKGROUND OF THE INVENTION
[0002] Solar heating systems for heating water circulating through pipes achieved through focusing the sun's rays onto the surface of the pipes is well known in the art. A fair number of prior art references teach magnifying lenses and arrays of magnifying lenses arranged to collect solar rays and configured such that focal points formed by these rays and lenses fall on the surfaces of water conducting pipes. The focal points concentrate the solar rays onto the surfaces of these pipes causing the surfaces of these pipes to heat up. The pipes and the magnifying lens arrays may be contained inside a housing configured to reduce heat losses to the environment. This is illustrated in the examples below.
[0003] U.S. Pat. No. 1,672,750 discloses sections of lenses enclosed inside a housing arranged at different angles positioned to direct sunlight through a receptacle containing water.
[0004] Likewise U.S. Pat. No. 2,277,311 provides a lens construction for picking up the sun's rays from various angles and for concentrating and intensifying them onto a confined area containing water.
[0005] U.S. Pat. No. 4,319,560 relates to a solar heating system comprising a heat accumulating structure for heating both air and water in which both the heated air and water are directed to an object to be heated such as a commercial building or private residence. The heat accumulating structure is below ground and includes a magnifying glass forming the roof thereof and protruding above ground, the magnifying glass concentrating the rays of the sun into the heat accumulating structure which includes a lower portion containing water and an air space there above. The solar heating system includes a piping arrangement whereby heated water can be directed to the object to be heated and piped away.
[0006] U.S. Pat. No. 4,601,282 describes an automatic solar collector system useful for heating and storing a heating fluid such as, for example, water. The automatic solar collector system of this invention is characterized by its construction including a photo cell-actuated hydraulic cylinder whereby the collector panel may be positioned at an angle to focus the sun's rays onto the fluid conduit disposed within the collector panel. Overall operation of the automatic solar collector system of this invention is regulated by a clock timer, and the entire system is essentially self-contained so that it may easily be moved from one location to another, or put in parts to be attached to a home or a building with the tank and controls below the roof.
[0007] U.S. Pat. No. 4,611,576 refers to an automatic solar collector system useful for heating and storing a heating fluid such as, for example, water. The automatic solar collector system of this invention is characterized by its construction including a photo cell-actuated hydraulic cylinder whereby the collector panel may be positioned at an angle to focus the sun's rays onto the fluid conduit disposed within the collector panel. Overall operation of the automatic solar collector system of this invention is regulated by a clock timer, and the entire system is essentially self-contained so that it may easily be moved from one location to another, or put in parts to be attached to a home or a building with the tank and controls below the roof.
[0008] U.S. Pat. No. 5,143,051 is for an apparatus for heating of a body of water. The collector includes a housing formed with an interior cavity containing aluminum oxide crystals in communication with collector tubes extending orthogonally downwardly relative to the housing also filled with the aluminum oxide crystals. A lens assembly plate is mounted above the cavity, with the lens assembly including a matrix of magnification lens members coextensively directed throughout the plate above the cavity.
[0009] U.S. Pat. No. 5,941,239 discloses a multiple lens solar heating unit consisting of a piping component, a housing component with a transparent housing cap, holes within the housing component for entry and exit of the piping component, multiple lens mounting braces affixed parallel wise to inner walling of the housing component, a plurality of external lens holders mounted to the braces by mounting pins and rotatably pivotable in an XY plane, an equivalent plurality of internal lens holders mounted one each to each external lens holder by mounting pins and rotatably pivotable in an XZ plane and an equivalent plurality of magnifying lens mounted one each within each internal lens holder.
[0010] U.S. Pat. No. 6,630,622 teaches an apparatus for converting solar energy to thermal and electrical energy including a photovoltaic grid for converting the concentrated solar energy into electrical energy mounted on a copper plate that provides even temperature dispersion across the plate and acts as a thermal radiator when the apparatus is used in the radiant cooling mode; and a plurality of interconnected heat transfer tubes located within the enclosure and disposed on the plane below the copper plate but conductively coupled to the copper plate for converting the solar energy to thermal energy in a fluid disposed within the heat transfer tubes. Fresnel lenses are affixed to the apparatus on mountings for concentrating the solar energy on to the photovoltaic grid and functioning as a passive solar tracker.
[0011] A configuration of a single array of lenses forms focal points that concentrate the heat produced by these focal points only through the center points of each lens. The number of such focal points is therefore limited by the space between lens centers. Additionally, where the magnifying lenses are circular or oval in shape, the joining of the lenses creates gaps between the lenses that allow light to pass through without producing additional focal points. For these reasons, a single array of lenses does not efficiently utilize solar light for heating in a given space configuration.
[0012] U.S. Pat. No. 2,277,311 describes a lens made of an upper bulb and a lower bulb. The upper bulbs are convex and are used to intercept the rays of the sun irrespective of their angle of the sun. These condensing lenses act to concentrate the heat effect from the sun's rays and direct the rays to the lower bulbs. The lower bulbs are also convex but are offset relative to the upper bulbs and therefore act as diffusing bulbs. Thus, although a second array of lenses is added, the disclosure in this prior art reference does not solve the problem of achieving only a limited number of focal points in a given space.
SUMMARY OF THE PRESENT INVENTION
[0013] The present invention provides a solar heating device comprised of multiple arrays of lenses enclosed in a housing configured to collect solar rays and concentrate the rays into multiple hot spots located on the outer surface of a water conduit. The heat from these spots is transferred to water circulating through the conduit. The number of heat producing focal points formed on the water conduit by solar rays passing through multiple arrays of lenses is significantly higher compared to the number provided by a single array.
[0014] It is therefore the object of the present invention to provide a high capacity solar heating device configured to efficiently utilize existing space.
[0015] In an aspect of the present invention, a solar device for heating circulating water comprises: a housing having a bottom, side walls having an inner portion and an outer portion, the housing also containing a substantially transparent top; a water conduit system disposed on the bottom of the housing, the water conduit system having an inlet and an outlet; a first planar array of magnifying lenses that is substantially parallel with the bottom of the housing, the first planar array of magnifying lenses being disposed between the transparent top and the water conduit system; and a second planar array of magnifying lenses that is substantially parallel with the bottom of the housing, the second planar array of magnifying lenses being disposed between the first planar array of magnifying lenses and the water conduit system.
[0016] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, descriptions and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a top view of the lens array assembly according to an embodiment of the present invention;
[0018] FIG. 2 is an illustration of a focal point pattern formed by solar rays propagating through a lens according to an embodiment of the present invention;
[0019] FIG. 2A is a depiction of the lens dimensions that affect the formation of the focal lengths according to an embodiment of the present invention;
[0020] FIG. 3 is an illustration of focal point formation by multiple arrays of lenses according to an embodiment of the present invention;
[0021] FIG. 4 is a cross sectional side view of the solar heating device having four planar arrays of lenses according to an embodiment of the present invention;
[0022] FIG. 5 is a top exploded view of the solar heating device having three planar arrays of lenses and enclosed water circulating tubes according to an embodiment of the present invention;
[0023] FIG. 6 is a top exploded view of the solar heating device having four planar arrays of lenses according to an embodiment of the present invention;
[0024] FIG. 7 is a side exploded view of the solar heating device having four planar arrays of lenses according to an embodiment of the present invention;
[0025] FIG. 8 is a side exploded view of the solar heating device having four planar arrays of lenses and enclosed water circulating tubes according to an embodiment of the present invention; and
[0026] FIG. 9 is an illustration of the path of a solar ray entering the lens system of the device as shown in FIG. 4 through the reflector attachment according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0028] The present invention relates to a device for heating water circulating through pipes that may be used in a number of applications such as domestic water heating, indoor and outdoor pool water heating and industrial water heating.
[0029] The device comprises of three systems: 1) a solar ray collection system configured for providing solar energy to be converted to heat, 2) a solar ray processing system for concentrating the solar energy into multiple focal points, and 3) a system for efficiently transferring the heat produced by the solar rays to heat water in a water conduit system that winds through the device.
[0030] In the preferred embodiment of the present invention, all three systems are enclosed in a rectangular shaped housing having a bottom, four side walls and a top. The top is transparent allowing solar light to enter the housing. In order to minimize heat losses to the environment, it would be desirable to limit the size of the housing. This however necessitates the efficient utilization of the available space in the housing for converting solar energy to heat. The design of the present invention provides enhanced solar light input into the housing. It also provides for a system of lenses for concentrating the light into multiple focal points that produce heat that may be transferred to the water. The water conduit contains a floor section and four side wall sections having enhanced length and surface area to allow for high exposure time of the water to the heat from the focal points. Each focal point provides an additional heating source for the water and contributes to the increase in water temperature.
[0031] The preferred embodiment for the solar ray processing system comprises three or four planar arrays of magnifying lenses; however, two arrays as well as more than four also fall within the scope of the present invention. In this context, each planar array is constructed with circular or oval lenses attached to three or four adjacent magnifying lenses, depending on the location of the lenses, such that the lenses in each array substantially define an x-y plane. The arrays are preferably disposed in parallel with the bottom of the housing and with each other; however non parallel arrangements also fall within the scope of the present invention.
[0032] Each array is supported by a frame attached to the side walls of the housing. The frames may be installed on railings attached to the side walls of the housing and adapted to slide alongside the inside of the walls. The arrays may be separated from each other by a distance determined by the characteristics of the lenses as described below.
[0033] A magnifying lens is typically characterized by the shape of the top and bottom surfaces, refractive index, and the radii of curvature of the top and bottom surfaces. A magnifying lens is further characterized by an optical center which is the point where light passes through the lens in a straight line and is not bent by the lens. The shape of the lenses in the thickness, or z-direction, which is perpendicular to the arrays' x-y plane may be convex or concave. The index of refraction typically varies from about 1 to about 2. The most common types of magnifying lenses used for concentrating solar rays and most suitable in the context of the present invention are ordinary convex glass lenses and Fresnel lenses.
[0034] In an embodiment of the present invention, three or four planar arrays of convex lenses are disposed in parallel with the bottom of the housing. Each array is separated from the next array by a distance ranging from about 1 inch to about 12 inches depending on the design of the device and the characteristics of the lenses. In order for each lens to form a focal point on the surfaces of the water conduit tubes which are in a fixed position, the focal lengths of each array of lenses must be progressively smaller going from the higher to the lower magnifying glass arrays. To accomplish this, the arrays of lenses may be configured according to the equation used for calculating the focal length of a convex lens as follows:
[0000]
1
f
=
(
n
-
1
)
[
1
R
1
-
1
R
2
+
(
n
-
1
)
d
n
R
1
R
2
]
,
[0035] Where:
[0036] f is the focal length of the lens,
[0037] n is the refractive index of the lens material,
[0038] R 1 is the radius of curvature of the lens surface closest to the light source,
[0039] R 2 is the radius of curvature of the lens surface farthest from the light source, and
[0040] d is the thickness of the lens (the distance along the lens axis between the two surface vertices).
[0041] Lens thicknesses, in the range of about 0.1 to about 0.5 inches, are typically small relative to the radii of curvature that may range between about 4 inches to about 12 inches. The refractive index of a lens ranges typically between 1 and 2. For this configuration, the equation simplifies to:
[0000]
1
f
≈
(
n
-
1
)
[
1
R
1
-
1
R
2
]
.
[0042] The table below illustrates exemplary combinations of refractive indexes and radii of curvature which produce decreasing focal lengths for the first through the fourth array of lenses.
[0000]
R2, inches
R1, inches
n, dimensionless
f, inches
First array
4
2.4
1.4
15
Second array
4.4
3
1.7
13.5
Third array
4.4
2.9
1.7
12.2
Forth array
4.5
2.8
1.7
10.6
[0043] Thus, arranging the arrays of lenses such that their respective lens centers are positioned approximately 15 inches, 13.5 inches, 12.2 inches and 10.6 inches respectively from the surface of the water tubes produces focal points from each of the four arrays.
[0044] It will be understood to those skilled in the art that multiple combinations of refractive indexes and radii of curvature values may be used to vary the focal length of the lens. Small adjustments that allow more accurately pinpointing the focal points onto the desired spots on the water tubes may be made by moving the frames of the lens arrays along the side walls of the housing.
[0045] As a general rule, solar rays projected onto the x-y plane of a convex magnifying lens' top surface form a focal point at a distance below the bottom surface of the lens determined by the characteristics of the lens and a line passing through the center of the lens and perpendicular to the lens x-y plane. Other lenses placed between the center of a lens and the location of its focal point do not impede the formation of the focal point except if the ray line passes through two lens centers. Thus it would be desirable to design the lens arrays such that the lineup of any two lens centers is minimized.
[0046] In a preferred embodiment of the present invention, the lengths, or radii in case of circular or oval shaped lenses, of the lenses in any array are equal and are progressively smaller going from the first array to the fourth array. This configuration minimizes lens center overlap and generally provides at least one lens center in the path of light passing through gaps in the lens arrays.
[0047] The present invention is illustrated in FIGS. 1-9 . The solar heating device 10 is enclosed in a housing 15 of rectangular shape having a top 22 . Four arrays of magnifying lenses are disposed inside the housing 15 . The first array of magnifying lenses 11 that is closest to the top has the longest lenses. The arrays of lenses below the first array include the second array 14 , the third array 17 and the fourth array 29 . The radii of the lenses of each of the successive arrays below the first array have progressively smaller magnifying lenses. Except for the end lenses, each lens in the arrays is attached to four adjacent lenses at four points in its circumference. Alternatively, the lens edges may be combined using edge holders. In a top view of the lens system 20 shown inside the housing 15 in FIG. 1 , the top array of circular lenses 11 has gaps between the lenses that are filled by the lower arrays 14 and 17 . Thus light passing through these gaps is picked up by magnifying lenses from the lower arrays which then form additional focal points. FIG. 2 shows the formation of focal points by solar rays passing through convex magnifying lenses. FIG. 2A shows the dimensions of a convex lens. If the bottom surface radius of curvature R 2 of the magnifying lens is equal to or greater than that of the top surface, a focal point is formed below the bottom surface of the lens. FIG. 3 illustrates the formation of additional focal points by adding arrays of magnifying lenses below that of the first array. The end lenses in each array are held by frames 23 as shown in FIGS. 4 and 6 . Also shown are the inlet 27 to the water conduit system and the outlet 33 . The water conduit comprises a floor section 37 and a side wall section 21 . A pole 34 attached to the bottom of the housing 15 provides pivot capability to tilt the housing in the direction of the sun. A handle 35 may also be attached to the housing 15 that allows for convenient transportation of the device 10 as needed. The reflector surface attachment 44 comprises a first reflecting surface 32 angled outwardly relative to the top 22 of the housing 15 for collecting the solar light and reflecting it onto the second surface 31 angled inwardly relative to the top 22 of the housing 15 for reflecting the rays into the housing 15 .
[0048] The side wall section of the water conduit system provides additional surface area for focal point and heat formation that enhance water temperature. The geometry of the reflector is such that the reflected rays are directed substantially to form focal points on the side wall section 21 of the water conduit system. FIG. 9 shows a path for an incidental ray 39 collected by the first reflecting surface 32 and reflected through the second surface 31 onto the side wall section 21 of the water conduit. A transparent enclosure 25 shown in FIGS. 5 and 8 enclosing water conduit system helps keep the heat generated by the focal points from dissipating away from the water tubes.
[0049] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention.
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An enhanced solar heating device comprising multiple arrays of lenses enclosed in a housing configured to receive solar rays and concentrate the rays into multiple hot spots located on the outer surface of a water conduit is disclosed. The solar ray collection system is supplemented by a reflector attachment used to increase the solar light fed into the device. The water conduit is configured with multiple sections to increase exposure to solar light and increased surface area for formation of hot focal points.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application relates to improvements in my prior application filed Feb. 17, 1977, Ser. No. 769,709 for Flare Gas Stack with Purge Control and my prior application filed May 11, 1977, Ser. No. 796,016 for Multi-Pilot Gas Conservation System for Flare Gas Burners.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to pilot gas conservation systems for flare stacks.
2. Description of the Prior Art
In my prior application for Letters Patent filed Feb. 17, 1977, Ser. No. 769,709, provisions are made for start up, steady state or transient purge gas control and for failure of the purge gas supply, and take into account variable wind speed at or near the top of the stack, and other conditions, with provisions for pilot burner gas supply and ignition.
In my prior application filed May 11, 1977, Ser. No. 796,016, provisions are made for varying the activation of pilot gas burners dependent upon wind direction and wind velocity.
No satisfactory provisions have heretofore been made by others looking to the conservation of pilot burner gas when conditions do not justify maintaining a high level of pilot burner flame.
In accordance with the present invention of supply of gas to the pilot burners is determined by the wind conditions and when ignition or reignition is required and with increase or decrease of pilot burner gas supply as determined by wind speed conditions. Provisions are also made for manual override of the control system.
It is a principal object of the present invention to provide a pilot burner gas conservation system for flare gas stacks and the like which will reduce unnecessary delivery of pilot gas to the pilot burners of a flare stack as measured by the wind speed at or near the top of the stack.
It is a further object of the invention to provide a pilot gas conservation system for flare stacks and the like in which the wind velocity at or near the discharge end of the stack is utilized for control purposes.
It is a further object of the invention to provide a pilot gas conservation system for flare stacks and the like in which the flow of gas to the stack is utilized for control purposes.
It is a further object of the invention to provide a pilot gas conservation system which is simple but effective in its action.
Other objects and advantageous features of the present invention will be apparent from the description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The nature and characteristic features of the present invention will be more readily understood from the following description taken in connection with the accompanying drawings forming part hereof in which:
FIGS. 1A and 1B are a diagrammatic view of a flare gas stack with a pilot burner gas conservation system in accordance with the invention; and
FIG. 2 is a diagrammatic view illustrating the operation of the pilot as determined by variations in wind speed.
It should, of course, ne understood that the description and drawings herein are illustrative merely and that various modifications and changes can be made in the structure disclosed without departing from the spirit of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
It is a common practice to utilize a flare stack for the disposal of waste combustible gas from chemical and industrial processes and particularly from oil refining. Such stacks may be vertical, horizontal or inclined. The waste combustible gas is not usually continuously available but is intermittently supplied as it becomes necessary to dump such gas. It is also necessary from time to time to dispose of combustible materials such as those stored underground, gas from pipe lines and gas from production platforms.
Referring now more particularly to the drawings a flare stack 10 is illustrated having a supply conduit 11 connected thereto for the supply of waste gas from a waste gas supply connection. The waste gas is combustible and may be derived from industrial operations and particularly from oil refineries.
The flare stack 10 may be of any desired type, may have a fluidic seal 12 spaced downwardly from the top to permit free upward movement of gas and provide a substantial obstacle to downflow in the stack. A suitable form of seal for this purpose is shown in my prior U.S. Pat. No. 3,730,673.
The flare stack 10 preferably has a burner 15 on the top or discharge end for aiding in the admixture with the waste gas of air for combustion, and with or without steam, and may have a hollow cylindrical slotted wind shield 16, closed at the bottom to protect the pilots 17 and the burner 15 from the wind. Suitable burners are shown in my prior U.S. Pat. Nos. 3,730,673; 3,797,991; 3,822,984; and 3,995,986 but the apparatus of the present invention is applicable to a wide range of burners. Purge gas may also be supplied to the supply conduit 11 and controlled in any desired manner.
The conduit 11 has a flow responsive switch 18 inserted therein which may be of any desired type but which is closed when there is gas flow through the conduit 11 and open if there is no flow.
The stack 10 preferably at the same elevation as its discharge end and subject to the same wind conditions has a wind responsive impeller 19, preferably an anemometer, which drives a signal source 20 for supplying a wind speed signal varying with the wind speed for utilization as hereinafter explained.
A source of combustible pilot gas under pressure is provided connected by a pipe 23 through a pressure regulator 24. A pipe 25, connected to the regulator 24, extends to an electrically actuated solenoid valve 26 which has a pipe 27 extending to and supplying gas to each pilot burner 17 through an air inducing venturi 28. A pressure gage 29 is provided connected to the pipe 27 for indicating the pressure of the pilot gas.
A valve 30 is provided in series in the pipe 27 controlled by a proportional controller 31, the controller 31 being connected by a conductor 32 from the signal source 20. A bypass orifice 33 is provided around the valve 30 to permit of minimum flow of pilot gas to the pilot burners 17. A manually operable bypass valve 34 is provided in a pipe 35 connected respectively upstream and downstream of the valves 26 and 30 for manual operation of the system, if desired.
The pipe 25 also has connected thereto a pipe 36 which has connected in series therein a solenoid controlled valve 37, and an orifice 38. A pressure gage 39 is provided connected to the pipe 36 for indicating the pressure of the gas. A manually operable bypass valve 21 is provided in a pipe 22 around the valve 37.
A source of compressed air is provided connected by a pipe 40 through a pressure regulator 41. A pipe 42, connected to the regulator 41 extends through a solenoid controlled valve 43 and an orifice 44 to the pipe 36 to provide a gas-air mixture for ignition. A pressure gage 45, connected to the pipe 42 indicates the pressure of the air at that location. A manually operable bypass valve 65 is provided in a pipe 66 around the valve 43.
A pipe 46 extends from the junction of the pipes 36 and 42 to a spark plug igniter 47 for delivery of an igniting flame through flame carrying pipes 48 to the pilot burners 17 to ignite the pilot gas at those locations.
A source 50 of electrical energy is provided which is connected by a conductor 51 to a manually operable switch 52 having one contact 53 for automatic operation of the system and another contact 54 for manual operation.
A conductor 55 extends from the automatic operation contact 53 of the switch 52 to the flow responsive switch 18 and a conductor 56 connected thereto has a conductor 57 which leads to the signal source 20 with a conductor 32 therefrom to the proportional controller 31 for the pilot gas valve 30 to vary the delivery of gas through the pipe 27 to the pilots 17 in accordance with the wind speed at the impeller 19.
Each of the pilot burners 17, two being shown in the drawing although more can be employed if desired, is provided with a thermocouple 60 which is connected respectively by conductors 61 to thermocouple temperature responsive control switches 62. Each control switch 62 has a signal light 63 connected thereto which is activated in the event that its pilot burner 17 is operating and a signal light 64 which is activated in the event of its pilot failure.
The flow switch 18 is connected by the conductor 56 to each of the control switches 62 for power input. The switches 62 are effective in the event of pilot failure, through conductor 67 to activate a timer motor 68 to rotate an interrupter wheel 69. A conductor 70 is connected from conductor 66 to a timer switch 71 operated intermittently by engagement of the timer wheel 69 engaging a tiltable timer arm 72.
The timer switch 71 controls the supply of current to a transformer 75 which is connected by a conductor 76 to the spark plug 47 for igniting the gas in the pipes 48 for flame delivery to the pilot burners 17. The conductor 56 is also connected by conductor 78 to the pilot valve 26. A conductor 79 connected to conductor 66 operates the solenoid valves 37 and 43 for the delivery of air and gas for mixing to provide the igniting flame. The conductor 66 is also connected by conductor 80 to a timer motor 81 which operates a timer wheel 82 which engages a spring returned arm 83 to activate an alarm timer switch 84 which activates a remote alarm to indicate pilot failure.
The manually operable switch 52 has a conductor 85 leading from its contact 54 through a switch 86 for manual activation of the spark plug 47 independent of the timer motor 68.
The mode of operation will now be pointed out, reference being had to FIGS. 1 and 2.
In FIG. 2, the relationship is shown between waste gas flow, ignition turn on, pilot burner turn on, wind speed, and pilot gas flow, elapsed time being represented horizontally and relative values of the other factors being represented vertically.
Automatic activation of the pilot burners 17 or delivery of the igniting flame can be effected if the flow switch 18 is activated by gas flow in the conduit 11.
Assuming that air is supplied through pipe 40, under the control of the solenoid valve 43 through the pipe 42 to the pipe 46, and that combustible gas is supplied through pipe 23, under the control of the solenoid valve 37 to the pipe 36 for mixing with the air to provide a flammable mixture for ignition by the spark plug igniter 47 and delivery through the pipes 48 to the pilot burners 17, when the spark plug is activated from the transformer 75.
At the same time gas from the pipe 36 through pipe 25, controlled by the solenoid valve 26, is supplied through the bypass orifice 33 and the pipes 27 to the pilot burners 17.
In the event that there is no heat at either of the thermocouples 60 because the respective pilot burners 17 are not operating, the control switches 62 activate the igniter sequence and the alarm switch 84 if ignition does not occur after three attempts.
The wind responsive impeller 19, dependent on the wind velocity, through its signal source 20 acts on the proportional controller to position the valve 30 to regulate the flow of pilot gas to the pilot burners 17 dependent on the wind velocity with reduction of gas delivery when the wind velocity is low.
Manual override control is effective for pilot burner and igniter by the valves 21, 34 and 65, and, in the manual control position of the selector switch 52, the manual switch 86 may be activated for manual control of ignition.
In FIG. 2 the relation of windspeed to pilot gas flow is indicated with the gas flow following the wind velocity fluctuations, minimum flow being provided through the orifice 33 whenever there is waste gas flow.
The relation of the ignition and pilot operation is also illustrated and shows the small time lag for pilot burner activation. A pilot failure is shown together with the activation of the ignition to overcome the pilot failure. The time delay of pilot operation in its relation to waste gas flow is also shown.
The shut down upon termination of waste gas flow, of ignition, pilot operation and pilot gas flow is also shown at the right side of FIG. 2.
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A pilot gas conservation system for flare stacks is provided in which the activation and control of the pilot gas burners is determined by the wind conditions so that if no flare gas is flowing the pilot burners are shut down and with moderate and minor wind conditions the supply of pilot gas is maintained at a lower level than that required for higher wind velocities. A flow responsive switch is provided to determine the flow of waste combustible gas to the stack so that, if required, the effect of the wind speed determines the pilot gas flow.
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[0001] This United States utility patent application claims priority on and the benefit of provisional application 61/772,740 filed Mar. 5, 2013, the entire contents of which are hereby incorporated herein by reference.
[0002] This patent application is a continuation-in-part application of application Ser. No. 13/469,306 filed on May 11, 2012, which itself claims priority on and the benefit of U.S. provisional application 61/485,849 filed May 13, 2011, the entire contents of both being hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a heat engine, and in particular in one embodiment to a rotary style heat engine and in another embodiment to a linear drive heat engine that can have any number of independent cylinders and one way clutches.
[0005] 2. Description of the Related Art
[0006] Heat energy, sometimes called thermal energy, is defines as the kinetic energy of a system's particles. Put another way, the heat energy of a system is the amount of potential energy in a system that is derived from the heat content within the system.
[0007] Temperature is not the same as heat energy. Yet, temperature makes up an integral part of the ideal gas law. The ideal gas law states:
[0000] PV=nRT
[0008] Wherein:
[0009] P is Pressure
[0010] V is Volume
[0011] n is the amount of gas
[0012] R is the universal gas constant and
[0013] T is temperature
[0014] This ideal gas law demonstrates that temperature and pressure are directly related when the other variables are held constant. Likewise, when temperature is held constant in a closed system, the pressure and volume are inversely related.
[0015] This is demonstrated as follows:
[0000] P 1* V 1= P 2* V 2
[0016] That is, the sum of pressure times volume stays constant in a closed system when the temperature remains constant.
[0017] It is known that pressure within a system can be used to perform work. For example, in a properly designed system, potential energy of a high pressure container can be extracted by allowing a user to convert potential energy to kinetic energy.
[0018] As an example, consider a tank that is under pressure two times atmospheric pressure. The gas will rush out of the tank when a valve is opened until the pressures inside and outside of the tank equalize. Stating this differently, the gas inside the tank expands (from inside to outside the tank) until the pressures equalize. The expansion of the gas can be utilized to perform work.
[0019] There have been many engine designs over the years. One design is the Wankel, engine design. The Wankel engine is a four-cycle internal combustion engine that uses a rotating rotor motion instead of reciprocating pistons. The four cycles takes place between a Reuleaux triangle shaped rotor and an epitrochoid-shaped housing.
[0020] The housing can be defined as having 360 degrees of rotation. The rotor can generally be described as an equilateral triangle with rounded faces. The sum of internal angles of an equilateral triangle is 180 degrees. In this regard, the rotor revolves around an offset crankshaft wherein the apexes of the rotor contact the housing at all times. An example of this engine 5 design is shown in FIG. 1 .
[0021] A single rotor engine is considered a three cylinder engine. In this regard, the space or volume between the apexes of the triangle and the housing wall define three chambers. Each chamber acts independently of the other chambers and each undergoes the intake, compression, ignition and exhaust cycles of the four-cycle design. Hence, three power cycles are produces by this engine.
[0022] The Wankel engine has been modified in many ways. Some modifications of the Wankel design, as well as examples of other designs are illustrated in the following patents and published application.
[0023] U.S. Pat. No. 3,426,525 to Rubin is titled Rotary Piston External Combustion Engine.
[0024] U.S. Pat. No. 3,509,718 to Fezer et al. is titled Hot Gas Machine.
[0025] U.S. Pat. No. 4,206,606 to Reich is titled Rotary Stirling Cycle Engine. It discloses a rotary Stirling cycle machine comprising at least two chambers, said chambers being epitrochoidal in cross-sectional area and having an upper portion, a middle waist portion and a lower portion, with the first chamber mounted to the second chamber in tandem, each chamber having a seal element attached to the waist portion and disposed inwardly, the crank shaft rotatably mounted within the chambers and extending therethrough with the first crank throw portion within the first chamber being 180.degree. out of phase with the second crank throw portion within the second chamber, the first and second rotor elements rotatably mounted on said respective crank throw portions with each rotor element being limicon shaped in circumference and adapted to register with the upper and lower portions of the respective chambers so that the rotor elements cyclically rotate about the rotating crank shaft from a position in registration with the upper portion to a position in registration with the lower portion, said seal elements being in constant sealing engagement with the respective rotor elements to define first cavities in the upper portions and second cavities in the lower portions, and heater-regenerator-cooler means operatively connected to said first and second cavities to condition a working fluid through repeated Stirling cycles.
[0026] U.S. Pat. No. 4,357,800 to Hecker is titled Rotary Heat Engine. It teaches a rotary external combustion heat engine for furnishing mechanical energy from a source of heat. The engine includes a ring-like stator having an oval rotor chamber enclosing a cylindrical rotor eccentrically placed within the chamber to define a high displacement high temperature fluid chamber and a lower displacement low temperature fluid chamber. A plurality of extensible vanes extend outwardly from the rotor in sliding contact with the inner surface of the rotor chamber. A source of heat supplies thermal energy to fluid supplied to the high temperature chamber, while a heat sink cools fluid supplied to the low temperature chamber. An economizer heat exchanger is also provided for preheating the working fluid. The relative position of the rotor within the rotor chamber is adjustable for varying the relative displacement of the fluid chambers to control engine working parameters. In another embodiment, a first heat engine is utilized as a motor and is mechanically coupled to a second heat engine utilized as a heat pump for providing an external combustion heat pump or refrigeration unit.
[0027] U.S. Pat. No. 4,760,701 to David is titled External Combustion Rotary Engine. The patent describes an external combustion rotary engine comprising a motor member, a free-piston combustion member and a storage tank serving also as a heat exchanger and located between the motor and the combustor. The motor rotors rotate inside an enveloping structure eccentrically with respect to a power shaft to form alternatively compression and expansion chambers. Compressed air produced thereby is ducted first to the storage tank and then to the combustor for burning fuel to produce combusted gases which are in turn ducted to the storage tank where heat is exchanged between the hot gases and the cooler compressed air. The combusted gas is then expanded in the expansion chambers. A fraction of the compressed air is further compressed to a higher pressure level so that it may be used in air pad cushions to isolate the various engine rotating parts from the fixed structures surrounding them. The use of such air cushions prevents contacts between moving parts and eliminates friction, heat production therefrom and wear. The need for lubrication is thus also eliminated. The “externally” performed fuel combustion is much slower than in comparable internal combustion rotary engines. This results in higher combustion efficiencies, lower combustion temperatures and lower rates of production of pollutants such as NO.sub.x.
[0028] U.S. Pat. No. 5,211,017 to Pusic is titled External Combustion Rotary Engine. It shows an external combustion rotary engine having a configuration which allows spatial separation of the heaters and coolers, and a process which enables rotary motion of the rotors to be performed without internal combustion. The engine includes the triangular rotors enclosed inside the housings shaped in the form of an epitrochoid curve, the heat generating units, and the heat absorbing and discharging units. The heat generating units and the heat absorbing and discharging units are located outside the housings and connected to the housings. The engine can also include the ultrasonic fuel atomizers inside the heat generating units and the turbine for the purpose of rapid acceleration. The present invention provides the simple, compact, lightweight, extremely energy-efficient and environmentally clean engine.
[0029] U.S. Pat. No. 5,325,671 to Boehling is titled Rotary Heat Engine. It describes an engine energized by an external heat source and cooled by an external cooling source, driven by a closed body of gas contained in chambers of variable volume and passages connected thereto, and operating on a Carnot cycle. The apparatus of the engine also has heat pump capabilities.
[0030] U.S. Pat. No. 6,109,040 to Ellison, Jr. et al. is titled Stirling Cycle Refrigerator or Engine employing the Rotary Wankel Mechanism. It illustrates a non-reciprocating Stirling-cycle machine which overcomes problems associated with high drive mechanism forces and vibration that seriously hamper reciprocating Stirling-cycle machines. The design employs Wankel rotors instead of the reciprocating pistons used in prior Stirling machines for effecting the compression and expansion cycles. Key innovations are the use of thermodynamic symmetry to allow coupling of the rotating compression and expansion spaces through simple stationary regenerators, and the coordination of thermodynamic and inertial phasing to allow complete balancing with one simple passive counterweight, which is not possible in reciprocating machines. The design can be scaled over a wide range of temperatures and capacities for use as a cryogenic or utilitarian refrigerator or to function as an external heat powered engine.
[0031] United States Patent Application Publication 2009/0139227 to Nakasuka et al. is titled Rotary Heat Device. It has a rotary heat engine having a cylinder and a rotor having a rotating shaft rotatably placed in the cylinder. The cylinder has a heat receiving section for supplying heat to the inside of the cylinder and a heat radiating section for radiating heat from the inside. The engine also has an engine section body and an operation liquid storage section. A vaporized gas supply channel and a gas recovery channel communicating with the inside of the cylinder are provided, respectively, on the heat receiving section side and heat radiating section side of the cylinder in the engine section body. The operation liquid storage section is between the vaporized gas supply channel and the gas collection channel in order to aggregate and liquefy recovered gas and is installed such that both channels fluidly communicate with each other. Also, the operation liquid storage section has a heat insulation dam provided with a through hole for preventing backflow of fluid flowing inside.
[0032] While each of these devices may be useful for their intended purposes, none show the unique advantages of one embodiment of the present invention.
[0033] Specifically none show an engine utilizing an elongated driving force due to opening of a valve when one of three apexes passes a prior exhaust port and the expansion chamber volume is small.
[0034] None show that an input valve can be closed at the appropriate timing whereby pressure in the expansion chamber and the pressure in the system outside of the expansion chamber will be approximately equal when the rotor leading apex passes the exhaust port.
[0035] Due to the geometry of adding a second inlet and exhaust ports, modified engines suffer from blow-by at certain times. The blow-by occurs as an expansion chamber will be open to both the inlet and exhaust simultaneously. None show the use of valves to prevent blow-by in a system having three apexes of a triangular rotor and two inlets and two exhaust ports spaced about the engine housing.
[0036] None show the use of fixed gates mounted in the housing to decrease expansion chamber volume and increase the portion of driving force about one side of a rotor as the rotor orbits about the housing center point.
[0037] Another type of design utilizes a linear drive. Some examples include:
[0038] U.S. Pat. No. 3,939,719 to Stovall titled An Improved Power Converter Apparatus shows an apparatus for converting the power of a reciprocating member to unidirectional rotation of an output shaft. A reciprocator is connected to a coupling shaft so as to rotate the coupling shaft in alternating directions. Gears and clutches driven by the coupling shaft convert the alternating movement of the coupling shaft to unidirectional rotation imparted to the output shaft. In other embodiments, the reciprocator drives coupling shafts which in turn impart alternating movement to clutch assemblies that cooperate to alternately impart unidirectional rotation to the output shaft.
[0039] U.S. Pat. No. 3,973,445 to Ballard titled Conversion Mechanism for Linear to Rotary Motion relates to mechanism for converting linear motion to rotary motion without the use of a crank or crankshaft. Two circular members which may be provided with teeth are driven simultaneously in opposite directions by a chain, belt or rack which is in turn connected to a piston reciprocating in a linear path. The invention is particularly adapted to vapor engines sometimes referred to as expanders. It also comprises both electrically and mechanically actuated valve motions, including a reverse means and means for varying cut-off.
[0040] U.S. Pat. No. 4,702,147 to Johnson, et al. titled Engine with Pneumatic Valve Actuation shows an invention providing a valving arrangement for a reciprocating engine in which there are two valve assemblies, each with a pressure responsive valve member. As the piston approaches the end of its stroke in either direction, the exhaust port is closed, such as by an extension on the piston, causing fluid pressure to build up in the end of the cylinder. This pressure is conducted to the valve assemblies through fluid lines, causing the pressure-responsive valve members to move in response to the pressure build-up in the end of the cylinder. These valve members control the inlet and exhaust connections to the cylinder so that the piston is caused to reciprocate by the working fluid as the valve members are moved pneumatically to open and close the lines.
[0041] U.S. Pat. No. 5,461,863 to Simonds titled Transducer for Converting Linear Energy to Rotational Energy shows that multiple steam powered cylinders reciprocate to pivot arms back and forth connected to output drive shafts through one way clutches with the output drive shafts being interconnected through gears such that when one shaft is powered, the other is coasting. The inlet and outlet valves for each cylinder chamber are controlled by an actuator which instantaneously snaps the valves between open and closed positions. The power cylinders may be operated individually, in parallel or in series and as required, a valve passageway through the piston may be operated to equalize pressure. A pair of O-rings on the piston engage the cylinder wall only when the adjacent chamber is pressurized, thereby reducing drag in operation of the piston.
[0042] While each of these devices may be useful for their intended purposes, none show the unique advantages of another embodiment of the present invention.
[0043] None of these patents show an engine with multiple double acting or two way actuators each operable with two one way clutches.
[0044] None of these patents show an engine with multiple double acting or two way actuators each being in offset phase of driving force.
[0045] None of these patents show a double acting or two way actuator operable with two one way clutches wherein each clutch turns a shaft and the shafts are coupled with a chain to achieve a unidirectional driving force.
[0046] Thus there exists a need for a heat engine that solves these and other problems.
SUMMARY OF THE INVENTION
[0047] In one embodiment of the present invention, it relates to a heat engine having a housing. A generally triangular shaped rotor can drive an offset crank as it eccentrically rotates within the housing. Two inlets with valves and two exhausts are provided. The volume between each face of the rotor and the housing defines three expansion chambers. Six power cycles are provided (one by each expansion chamber times two inlets) per revolution of the rotor. Each valve controls the length of time that high pressure gas is allowed to enter each expansion chamber. The valves are controlled by a processor and close when enough pressure is supplied so that the pressures inside and outside the expansion chamber are equal when the chamber is fully expanded just prior to exhaust. Gates can provide a mechanical advantage to the rotor by reducing the amount of pressure applied to the back side of the fulcrum.
[0048] According to one advantage of the present invention, the engine utilizes an elongated driving force due to opening of a valve when one of three apexes passes a prior exhaust port and the expansion chamber volume is small. The faces of the rotor are smooth and undished in order to minimize the volume in each chamber when the valve first opens.
[0049] According to another advantage of the present invention, the input valve can be closed at the appropriate timing whereby pressure in the expansion chamber and the pressure in the system outside of the expansion chamber will be approximately equal when the rotor leading apex passes the exhaust port. In this regard, the efficiency of the expansion phase is maximized because all of the energy is utilized as the pressures are equalized when the system opens to the exhaust.
[0050] According to further advantage of the present invention, the use of valves prevents blow-by in the system. Blow-by would otherwise occur in a system having three apexes of a triangular rotor and two inlets and two exhaust ports spaced about an engine housing since at times in the revolution of the rotor a chamber would be open to both an inlet and an exhaust port at the same time. Using a valve prevents this occurrence from happening.
[0051] According to a still further advantage of the present invention, fixed gates are provided to decrease expansion chamber volume (start of the expansion) and also to increase the mechanical advantage of the rotor during the expansion (the portion of driving force about one side of a rotor as the rotor orbits about the housing center point). The side of the rotor upon which driving force acts is called the positive side of the fulcrum. Further, the undished face allows the gates to fully divide the expansion chambers into two portions due to being able to fully engage the rotor.
[0052] The gates can have a selected angular alignment whereby pressure within the expansion chamber acts to force the gates against the rotor face to form a strong seal.
[0053] The use of gates also allows the exhaust ports to be moved to different locations about the housing. In one embodiment, the pressure can be applied over about 30 degrees of rotation. However, by adding the gate and moving the outlet, the pressure can be applied over approximately 70 degrees of rotation, greatly increasing the driving force applied to the rotor.
[0054] According to a still further advantage of the present invention, the engine has six power cycles per revolution. This is due to three expansion chambers and two inlets. Each power cycle is offset from each other, whereby the combined power curve is smoothed out.
[0055] According to a still further advantage of the present invention, a processor is provided to control the opening and closing of the valves. The opening will be at a set point when the volume in the expansion chamber is at or near a minimum. The processor interprets both the input and exhaust pressures and closes the input valve at an exact time which allows for the high pressure gas entering the chamber to fully expand and be approximately equal to the pressure on the low pressure side of the system at exhaust.
[0056] According to a still further advantage of the present invention, a partial vacuum can be provided as the gas cools in the condensation chamber. This lower pressure can help to pull to rotor around its rotation.
[0057] According to another embodiment of the present invention, it relates to a heat engine having shafts with gears, position gears and a plurality of actuators each having gears. Energy can be harnessed from the first shaft as it rotates. The second shaft can be coupled to the first shaft to transfer energy from the second shaft to the first shaft. One coupler is a chain. Position gears orient the chain wherein the rotation of the second shaft is inverted upon the first shaft so that the first shaft has a constant rotational orientation. Each actuator is preferably a double acting actuator that can supply force to both push and pull upon a belt connected to the actuator rod. A 1-way clutch and gear connects the belt to each shaft wherein the belt (driven by actuator) imparts a positive force upon the first shaft on the out stroke and a positive force upon the second shaft on the return stroke.
[0058] According to one advantage of the present invention, the actuators are linear double acting or two way actuators. In this regard, the actuators provide positive pressure in both the extension or out stroke and the retraction or return stroke.
[0059] According to another advantage of the present invention, there is preferably a plurality of independent actuators. In this regard, the output power of the engine approaches a relative uniform output.
[0060] According to another advantage of the present invention, the timing of the actuators is offset. In a preferred embodiment, the phase timing is calculated as the inverse of the number of actuators. Advantageously, having an offset phase of multiple actuators eliminates a dead spot (when an individual actuator is fully extended or retracted immediately before being energized to move in the opposite direction).
[0061] Related, and according to a further advantage of the present invention, a position sensor is provided (and coupled to the belt of the first actuator) so that the position of the actuator is known. Since the timing of each actuator is offset, knowing the position of all actuators is known when the position of any one of them is known (via the processor and encoder).
[0062] According to another advantage of the present invention, each actuator is independently energized. In this regard, failure or problems with a single actuator will not directly result in failure or problems with the other actuators.
[0063] According to another advantage of the present invention, the actuator cylinder has two ports. Each port has a valve that is closed via a processer at an appropriate time wherein the pressure inside the port equals the pressure outside the port at the end of the stroke. The closing of the valve is determined by the formula P 1 ×V 1 =P 2 ×V 2 wherein P 1 is the pressure on the input side of the cylinder, V 1 is the volume within the cylinder when the valve closes, P 2 is the low pressure on the exhaust side of the cylinder and V 2 is the volume of the cylinder when the stroke is complete (fully extended or retracted).
[0064] In this regard, the actuator can utilize a full amount of energy (potential energy of expanding gas) in each stroke direction. The valves on the back side of the piston head are open during the actuator stroke to exhaust gas from the cylinder (i.e. first valve open on return stroke and second valve open on extension stroke).
[0065] According to a further advantage of the present invention, the output force of the actuators is cumulative. This allows the individual force of each actuator to be extracted even if individually the actuator does not have enough force remaining to rotate a shaft (at or near the end of the stroke).
[0066] According to another advantage of the present invention, 1-way clutches are provided. In this regard, the clutches allow force to be transferred from the actuator to a shaft in one direction, and allowed to rotate about the shaft without transferring energy in the other direction. Advantageously, this allows a belt to be used as it imparts a force while under tension and will not need to carry a load under compression.
[0067] According to a further advantage of the present invention, position gears are provided to position a chain that couples the shafts. In this regard, the chain can be positioned to invert rotation of the second shaft onto the first shaft. This can be accomplished by going over the top of one shaft and under the bottom of the other shaft, as the shafts rotate in opposite rotational orientations under the push and pull of the actuators. Inversion of the rotational force advantageously allows the first shaft to maintain rotation in a single rotational orientation (unidirectional driving force).
[0068] According to a still further advantage yet of the present invention, an engine with multiple double acting or two way actuators each operable with two one way clutches is provided.
[0069] According to a still further advantage yet of the present invention, an engine with multiple double acting or two way actuators each being offset in driving force is provided.
[0070] According to a still further advantage yet of the present invention, a double acting or two way actuator operable with two one way clutches wherein each clutch turns a shaft and the shafts are coupled with a chain to achieve a unidirectional driving force is provided.
[0071] Other advantages, benefits, and features of the present invention will become apparent to those skilled in the art upon reading the detailed description of the invention and studying the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0072] FIG. 1 is a schematic view of a traditional Wankel style engine.
[0073] FIG. 2A is a schematic view of a preferred embodiment of the present invention.
[0074] FIG. 2B is similar to FIG. 2A , but shows an additional reheat circuit between a pump and a high pressure tank.
[0075] FIG. 3 shows a controller in electrical communication with a first valve and a second valve.
[0076] FIG. 4 is a top view showing the rotor in selected position within the housing.
[0077] FIG. 5 is a top view showing the rotor in selected position within the housing.
[0078] FIG. 6 is a top view showing the rotor in selected position within the housing.
[0079] FIG. 7 is a top view showing the rotor in selected position within the housing.
[0080] FIG. 8 is a top view showing the rotor in selected position within the housing.
[0081] FIG. 9 is a top view showing the rotor in selected position within the housing.
[0082] FIG. 10 is a top view showing the rotor in selected position within the housing.
[0083] FIG. 11 is a top view showing the rotor in selected position within the housing.
[0084] FIG. 12 is a top view showing the rotor in selected position within the housing.
[0085] FIG. 13 is a top view showing the rotor in selected position within the housing.
[0086] FIG. 14 is a top view showing the rotor in selected position within the housing.
[0087] FIG. 15 is a top view showing the rotor in selected position within the housing.
[0088] FIG. 16A is a chart showing Pressure vs. Volume within an expansion chamber of the present invention.
[0089] FIG. 16B is a chart showing pressure within an expansion chamber as apex A moves around the housing.
[0090] FIG. 16C is similar to FIG. 16B , but shows an increased pressure throughout the revolution of apex A.
[0091] FIG. 17 is a top view of an embodiment of the present invention including an alternative gate structure.
[0092] FIG. 18 is a side view of FIG. 17 .
[0093] FIG. 19 is similar to FIG. 18 , but shows two housings with rotors in opposed positions.
[0094] FIG. 20 is an isolation perspective view of a rotor showing smooth rotor faces.
[0095] FIG. 21 shows pressure being applied to ½ of the rotor, wherein an expansion chamber is bisected by a gate.
[0096] FIG. 22 is a close up view showing an alternative embodiment of a gate with the rotor in a selected position.
[0097] FIG. 23 is similar to FIG. 22 , but shows the rotor in a different position.
[0098] FIG. 24 is a close up view showing an alternative embodiment of a gate with the rotor in a selected position.
[0099] FIG. 25 is a close up view of the gate illustrated in FIG. 24 .
[0100] FIG. 26 is similar to FIG. 25 , but shows the rotor in a different position.
[0101] FIG. 27A is a schematic view with an apex approximately 20 degrees before top dead center.
[0102] FIG. 27B is a schematic view with an apex approximately 10 degrees before top dead center.
[0103] FIG. 27C is a schematic view with an apex approximately at top dead center.
[0104] FIG. 27D is a schematic view with an apex approximately 10 degrees after top dead center.
[0105] FIG. 27E is a schematic view with an apex approximately 20 degrees after top dead center.
[0106] FIG. 27F is a schematic view with an apex approximately 30 degrees after top dead center, wherein the bottom gate ceases to seal the bottom expansion chamber.
[0107] FIG. 28 is a schematic view showing alternative inlet and exhaust locations.
[0108] FIG. 29 is a layout view of an additional embodiment of an engine and other components.
[0109] FIG. 30 is a top view showing several working parts of the engine of the present invention.
[0110] FIG. 31 is a side view showing shafts coupled to a belt.
[0111] FIG. 32 is a side view showing a chain coupling the shafts.
[0112] FIG. 33A is a side view of an actuator showing a first valve in an open position in the extension stroke and the second valve in the open position to exhaust gas from behind the actuator head.
[0113] FIG. 33B is a chart showing the pressure within the actuator shown in FIG. 33A .
[0114] FIG. 34A is a side view of the actuator shown in FIG. 33A but showing the first valve in the closed position in the extension stroke and the second valve in the open position to exhaust gas from behind the actuator head.
[0115] FIG. 34B is a chart showing the pressure within the actuator shown in FIG. 34A .
[0116] FIG. 35A is a side view of the actuator shown in FIG. 33A but showing the first valve in the closed position at the end of the extension stroke and the second valve in the open position to exhaust gas from behind the actuator head.
[0117] FIG. 35B is a chart showing the pressure within the actuator shown in FIG. 35A .
[0118] FIG. 36A is a side view of an actuator showing the second valve in an open position in the return stroke and the first valve in the open position to exhaust gas from behind the actuator head.
[0119] FIG. 36B is a chart showing the pressure within the actuator shown in FIG. 36A .
[0120] FIG. 37A is a side view of the actuator shown in FIG. 36A but showing the second valve in the closed position in the return stroke and the first valve in the open position to exhaust gas from behind the actuator head.
[0121] FIG. 37B is a chart showing the pressure within the actuator shown in FIG. 37A .
[0122] FIG. 38A is a side view of the actuator shown in FIG. 36A but showing the second valve in the closed position at the end of the return stroke and the first valve in the open position to exhaust gas from behind the actuator head.
[0123] FIG. 38B is a chart showing the pressure within the actuator shown in FIG. 38A .
[0124] FIG. 39 is a schematic view showing the positions of the actuators at the neutral position.
[0125] FIG. 40 is similar to FIG. 39 , but shows the first actuator being energized in the extension stroke.
[0126] FIG. 41 is similar to FIG. 40 , but shows the second actuator being energized in the extension stroke.
[0127] FIG. 42 is similar to FIG. 41 , but shows the third actuator being energized in the extension stroke.
[0128] FIG. 43 is similar to FIG. 42 , but shows the fourth actuator being energized in the extension stroke.
[0129] FIG. 44 is similar to FIG. 43 , but shows the first actuator being energized in the return stroke.
[0130] FIG. 45 is similar to FIG. 44 , but shows the second actuator being energized in the return stroke.
[0131] FIG. 46 is similar to FIG. 45 , but shows the third actuator being energized in the return stroke.
[0132] FIG. 47 is similar to FIG. 46 , but shows the fourth actuator being energized in the return stroke.
[0133] FIG. 48 is similar to FIG. 47 , but shows the first actuator being energized in the extension stroke.
[0134] FIG. 49 is similar to FIG. 48 , but shows the second actuator being energized in the extension stroke.
[0135] FIG. 50 is similar to FIG. 49 , but shows the third actuator being energized in the extension stroke.
[0136] FIG. 51 is similar to FIG. 50 , but shows the fourth actuator being energized in the extension stroke.
[0137] FIG. 52 is a chart showing combined horsepower during the extension stroke of the first actuator and the other actuators at corresponding positions.
[0138] FIG. 53 is a chart of the data supporting the chart of FIG. 52 .
[0139] FIG. 54 is a chart showing actuator operation data.
[0140] FIG. 55 is a schematic view of a valve showing input and exhaust routing.
[0141] FIG. 56 is a perspective view of a preferred embodiment of the present invention.
[0142] FIG. 57A is a chart showing actuator data in an extension stroke.
[0143] FIG. 57B is a chart showing additional actuator data in an extension stroke.
[0144] FIG. 58A is a chart showing actuator data in a retraction stroke.
[0145] FIG. 58B is a chart showing additional actuator data in a retraction stroke.
[0146] FIG. 59 is a chart showing combined horsepower data of actuators having an offset timing.
[0147] FIG. 60 is a graph showing the combined horsepower illustrated in FIG. 59 .
[0148] FIG. 61 is a chart showing preferred operating parameters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0149] While the invention will be described in connection with several embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
[0150] A first embodiment can be viewed by looking at FIGS. 1-28 .
[0151] Looking now to FIG. 2A , it is seen that an engine 10 is provided having a housing 20 . A rotor 60 is further provided. The rotor 60 rotates within the housing 20 as described below.
[0152] A high pressure tank 120 is provided. The tank can be any suitable size. The tank 120 can hold a selected amount of working medium 130 . The working medium is preferably a commonly available refrigerant that undergoes a phase change between liquid 131 and gas 132 at predictable temperatures and pressures. One preferred refrigerant is R-123. However it is understood that other refrigerants could be used without departing from the broad aspects of the present invention.
[0153] A heat source 140 is provided. The heat source 140 is in close proximity to tank 120 , whereby the heat source can heat the working medium 120 causing selected amounts of liquid 131 to undergo a phase change to gas 132 . The tank can hold the gas at high pressures. It is understood that operating pressures and temperatures are determined based on system requirements and refrigerants used. A gauge 150 is provided for measuring the pressure in the high pressure tank 120 .
[0154] A high pressure delivery system 160 is provided. The high pressure delivery system 160 can be split into two lines, a first line 165 and a second line 166 . The lines are fluidly connected wherein the pressure in each line 165 and 166 are preferably the same. The high pressure delivery system 160 provides high pressure gas to the housing 20 of the engine 10 .
[0155] A low pressure exhaust system 170 is further provided. The low pressure exhaust system receives low pressure exhaust from the housing 20 of the engine. The low pressure exhaust system has a first line 171 and a second line 172 . The first and second lines 171 and 172 , respectively, combine in line 173 .
[0156] The low pressure exhaust 170 goes through a condensation chamber 180 having a heat exchanger 185 . The condensation chamber 180 has a gauge to measure pressure within the system on the low pressure side of the system. The condensation chamber 180 empties liquid condensate into a low pressure condensation tank 200 . From there, a pump 210 is used to route liquid 131 back into the high pressure tank 120 to repeat the cycle. Looking briefly at FIG. 2B , it is seen that an alternative line 420 can be provided to route liquid through a heat exchanger 421 prior to entering the high pressure tank to pre-heat the liquid.
[0157] A processor 230 is provided. The processor 230 communicates with position sensors or locators 240 and 241 (which monitor the location of the rotor 60 within the housing 20 ). The processor 230 , as seen in FIG. 3 , is also in communication with valves 41 and 46 , described below. The processor controls the opening and closing of the valves 41 and 46 .
[0158] Turning now to FIGS. 4-15 , it is seen how the rotor 60 moves about the housing 20 .
[0159] The housing 20 has a wall 21 with an inside surface 22 . The inside surface defines a general epitrochoid shaped structure having a first section 23 and a second section 24 . The sections are generally open to each other, but have a first radius 30 and second radius 35 there between. The radii 30 and 35 protrude a small amount toward the center of the housing 20 . The radii 30 and 35 have openings or recesses 31 and 36 respectively, to accommodate stationary gates (described below). The openings preferably span from the top to the bottom or the full dimension of the housing and are complimentary in shape to the respective gates. It is appreciated that the openings or recesses may not span the full dimension so long as they support gates that do span the entire dimension.
[0160] The housing has an inlet 40 with a valve 41 , an inlet 45 with a valve 46 , an outlet 50 and an outlet 55 . The inlets 40 and 45 are spaced apart (preferably approximately 180 degrees on separate sides of the housing) and are separated by outlets 50 and 55 . The valves 41 and 46 are preferably selectably opened and closed under the direction of the processor 230 based on the location of the rotor 60 within the housing 20 .
[0161] The rotor 60 is generally reuleaux shaped. In this regard, the rotor 60 has three faces, namely a first face 65 , a second face 66 and a third face 67 . The faces meet at apexes, namely the apex A 70 , apex B 71 and apex C 72 . Seals 75 , 76 and 77 are provided respectively at apex A 70 , apex B 71 and apex C 72 . The rotor 60 is shown prospectively in FIG. 20 . Faces 65 , 66 and 67 are preferably smooth and are formed without cavities or other recesses therein. In this regard, the faces travel closely to the inside surface 22 of the housing.
[0162] It is understood that the seals actually contact the housing, but for sake of simplicity in description, it is described herein as apex's passing certain points such as inlets and exhausts.
[0163] As is best seen in FIG. 18 , the housing 20 has a center or fulcrum 81 . The rotor has a center line 80 as well. The rotor center line 80 is offset from the fulcrum 81 a selected amount as the rotor 60 rotates in an eccentric manner about the housing 20 . The frame of reference of the viewer determines the direction of rotation. For example, staying with FIG. 18 , the rotor rotates in a clockwise direction within the housing. However, the direction of rotation would be opposite if the field of view likewise is opposite.
[0164] A first expansion chamber 90 , a second expansion chamber 100 and a third expansion chamber 110 are provided. The expansion chambers are located between the rotor 60 and the housing 20 . A driving force is provided in an expansion chamber due to the offset orientation of the fulcrum and the rotor center.
[0165] It is understood, looking at FIGS. 4-15 , that one of the expansion chambers may be exposed to either the first inlet and first outlet or the second inlet and second outlet simultaneously. However, since the first inlet and second inlet both are valved (and can be closed) blow-by is prevented in the present invention as the respective valves will be closed when the condition exists when the expansion chambers are so exposed.
[0166] A gate 250 is provided and shown in FIGS. 4-15 and 24 - 26 . Gate 250 is preferably removably received (via the top or bottom of the housing) within opening 31 of radius 30 . Gate 250 has a first end 251 pivotally held within the opening 31 and an opposed second end 252 that contacts the rotor 60 at a tip. A face 253 is provided facing the rotor 60 and a back is provided facing the inside of the opening 31 . A spring 255 is provided for biasing the gate end 252 away from the opening 31 and towards the rotor 60 . A seal 256 is provided on the rear side of the gate. Gate 250 preferably spans the entire height of the housing 20 . Gate 250 has a lip 257 that engages in inside wall of the opening to hold the gate 250 within the opening so that the gate cannot escape from the opening.
[0167] A gate 260 is further provided. Gate 260 is identical to gate 250 . Gate 260 is removably received within opening 36 .
[0168] As seen in FIGS. 27A-27E , the gate 250 preferably engages the rotor from approximately 20 degrees before top dead center until approximately 20 degrees after top dead center, and lets off the rotor at approximately 30 degrees after top dead center. The gate 250 bifurcates the expansion chamber when it contacts the rotor, whereby it prevents pressure from acting on the rotor behind the gate. Bifurcation or splitting of the expansion chamber into two parts is accomplished since the rotor faces are undished so that the gates can engage the rotor.
[0169] An alternative gate 450 is illustrated in FIGS. 17 , 22 and 23 . Gate 450 has ends 451 and 452 . Gate 450 can be a flat piece of spring steel that bends or pivots. The gate is biased to be flat, but can be bent or pivoted to contact the rotor 60 . In this embodiment, a slot or slit can form the opening in the radius and the gate 450 can be press fit or adhesively held within the opening. It is appreciated that the gate 450 projects from the housing wall in a slanted manner toward the adjacent inlet and away from the adjacent outlet.
[0170] Gate 460 can be provided and is similar to gate 450 .
[0171] It is understood that the portions of the gates within the housing are movable. It is preferred that the gates are movable from a first gate position wherein the gate is flush with the housing wall to other positions wherein the gate either contacts the rotor or is projected into an expansion chamber without contacting the rotor. The gates preferably are operable to rotate in the same direction as the rotor. This allows pressure to press the gates against the rotor, as well as allowing the rotor to slide over the gates.
[0172] As seen in FIG. 16 , there are three volumes, V 1 , V 2 and V 3 respectively that occur at different times for each of the three expansion chambers of the rotor 60 .
[0173] V 1 is that volume occurring when an inlet valve opens. This occurs when the leading apex passes an inlet and the trailing edge passes an exhaust.
[0174] V 2 occurs when the rotor advances a sufficient amount to a maximum efficiency point. The maximum efficiency point occurs when the input valve closes at a volume so that the high pressure gas entering the expansion chamber is allowed to fully expand and be equal to the pressure on the low pressure side of the system when the leading apex reaches the exhaust port and the volume is at V 3 .
[0175] FIGS. 4-15 represent a full cycle of the rotor 60 within the housing 20 . The state of each expansion chamber as shown in these drawings is shown in the following table:
[0000]
Expansion
Expansion
Expansion
Chamber 1
Chamber 2
Chamber 3
FIG. 4
Fully exhausted
V3
V1
FIG. 5
Fully exhausted
Fully exhausted
V2
FIG. 6
V1
Fully exhausted
V3
FIG. 7
V2
Fully exhausted
Fully exhausted
FIG. 8
V3
V1
Fully exhausted
FIG. 9
Fully exhausted
V2
Fully exhausted
FIG. 10
Fully exhausted
V3
V1
FIG. 11
Fully exhausted
Fully exhausted
V2
FIG. 12
V1
Fully exhausted
V3
FIG. 13
V2
Fully exhausted
Fully exhausted
FIG. 14
V3
V1
Fully exhausted
FIG. 15
Fully exhausted
V2
Fully exhausted
[0176] It is appreciated from studying of the above-chart that there are six power cycles per revolution of the rotor 60 within the housing 20 .
[0177] As means of an example only, at V 2 , the volume can be 1 unit and the pressure 4 units. Then, at V 3 , the volume can be 4 units and the pressure 1 unit Likewise, the pressure external of the expansion chamber is 1 unit. In this regard, the pressure inside and outside of the expansion chamber are equal at V 3 . The timing of the opening and closing of the input valves is determined by the processor whereby this result is achieved.
[0178] FIG. 16B shows graphically pressure within the first chamber as a function of the location of apex A 70 relative the housing (in degrees of rotation).
[0179] FIG. 16C shows graphically the pressure within the first chamber as a function of the location of apex A 70 with an elongated driving force due to 1) opening the valve approximately 20 degrees earlier and closing approximately 20 degrees later. Both early opening and late closing are allowed by the gate.
[0180] Turning now to FIG. 19 , it is seen that a second housing 520 and rotor 560 can be provided. The rotor 560 has a center point 580 and the housing has fulcrum 581 . The housing 520 is preferably oriented similarly as housing 20 . In this regard, the respective rotors are offset from each other, which allows an engine with two housings to drive an offset crankshaft.
[0181] Turning now to FIG. 28 , it is seen that a housing 620 is provided. The housing 620 has a rotor 630 and gates 640 and 650 . The gates allow inlets 660 and 670 and outlets 680 and 690 to be located at alternative locations about the perimeter of the housing 620 . In particular, the gates and alternative exhaust locations allow for larger exhaust volumes, which in turn allow for elongated driving forces to be applied (high pressure applied longer in the cycle so that exhaust pressures are equal).
[0182] Also, the gates allow the exhaust to be much closer to the next successive inlet, as the gate prevents back-flowing within an expansion chamber as it bifurcates the expansion chamber. The inlet valves can also be opened earlier in the cycle thereby elongating the driving force. In this regard, in an embodiment without a valve, the inlet valve can be opened with the trailing apex passes the exhaust port. However, when a gate is provided, there is no way for the gas to reach the exhaust port and the valve can be opened before the trailing apex passes the exhaust port.
[0183] Looking now at FIG. 21 , it is seen that if an equilateral triangle were centered within the housing, that it would be equidistant between the inlet and outlet. Further, a center line from the top apex of the triangle to the center point of the base would pass directly through the fulcrum of the housing. If there was no gate, adding pressure at this point in rotation would lead to a locked rotor (equal pressure on each side of the fulcrum) The solutions to this problem are either 1) retarding the input until the trailing apex passes the outlet or 2) adding the gate to block gas and hence pressure from being able to act on the triangle behind the gate. Hence, all of the pressure acts on the first side of the triangle which applies a force to move the triangle in clockwise orientation.
[0184] It is appreciated that the engine 10 of the present invention is able to power many types of devices. Two examples are as an automobile engine and as a means to extract energy out of an existing heating system such as a building heating system.
[0185] One typical building heating system is a furnace. In this regard, the current furnace simply burns fuel and uses the waste heat to warm a building. By installing a heat engine, the fuel would still be burned, but the heat energy from said burning is used to propel the heat engine, such as the heat engine of the present invention, which can be used to generate electric power via generator.
[0186] The waste heat contained in the gas exiting the exhausts is still routed through the condensation chamber 180 . Yet, heat exchanger 185 can be used to draw heat from the condensation chamber 180 and transfer it to a building via the building HVAC system. In this regard, the heat of the exhaust gas is not lost, and not dissipated generally. Instead, the dissipated heat is redirected to the building to fulfill the environmental requests of the HVAC system.
[0187] Another embodiment is illustrated in FIGS. 29-61 .
[0188] Looking first at FIG. 29 , it is seen that a boiler 710 is provided. The boiler can heat a liquid and force it through a two way valve 715 . On one side of the valve, the fluid is rerouted to the boiler (when it is not needed) and on the other side of the valve, the fluid is routed to a heat exchanger 720 before being returned to the boiler. Reservoir 730 has a refrigerant therein. The reservoir pipes fluid to the heat exchanger 720 wherein it evaporates and forms a high pressure gas. The high pressure gas is used to drive the engine 750 , as described below. The gas leaves the engine and passes through a heat exchanger 725 prior to entering a condenser 735 . Any gas that does not evaporate can pass through a 1-way return valve 740 to cycle back through the condenser an additional time. A second 1-way valve 741 is provided to prevent backflow into the engine 750 . A pump 745 is provided to return condensed liquid back through the heat exchanger 725 and to the reservoir 730 .
[0189] A valve is shown generically in FIG. 55 . In this figure, it is seen that the valve has an inlet and an exhaust. A gate, wall or other structure could be utilized to allow gas to enter or leave via the appropriate path.
[0190] It is appreciated that while these above-mentioned components are shown and described, that alternatives and substitutions may be made without departing from the broad aspects of the present invention, and specifically the broad aspects of the engine 750 as it is described below.
[0191] Turning now to FIG. 56 , it is seen that an engine 750 is provided. Engine 750 has a base 760 , two shafts 770 and 780 and respective gears 772 and 782 , position gears 790 and 800 positioning a chain 810 and a plurality of actuators 820 , 920 , 1020 and 1120 each with associated gears. It is understood that while four actuators are shown, that more or fewer may be used without departing from the broad aspects of the present invention. Specifically, the engine could work with a single actuator, yet, in the preferred embodiment, several actuators are utilized in order to flatten or normalize the engine power output. It is also preferred that, as described below, that the actuators are double acting actuators. Yet, the principles of the present invention could be utilized using single acting actuators without departing from the broad aspects of the present invention.
[0192] Each of these components is described below in detail. A processor 755 is provided and is not described in detail below. However, the processor controls the opening and closing of the valves.
[0193] Base 760 is shown in FIG. 56 . The base can be made of any suitable material that is strong and durable enough to support the components of the system.
[0194] Turning now to FIGS. 30-32 , it is seen that a shaft 770 is provided and is supported by the base 760 . Shaft 770 has two ends and is rotatable about an axis of rotation 771 . A gear 772 is at the second end of the shaft 770 . The gear 772 is preferably fixed to the shaft 770 such that the rotation of the shaft causes the gear to rotate in a likewise manner. Shaft 770 can be connected to an additional device to harness energy from the shaft as it rotates. In this regard, shaft 770 is a drive shaft.
[0195] A second shaft 780 is also provided. The second shaft 780 has two ends and is rotatable about an axis of rotation 781 . A gear 782 is at the second end of the shaft 780 . The gear 782 is preferably fixed to the shaft 780 such that the rotation of the shaft causes the gear to rotate in a likewise manner.
[0196] Shafts 770 and 780 are preferably parallel to each other. In this regard, the axis of rotation 771 of shaft 770 is parallel to but offset from the axis of rotation 781 of shaft 780 .
[0197] A positioning gear 790 and a positioning gear 800 are also provided and are supported by the base 760 . Gear 800 is preferably fixed relative the base 760 . However, a slot 791 is provided so that gear 790 is adjustable supported relative the base. The slot is preferably oriented towards and away from the center of the second positioning gear 800 so that the first and second positioning gears 790 and 800 can be moved closer to and further away from each other to provide tension to the chain.
[0198] A chain 810 having an inside 811 and an outside 812 is further provided, and is best seen in FIG. 32 . The chain 810 wraps around gear 772 , gear 782 , position gear 790 and position gear 800 . Specifically, the inside 811 of chain wraps around gear 782 , 790 and 800 . The outside 812 of chain 810 wraps around gear 772 . It is preferred that there is at least ¼ turn of contact between the chain and the gears to avoid putting too much pressure on the gear teeth. It is appreciated that chain 810 operatively couples shafts 770 and 780 . Shaft 770 preferably always rotates in a single rotational direction. Rotational force from the second shaft 780 is transferred in an inverted manner to the first shaft 770 due to the inversion of the chain 810 .
[0199] Looking now at FIG. 30 , it is seen that in the preferred embodiment, four actuators 820 , 920 , 1020 and 1120 are provided. Each actuator is preferably similar or identical. One actuator 820 is described in detail below. It is understood that the other actuators are similar or identical to the actuator described below. The actuators generally are linear gas powered actuators that are dual power or two way operational actuators. In this regard, the actuators are powered in the extension stroke as well as the return or retraction stroke.
[0200] Actuator 820 has a cylinder 825 . The cylinder 825 has two ends. A port 830 operable with a valve 831 is at the first end. A port 840 operable with a valve 841 is at the second end. Valves 831 and 841 can be selectably opened and closed to allow high pressure gas to enter the cylinder and drive a rod 850 by acting on a selected side of a head or boss 851 . In this regard, when pressure is introduced on the first side of the head 851 the rod extends, and when pressure is introduced on the second side of the head, the rod retracts. A clamp 855 is provided on the outer end of the rod 850 . The clamp 855 is used to connect the rod to a belt 860 .
[0201] A position sensor 865 is provided and communicates the location of the belt 860 to a controller. In this regard, the timing of the actuator 820 can be monitored and maintained. Position sensor 865 fits within the grooves on the inside portion of the bottom of the belt. Sensor 865 communicates with an encoder to determine the position of the head of the actuator and communicates the information to the processor 755 .
[0202] A gear 870 with a perimeter 871 is provided. The gear has a clutch bearing 872 . Clutch bearing 872 is preferably a 1-way clutch bearing that is press fit securely within gear 870 . Gear 870 is attached to shaft 770 . The gear, via the clutch bearing 872 , locks in one direction wherein it will cause the shaft to rotate, yet turns freely in the opposite direction without imparting a force onto the shaft.
[0203] A second gear 880 also with a perimeter 881 and a clutch bearing 882 is provided. Gear 880 is attached to shaft 780 . The second gear is similar in operation to the first gear.
[0204] Belt 860 is preferably wrapped about gears 870 and 880 . The belt rotates in a first direction about gears 870 and 880 when the rod 850 is extending from the cylinder 825 . The belt rotates in the opposite direction about gears 870 and 880 when the rod is retracting into the cylinder 825 . Clutch bearings 872 and 882 are 1-way clutch bearings. In this regard, the bearings can affect rotation of respective shafts in one direction yet freely rotate about the respective shaft when rotating in the opposite direction. Specifically, during the extension phase, gear 870 causes shaft 770 to rotate while gear 880 is not engaged with shaft 780 . Yet, during the retraction or return phase, gear 880 engages and causes shaft 780 to rotate while gear 870 is disengaged with shaft 770 .
[0205] Looking now to FIGS. 33A-38B , the sequence of opening and closing the valves (and the associated pressures within the cylinder) are provided. In the extension stroke, valve 841 is open the entire time so that back pressure does not build up behind head 851 . Valve 831 opens at the start of the extension ( FIG. 33A ) and remains open until a point (an intermediate point) where it closes when the head is between the ends ( FIG. 34A ). The first valve 831 then remains closed as the rod becomes fully extended ( FIG. 35A ). The pressure inside the cylinder 825 is charted in FIGS. 33B-35B during the extension stroke.
[0206] The return or retracted stroke is illustrated in FIGS. 36A-38B . Valve 831 remains open during the entire return stroke so that pressure does not build up behind the head 851 . Valve 841 opens at the start of the retraction ( FIG. 36A ) and remains open until a point (an intermediate point) where it closes when the head is between the ends ( FIG. 37A ). The first valve 841 then remains closed as the rod becomes fully returned or retracted ( FIG. 38A ). The pressure inside the cylinder 825 is charted in FIGS. 36B-38B during the return stroke.
[0207] The closing of the valves is preferably determined to be to point where the pressure inside and outside of the cylinder are equal at the end of the stroke. The closing of the valves is driven by a processor 755 that interprets the following formula: P 1 ×V 1 =P 2 ×V 2 . Where:
[0208] P 1 =High pressure on the input side of the engine.
[0209] V 1 =The volume within the driving side of actuator when input valve closes.
[0210] P 2 =Low pressure on the Exhaust side of the engine.
[0211] V 2 =The full volume within the driving side of the actuator when the stroke is completed.
[0212] FIG. 54 illustrates a specific set of preferred manufacturing parameters regarding the actuators. It is understood that this data is illustrative only and that pressures, dimensions and other parameters may vary without departing from the broad aspects of the present invention. In this example, the input valve is opened longer than necessary as is evidenced in a higher horsepower output. FIGS. 52 and 53 show the engine output yielded by such parameters. However, the higher horsepower is achieved with lowered efficiency. Specifically, a relatively high input pressure times volume product is provided at the point where the valve closes. Then, right before the end of the stroke, more than necessary pressure remains in the actuator representing potential energy that is not harvested by the engine.
[0213] Looking now to FIGS. 57A to 61 , it is seen that a more preferred embodiment of parameters ( FIG. 61 ) is illustrated. FIGS. 57A to 58B illustrate the output of a single actuator during its extension and retraction strokes, respectively. As is seen, the horsepower goes to zero at the end of the stroke as the last of the potential energy of the expanding gas is utilized. The pressure within the actuator is approximately the same as the pressure outside of the actuator at the end of the stroke as shown in this example. The efficiency of harvesting potential energy is maximized when the pressure within the actuator is approximately the same as the pressure outside of the actuator at the end of the stroke. FIG. 59 shows the combined horsepower of four actuators operating in offset phase to achieve the cumulative output illustrated in the graph of FIG. 60 .
[0214] The second, third and fourth actuators are similar to the first actuator, and are briefly described below. Then, following this brief description, independent operation of the four actuators is shown and described.
[0215] Actuator 920 has a cylinder 925 with two ends. A port 930 with a valve 931 is at the first end, and a port 940 with a valve 941 is at the second end. A rod 950 with a head 951 can be extended from and retracted into the cylinder 925 under operation of the valves. A clamp 955 connects the end of the rod 950 to a belt 960 . The belt 960 operates gears 970 and 980 driving shafts 770 and 780 , respectively.
[0216] Actuator 1020 has a cylinder 1025 with two ends. A port 1030 with a valve 1031 is at the first end, and a port 1040 with a valve 1041 is at the second end. A rod 1050 with a head 1051 can be extended from and retracted into the cylinder 1025 under operation of the valves. A clamp 1055 connects the end of the rod 1050 to a belt 1060 . The belt 1060 operates gears 1070 and 1080 driving shafts 770 and 780 , respectively.
[0217] Actuator 1120 has a cylinder 1125 with two ends. A port 1130 with a valve 1131 is at the first end, and a port 1140 with a valve 1141 is at the second end. A rod 1150 with a head 1151 can be extended from and retracted into the cylinder 1125 under operation of the valves. A clamp 1155 connects the end of the rod 1150 to a belt 1160 . The belt 1160 operates gears 1170 and 1180 driving shafts 770 and 780 , respectively.
[0218] Turning now to FIGS. 39-51 , the advancement and retraction of the various actuators is illustrated. It is appreciated that the actuators 820 , 920 , 1020 and 1120 have an offset phase. In this regard, each actuator is offset by ¼ stroke. The offset is preferably determined as the inverse of the number of actuators whereby the output power generation curve is leveled off to reduce spikes and dips in power. Being offset in phase is determined by when each actuator is energized (in both the positive or extension stroke and the negative or retraction stroke) and accordingly the distance each actuator is offset. Hence it is illustrated that the actuators are independently energized and operate independent of each other in offset phases. The actuators can accordingly be in relative different positions relative to their respective stoke distances or operate in different directions (positive or negative stroke) as they are independent of each other. Yet, the output forces are cumulative. The offset timing and cumulative output continue during each cycle of operation of the engine.
[0219] The actuators apply positive force to shaft 770 during the extension stroke and apply positive force to shaft 780 during the return stroke. The forces applied are cumulative to the pressure within the respective cylinder.
[0220] It is appreciated that the rotational force of the shafts 770 and 780 is perpendicular to the extension and retraction force of the actuators. The belts driven by the respective actuators are preferably offset from the center of the shafts by about 2.25 inches. Of course, the offset can vary depending on the size of the cylinders and other components. The preferred (but not limited) offset is between 1 and 12 inches. Yet, this amount could be more or less without departing from the other aspects of the present invention.
[0221] Rotational energy from shaft 770 can be used for any number of purposes, including being connected to a generator to produce electricity. Given the operable connection between the shafts and the use of 1-way clutches, it is appreciated that the force of the actuators is cumulative from the engine 750 . The force output in one embodiment is shown in chart and data form in FIGS. 52 and 53 and in another embodiment in FIGS. 59 and 60 . Noteworthy, due to the diameter of the rod (and specifically its displacement) acting on the back side of the rod head in the return stroke, the pressure time volume product on the return stroke is less than the pressure times volume product on the extension stroke due to the volume occupied by the rod. To account for this, it is understood that the closing timing on the return stroke may vary from the closing timing on the extension stroke without departing from the broad aspects of the present invention.
[0222] It is thus seen that the actuators independently follow the formula P 1 times V 1 equals P 2 times V 2 in harvesting potential energy from the actuator. The output from each actuator is cumulative with the output of the other actuators.
[0223] Thus it is apparent that there has been provided, in accordance with the invention, a heat engine such as a linear drive heat engine that fully satisfies the objects, aims and advantages as set forth above. While 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 in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.
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The present invention relates to a heat engine having shafts with gears, position gears and a plurality of actuators. Energy is harnessed from the first shaft as it rotates. The second shaft can be coupled to the first shaft to transfer energy from the second shaft to the first shaft. One coupler is a chain. Position gears orient the chain wherein the rotation of the second shaft is inverted upon the first shaft so that the first shaft has a constant rotational orientation. Each actuator is preferably a double acting actuator that can supply force to both push and pull upon a belt connected to the actuator rod. A 1-way clutch and gear connects the belt to each shaft wherein the belt (driven by actuator) imparts a positive force upon the first shaft on the out stroke and a positive force upon the second shaft on the return stroke.
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FEDERAL RESEARCH STATEMENT
The invention described herein may be manufactured, used or licensed by or for U.S. Government purposes without the payment of royalties thereon.
BACKGROUND OF INVENTION
I. Field of Invention
This invention applies to the field of rail guns and more particularly, to a barrel assembly in an electromagnetic rail gun.
II. Background of the Invention.
Challenges presented by rail gun construction have existed since the early 1920s. Examples of such guns are taught in U.S. Pat. Nos. 1,370,200; 1,421,435; and 1,422,427. Current laminated-type rail gun barrels 10 for applications requiring light weight mobile use typically comprise stacked metallic annular or rectangular laminations in combination with pre-stressed tension elements to add radial and longitudinal stiffness. These laminations 11 have engineered shapes (often an elongated annular shape) to accommodate a plurality of longitudinal rails 12 within the barrel 10 , and the lamination shape is optimized to contain radial forces (tending to spread the rails 12 ) associated with the launching of rail gun projectiles.
Longitudinal stiffness of a rail gun barrel 10 can be obtained from tension elements 13 that may be spirally wound around the barrel at a preferred angle with the barrel longitudinal axis as taught in U.S. Pat. No. 5,454,28? entitled “Lightweight High L” Electromagnetic Launcher.” Alternatively, axial tension rods 14 may be used to preload the metallic laminates 11 in compression as shown in FIG. 1 (Prior Art), to provide a high effective bending modulus, provided the preload is not defeated by disturbance loads, Ref. “A High Performance Rail Gun Launcher Design,” Juston, John M. and Bauer, David P., IEEE Trans Mag., v33n1, pp. 566-570, Jan. 1997.
Radial stiffness of a rail gun barrel 10 is required in order to contain the rails 12 of the gun. In strong analogy with gas propulsion guns, the electromagnetic forces that propel the projectile out of a rail gun, also apply substantial loads to drive the rails 12 apart. The resulting strain of the rails 12 under the imposed magnetic stress may impair performance of the launcher as it propels projectiles at velocities in excess of 2/km/s. Since the rails 12 must be electrically insulated from each other, current practice is to place an insulator 15 between the two rails 12 . Since it is most challenging to engineer a structure that would allow the insulator material 15 to both bind to the rails, and to provide stiffness in tension, high performance rail gun designs incorporate a substantial compressive preload of the rails 12 against the insulator 15 that separates them. Using this approach, the modulus of the insulator 15 (often a ceramic), may contribute to reducing the dynamic strains of the rails 12 during operation, as long as the stresses do not exceed the preload magnitude. This is in complete analogy with any engineered tension compression system including tires and pre-stressed concrete.
Two methods of achieving this desirable pre-stress are depicted in FIGS. 2A (PRIOR ART) and 2 B (PRIOR ART). In FIG. 2A (PRIOR ART), a wedge 16 is driven between a split insulator 15 after the rail gun assembly has been undertaken. In FIG. 2B (PRIOR ART), a “flatjack” 18 is assembled between the main rails 12 and outer tensile containments structure 11 . After assembly, the “flatjack” 18 is pressurized with epoxy driving the rails 12 inward against the insulator (ceramic sidewall 19 ) while pulling the composite overwrap 20 out in tension. The epoxy subsequently cures to a solid state, making the pre-stress permanent.
Active cooling channels 21 are also generally required for heat dissipation in rail guns due to the very high ohmic heat loss effects which are on the order of twenty times more heat input to the launcher than a traditional gas gun. Thus active cooling channels 21 are desirable. In the design shown in FIG. 2B, active cooling channels 21 are integrated directly with the conducting rails 12 , see “Cannon-Caliber Electromagnetic Launcher, ” Zielinski, Alex E. and Werst, M. D. . IEEE Trans Mag, v33n1, pp. 630-635, Jan. 1997. With the design shown in FIG. 2A, conduction of the heat from the rails 12 through the containment structure 11 is sought to later dissipate the heat to the environment through the outer layer of the barrel 10 . Both of these approaches have limited success due to the fact of the small heat capacity of the surrounding air, and the low surface area of the outer skin of these types of rail designs.
To date, there is a need in this art for robust structural components in a rail gun, wherein these components can be preloaded to provide adequate pre-stressing of the containment structure for applications requiring light-weight mobile use.
Accordingly, it is an object of this invention to provide an improved containment barrel for a rail gun that enables increased muzzle energy and accuracy of a projectile.
Another object of this invention is to provide a design for a rail gun, wherein the barrel incorporates desired preload stresses in the gun containment structures.
Another object is to provide a design for a rail gun, wherein location of the cooling channels are in an area of low structural strain to provide active cooling of the rail gun, yet impart minimal impact to a rail gun design.
Finally another object of this invention is to substantially overcome the shortcomings in prior rail gun barrels and methods for making them, relating particularly to rail guns which are sufficiently strong, lightweight and stiff for mobile applications.
SUMMARY OF INVENTION
It has now been discovered that the above and other objects of the present invention may be accomplished by the following mechanism and in the following manner.
The rail gun barrel of the present invention comprises a pair of elongated, generally parallel conductive rails extending along opposite sides of the bore and being symmetrical about a longitudinal axis of the bore; a pair of elongated insulators disposed generally coextensively with the rails and circumferentially between them and maintained in a compressed state; a circumferential sleeve surrounding the insulators; a plurality of Belleville containment disks maintained in a stack that are compressed and surround the circumferential sleeve, each containment disk having a substantially hollow form with an outer surface, and an inner surface; and a plurality of longitudinal tension rods, disposed substantially parallel to the longitudinal axis of the bore and disposed external to the sleeve, the tension rods compresses the plurality of Belville containment disks.
BRIEF DESCRIPTION OF DRAWINGS
The features of the present invention and the manner of attaining them will become apparent, and the invention itself will be understood by reference to the following description and the accompanying drawings. In these drawings, like numerals refer to the same or similar elements. The sizes of the different components in the figures might not be in exact proportion and are shown for visual clarity and for the purpose of explanation.
FIG. 1 (PRIOR ART) is a diagrammatic perspective view of a laminated rail gun containment structure.
FIG. 2A and 2B (PRIOR ART) are transverse sectional views of a containment structure using laminated steel and composite overwrap methods.
FIGS. 3A, 3 B, 3 C, and 3 D are plots of internal stresses of a cylindrical gun barrel as a function of radius for (a) normal gun firing, (b) during autofrettage, (c) after autofrettage, and (d) autofrettage gun during firing respectively.
FIG. 4 shows a longitudinal sectional view of a barrel in accordance with the invention.
FIG. 5 is a transverse sectional view a—a of the barrel shown in FIG. 4 .
FIGS. 6A, 6 B, 6 C, and 6 D show alternative forms of the Belleville effect disk that can be used by the invention.
DETAILED DESCRIPTION
During firing of a cylindrical gas-type gun as in FIG. 1, such a gun exhibits peak stresses at the bore 17 . A radial compressive stress, sigma r, results as the bore 17 is prevented from being pushed out by the outer wall of the barrel. In addition, a tangential or “hoop” stress, sigma t, is formed as the bore 17 resists enlargement itself. Neglecting the axial tension load of recoil as it is small, these two principal stresses combine to form the equivalent (von Mises) stress, sigma e, shown in FIG. 3A. A uniform stress distribution over the entire tube cross section during firing can be attained by means of autofrettage, see “Guns,” Horn, F., in “Handbook on Weaponry,” Second Edition Ed., Rheinmetall Gmbh.Dusseldorf, 1982.
Autofrettage is the process of pre-stressing traditional high pressure guns by applying an internal pressure sufficient to cause a plastic radial dilation of the bore. As high pressure guns are thick walled pressure vessels, the strain imposed by the autofrettage pressure may result in decreasing levels of plastic deformation at outer radial portions of the wall. Typically, the autofrettage pressure results in strains that are insufficient to cause plastic deformation of the outer hoop layers of the gun barrel. FIG. 3B depicts that once the material begins plastic deformation, the stress no longer increases, the equivalent stress flat-lines in the plastic zone during autofrettage. Once the autofrettage pressure is relieved, the outer hoop layers are left in a state of tension as they attempt to drive the permanently enlarged bore hoop layers back to their original size. FIG. 3C shows the results that being in the compression of the surface of the bore. Upon firing, a nearly constant equivalent stress is achieved through out the radius of the gun barrel. The propulsion pressure overcomes the compression preload gun as shown in FIG. 3 D.
Autofrettage is distinct from the current pre-stressed rail gun construction as typified by the designs shown in FIGS. 2 a and 2 b (PRIOR ART). First, the bore 17 of the gas gun (typically constructed of steel) is fully capable of tolerating substantial tension. This is in sharp contrast to the insulators 15 of the rail guns that must be bound in compression to prevent separation of the rails 12 from the insulator 15 . Second, autofrettage achieves a favorable stress distribution throughout the structure. The outer tensile containment structure of these rail guns exhibits the highest strain at the inner layers of the tensile containment structure.
Using principles presented by autofrettage in gun construction as discussed above, it has been discovered -that modified designs of rail guns can incorporate principles of this phenomenon. The present invention, embodying a rail gun barrel defined by an elongated bore 31 shown at FIG. 4 for passage of a projectile, is explained as follows.
FIGS. 4 and 5 depict a preferred rail gun barrel 22 construction which comprises a pair of elongated, generally parallel, electrically conductive rails 23 and a pair of elongated generally parallel insulators 24 . FIG. 4 shows the gun wherein Belleville containment disk 25 are in a non-compressed state and in a compressed disk 26 when assembled. The insulators 24 are disposed circumferentially between the rails 23 . That is the rails 23 and insulators 24 are disposed alternately about the circumference of the barrel so that the rails 23 do not contact one another. The rails 23 are preferably made of a copper alloy. The compressed insulators 24 herein are made of a ceramic material. The rails 23 are disposed symmetrically about the longitudinal axis of the barrel, as are the insulators 24 . Each rail 23 has a pair of generally planar side surfaces that abut generally side surfaces of the insulators 24 at interfaces that define radial planes. The rails 23 are electrically connected at their respective rearward or breech ends to opposite terminals of a source of direct current(not shown).Means for loading projectiles into the barrel 22 are provided at the breech end.
The rails 23 preferably have cooling passages 27 adjacent to them for coolant flow. These cooling passages are located in an area of low structural strain so as to provide active cooling of the rail gun 22 . These passages contained within the compressed containment disks 25 , 26 after assembly enable liquid coolant to effect heat transfer from the compressed containment disks 26 to an external heat exchanger (not shown). The location for these cooling passages 27 are symmetrically disposed about the barrel 22 with the axial tension rods 28 .
The rails 23 and insulators 24 herein define a substantially cylindrical bore 31 through which the projectile (not shown) travels. More specifically, the rails 23 and insulators 24 have curved inner surfaces that collectively define the substantially cylindrical bore 31 . The bore may be of circular or may alternatively be of rectangular or other suitable cross section.
The rails 23 and insulators 24 are contained within a circumferential insulator sleeve 29 that prevents current flow from rails 23 from passing through containment disks 26 . This sleeve 29 also provides adequate lubrication to enable the Belleville effect containment disk 25 to be compressed during manufacture.
A circuit through the rails 23 may be completed either by a conductor or a plasma arc disposed between the rails 23 . Where a plasma arc is used, high fluid pressures are generated within the bore 31 by vaporization of a strip of metal. As current flows through the circuit, magnetic flux is generated between the rails 23 . The magnetic flux cooperates with the current in the conductor or plasma arc to accelerate the conductor or plasma forward between the rails 23 . The projectile may include the conductor or may be positioned forward of the conductor or plasma arc and driven forward thereby.
When the rail gun is fired, bursting forces resulting from the interaction of the current in the rails 23 with the magnetic flux generated thereby urge the rails 23 , outwardly. In addition, where a plasma arc is present within the bore, high fluid pressures urge both the rails 23 and insulators 24 radially outward.
The bursting forces are not uniform along the length of the barrel 22 , but rather act only on the portion of the barrel 22 behind the projectile. Thus, at any point in time during firing, each of the internal barrel components 23 , 24 has a highly stressed region behind the projectile and a less stressed region ahead of the projectile.
A circumferential insulator sleeve 29 prevents the rails 23 and insulators 24 from being displaced radially outward, but it has been found that the inner surfaces of the rails 23 and insulators 24 may be displaced outward by compression of these components. The sleeve provides a thin electrically insulating layer to prevent current flow from the rails 23 from passing through the compressed containment disks 26 . This also functions to provide adequate lubrication to enable the Belleville effect containment disks 25 to become compressed containment disks 26 during the assembly of the rail gun barrel.
The above described stress pattern thus may instantaneously compress rearward portions of the rails 23 and insulators 24 more than forward portions thereof, generating bending moments along the inner surfaces of the rails 23 and insulators 24 which define the bore 31 . The tensile stresses attendant to the bending moments in the rails 23 are generally not of sufficient magnitude to damage the rails 23 , but those in the insulators 24 , which are preferably made of a ceramic material having very good electrical insulating properties, may cause cracking because such ceramic materials typically have low tensile strength and are relatively brittle.
In accordance with the invention, the insulators 24 are pre-stressed axially so that bursting forces acting thereon during firing which could otherwise produce axial tensile stresses near the inner surfaces thereof instead simply diminish the magnitude of the axial compressive stresses near the inner surfaces. Axial compressive pre-stressing of the insulators 24 maintain spacing of rails 23 .
Axial tension rods 28 , which can be hollow, are used to compress the Belleville effect containment disks 25 from their relaxed state to a compressed state shown as disk 26 after assembly of the rail gun barrel 22 . These rods 28 provide sufficient axial preload to achieve high bending modulus, as described above.
The Belleville effect containment disk ( 25 -unassembled and 26 -after assembly) are laminated containment plates. Laminations (disk) 25 , 26 are typically required to reduce unwanted eddy currents when the gun is fired. The disk 25 , 26 have an out-of-plane distortion that minimizes this eddy current effect. The Belleville effect containment disk 25 , 26 , having characteristics similar to Belleville washers, thereby enabling improved flexibility in the control of preloads that result within the structure when compressed. These disk may also include perforations to induce discontinuous strain distributions upon their compression. For example, inward facing fingers that are deflected upwards out of plane. FIGS. 6A-D depict various Belleville containment effect disk designs that can be used in this invention.
When the Belleville effect containment disk 26 are compressed, the non-compressed disk 25 are subject to axial compression sufficient to defeat any out of plane distortion. As in the case of Belleville washers, as long as the disks 26 , 27 are assembled with alternating out of plane deformations, the net load required to prevent distortion is the same for either on one disk or as may as a hundred disks. This is due to the fact of an additive superposition of each disk spring effect, as opposed to a parallel addition effects that occurs if the deformations were not alternating. As the disks 25 are compressed, the strain of defeating the out of plane deformations results in stress distributions that vary with both radius and azimuth imposed throughout the laminate. Depending upon the magnitude of deformation of the Belleville effect containment disks 25 , 26 , plastic deformation can be achieved, if desired. Using FIG. 5, for most configurations, the accompanying radial and azimuthal strain will tend to contract the bore of the laminate, applying a compressive preload through the circumferential insulator sleeve 29 and rails 23 and compressed insulators 24 .
For preferred packaging of the gun, FIG. 5 shows a wrapping shroud 30 which provides environmental protection, additional bending stiffness if required, thermal insulation from uneven heating sources, and for minimizing electromagnetic signature emanation for stealth use in the field.
Other types of Belleville effect containment disk 25 prior to compression during assembly of the barrel may be used to achieve discontinuous changes in pre-strain. For example, these disks 25 can include perforations as shown in FIGS. 6A, 6 B, 6 C, and 6 D, which are generally referred to as rectangular speed nuts, push nuts for screws and studs, and external-internal respectfully.
From the foregoing, it will be appreciated that the invention provides an improved rail gun barrel and an improved method of manufacturing rail gun barrels. However, the embodiments described herein are included for the purposes of illustration, and are not intended to be exclusive; rather, they can be modified within the scope of the invention. Other modifications may be made when implementing the invention for a particular application.
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Methods and apparatus related to design and construction of lightweight and mobile rail gun barrels. The barrels comprise a pair of elongated, generally parallel conductive rails extending along opposite sides of the bore and being symmetrical about a longitudinal axis of the bore; a pair of elongated insulators disposed generally coextensively with the rails and circumferentially between them and maintained in a compressed state; a circumferentially sleeve surrounding the insulators; a plurality of Belleville containment disk maintained in a stack that are compressed and surround the circumferential sleeve, each containment disk having a substantially hollow form with an outer surface, and an inner surface; and a plurality of longitudinal tension rods, disposed substantially parallel to the longitudinal axis of they bore and disposed external to the sleeve, the tension rods compress the plurality of Belleville containment disk. A protective sleeve and cooling channels can form part of the barrel.
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to rear view mirror assemblies for motor vehicles and more particularly to exterior motor vehicle mirror assemblies which incorporate auxiliary warning lights.
[0003] 2. Discussion
[0004] Auxiliary warning lights have long been incorporated on the sides of motor vehicles to provide a means of communicating the intentions of the operator thereof to adjacent vehicles such as for example the intention to change traffic lanes or to make a turn. Such lights are advantageous in providing notice to an adjacent vehicle that may be located in a blind spot and positioned such that the signaling vehicle's tail lights are hot visible to the adjacent vehicle's operator.
[0005] While incorporation of such auxiliary warning lights is relatively easy and straightforward on work-type vehicles it becomes a somewhat more complex problem when passenger-type vehicles are involved due in part to the importance of aesthetic appearance. Other considerations which may apply to any type of vehicle include the need to position the lights so as to minimize any impact on the vision of the vehicle operator and to maximize the area to the side and rear of the vehicle from which the auxiliary lighting is visible. Additionally, because in many cases the vehicle manufacturer may want to offer the auxiliary lighting arrangement as an option on certain vehicles, it is highly desirable that the lighting system be designed to easily and conveniently integrate with the existing vehicle design so as to minimize added labor and/or costs associated with its installation.
[0006] The present invention provides a highly effective and aesthetically pleasing auxiliary lighting system which is integrated into the vehicle's exterior rear view mirror assembly. Preferably, the auxiliary warning light of the present invention will be positioned on the laterally outer surface of the vehicle's exterior rear view mirror in such a manner as to be visible throughout an arc extending about 90 degrees rearwardly from a line extending generally perpendicular to the longitudinal axis of the vehicle. In this manner maximum visibility of the auxiliary warning light is provided to vehicles coming alongside the equipped vehicle while still preventing the emitted light from being visible to the vehicle operator or oncoming traffic. It should be noted, however, that the auxiliary warning light may be positioned so as to be visible to oncoming traffic in addition to the above referenced arc should this be desired and may in fact replace fender side marker lights required in certain countries.
[0007] In one form the light is integrated into a removable decorative covering which is secured to the mirror housing and a pigtail is provided for connecting the light to a wiring harness in the interior of the mirror housing. In a modification of this embodiment, the decorative cover member incorporating the light assembly is provided with a plug and the mirror housing includes a receptacle whereby electrical contacts on the cover member may be “plugged into” the receptacle as the decorative cover member is fitted to the housing. This last arrangement further reduces the costs associated with final assembly as no separate effort is required to make the electrical connections for the auxiliary warning light. Further, the integration of the light assembly into the decorative cover member greatly facilitates the offering of the auxiliary lighting feature as an option because only the decorative cover member need be changed to add or delete this auxiliary lighting feature.
[0008] Additional advantages and features of the present invention will become apparent from the subsequent description and the appended claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a fragmentary perspective view of a side of a motor vehicle having an exterior rear view mirror assembly incorporating an auxiliary warning light provided thereon all in accordance with the present invention;
[0010] FIG. 2 is a side view of the mirror assembly of FIG. 1 ;
[0011] FIG. 3 is a section view of the mirror light assembly of FIG. 1 , the section being taken along line 3 - 3 of FIG. 1 ;
[0012] FIG. 4 is a perspective view of a mirror housing with alternative decorative cover members shown in position for installation thereon, all in accordance with the present invention;
[0013] FIG. 5 is a view of the back side of a decorative cover member having a light assembly incorporated therein which includes an integrally formed electrical connector in accordance with the present invention;
[0014] FIG. 6 is a view of a portion of a mirror housing incorporating an electrical outlet adapted to mate with the plug shown in FIG. 5 , all in accordance with the present invention; and
[0015] FIG. 7 is a plan view of a motor vehicle having mirrors in accordance with the present invention secured to opposite sides thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring now, to the drawings and in particular to FIGS. 1 and 7 , there is shown an exterior rear view mirror assembly indicated generally at 10 installed on the door 12 of a motor vehicle 14 . Mirror assembly 10 is of the typical breakaway design and includes a housing 16 pivotably supported on an arm 18 extending outwardly from a generally triangularly shaped mounting plate 20 . As shown in FIG. 7 , preferably two mirrors 10 will be mounted on a vehicle 14 , one on each side thereof.
[0017] Housing 16 may be of any desired shape and includes an upper wall portion 22 , a lower wall portion 24 , a forwardly facing wall portion 26 and inner and outer wall portions 28 and 30 all of which merge smoother together so as to present a pleasing appearance. The rearwardly facing portion of housing 16 is open and is adapted to receive a reflective mirror 32 . Mirror 32 may be either of any suitable type such as flat, concave or convex or of the type which automatically adjusts to reduce glare. A suitably shaped support member (not shown) is secured within the housing and serves to movably support mirror within the opening. The support member may include suitable drive motors and the like for remote control adjustment of mirror as well as means for heating the mirror if desired. Housing 16 also contains a recessed portion 34 extending over at least a part of upper, inner, outer and forwardly facing portions 22 , 28 , 30 and 26 which is adapted to receive a decorative cover member 36 which cover member may be chromed, colored to match the vehicle or of some other finish to present an aesthetically pleasing appearance.
[0018] As thus far described, mirror assembly 10 is typical of existing rear view mirror assemblies currently employed on various motor vehicles. However, mirror assembly 10 of the present invention also incorporates an auxiliary warning light assembly 38 integrated with the decorative cover member 36 .
[0019] As best seen with reference to FIG. 3 , auxiliary warning light assembly 38 includes a light housing comprising a base member 40 having an opening 42 therein which is adapted to receive a suitable electrical socket 44 having a light source 46 provided thereon. Preferably opening 42 will be designed with two or three radially outwardly and circumferentially extending open portions whereby segmented inner flange 48 of light socket 44 may be inserted and then turned a few degrees to lock it in place. It should be noted that any suitable available light source 46 may be utilized. A suitable pigtail and associated electrical connector 50 is also provided extending outwardly from socket 44 which is adapted to be connected to connector 52 of wiring harness 54 provided in housing 16 . A lens member 56 is secured to base member 40 and is designed so as to direct light emitted from light source outwardly from mirror housing through an arc 58 extending approximately 90 degrees rearwardly from a line 60 passing through the mirror 10 and extending substantially perpendicular to the longitudinal axis 62 of the motor vehicle 14 . In order to enhance the visible light transmitted by the lens 56 the inner surface 64 of base member 40 will preferably be coated with a reflective material and shaped so as to direct a maximum amount of light from the light source 46 to the lens 56 .
[0020] Light assembly 38 will preferably be mechanically secured to decorative cover member 36 by means of integrally formed snap fasteners so as to form a one-piece assembly therewith. Although any other suitable manner of securing light assembly 38 to decorative cover member 36 may be used such as for example adhesive bonding, sonic welding, molding or even suitable separate fasteners. It is desirable that lens 38 have an outer surface which is shaped so as to form a substantially smooth continuation of the outer contour of decorative cover member as is shown in FIGS. 1 and 2 .
[0021] In order to accommodate light assembly 38 , housing 16 is provided with an opening 66 on the recessed part of outer surface portion 30 which underlies decorative member 36 . While housing 16 is shown as providing an opening 66 to accommodate light assembly 38 , in some applications it may be desirable to provide an enclosed recess in place thereof. Additionally, as mentioned above, a wiring harness 54 having a suitable electrical connector 52 will be provided within housing 16 so as to be accessible through opening 66 or within the recess if such is provided in place of the opening 66 .
[0022] In order to assemble decorative member 36 and associate light assembly 38 , one need merely interconnect the two electrical connectors 50 , 52 and thereafter assemble decorative member 36 to housing 16 . As shown in FIG. 4 , decorative member 36 is provided with a plurality of spaced outwardly extending tangs 68 on the back surface 70 thereof. These tangs 68 are designed to be received within suitable openings provided in housing 16 and to cooperate with latch members provided therein to retain the decorative member 36 thereon in the same manner as in currently available mirror assemblies of this type.
[0023] Warning light assembly 38 is intended to be interconnected with the vehicle turn signal system so that when one or the other of the turn signals are actuated, the light assembly 38 provided on the exterior mirror on the corresponding side of the vehicle will also be actuated. In this manner any other vehicle that may be approaching the vehicle equipped with the subject invention or that may be traveling in its blind spot will immediately be appraised of the equipped vehicle's intention to turn or change lanes even though they may not be in a position to see the vehicle tail lights. However, because the light is positioned on the outer wall portion 30 of the mirror assembly, the housing 16 and mirror 32 will prevent the driver of the vehicle from being distracted by this light when actuated.
[0024] As previously mentioned, the subject invention is particularly well suited for offering of the auxiliary warning light as an optional accessory by vehicle manufacturers. As shown in FIG. 4 , the overall size and shape of the decorative member 36 incorporating the light assembly 38 is such that it may be easily and conveniently interchanged with a decorative member 72 which does not include the light assembly. Thus, during final assembly of the mirror, the assembler need merely select one or the other of the two decorative cover members 36 , 72 for attachment to the mirror housing 16 depending upon the desires of the intended customer. Further, should a purchaser of a vehicle decide at a later date to either add or delete the auxiliary lighting feature, it is only necessary to replace the decorative cover member 36 or 72 with the other cover member:
[0025] Referring now to FIGS. 5 and 6 , another embodiment of the subject invention is disclosed which further facilitates rapid and low cost assembly of the subject invention. In this embodiment, base member 40 , light socket 44 and connector 50 are replaced by a base member 73 and a light socket 74 having a pair of electrically conductive pins 76 extending outwardly therefrom. Mirror housing 16 ′ is also modified by replacing opening 66 with a molded-in cavity 78 in which a pair of spaced openings 80 are provided positioned so as to receive pins 76 when decorative member 82 is assembled thereto. Thus, with this embodiment the assembler need not first interconnect the two electrical connectors 50 , 52 but rather needs merely install the decorative cover member 82 during which pins 76 will be received within openings 80 thereby electrically connecting light assembly to the existing vehicle turn signal system. As with the previous embodiment, should a purchaser not desire to include the light assembly, a cover member without the light assembly included is easily assembled to mirror housing 16 and will cover and conceal cavity 78 provided therein.
[0026] While it will be apparent that the preferred embodiments of the invention disclosed are well calculated to provide the advantages and features above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.
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An exterior rear view mirror assembly is disclosed which incorporates a warning light actuatable in conjunction with the vehicle turn signals to alert adjacent motor vehicles of an anticipated turn. The warning light is integrated into a first decorative cover member and may be connected to the vehicle turn signal circuit by way of connectable electrical leads or by an integrally formed plug and outlet arrangement. A second decorative cover member may be substituted for the first decorative cover member when it is not desired to incorporate the warning light.
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BACKGROUND OF THE INVENTION
This invention relates to an apparatus for monitoring the presence of metallic foreign bodies in a textile lap which is fed, for example, into a carding machine.
According to a known method, the driving torque for the feed roller of the carding machine is limited by means of, for example, a slip clutch. The foreign body carried by the advancing lap enters the bite of the feed roller and increases the torque resisting the roller drive. By virtue of the slip clutch, the roller drive continues its rotation, while the feed roller is at a standstill. This known method, however, is adapted to react only to relatively large and hard foreign bodies (that is, impurities having a relative high physical resistance). Further, an arrangement achieving torque limitation involves substantial expense.
French Pat. No. 1,411,766 discloses another type of sensing system for stopping the feed rollers upon detecting foreign bodies in a textile lap. As disclosed in this patent, in case the textile lap, passed between the feed roll and the feed table, contains undesirable foreign bodies, the latter displace the feed roll vertically upwardly against a spring-biased contact which, in turn, electronically causes stoppage of the feed roller. The sensing proper of the foreign bodies is thus effected by mechanical contacting. Such a mechanical detection is again effective only in case of relatively large and hard foreign bodies. Further, the shiftable bearing for the feed roller is a likely source of malfunctioning. Also according to this French patent, apart from the mechanical detection of foreign bodies, the fleece delivered by the carding machine is optically monitored by means of a light beam and a light barrier to detect ruptures or other defects in the fleece. It is apparent that while light beam testing of various quality-determining properties of the fleece is feasible, a light-beam monitoring is not adapted for the detection of foreign bodies embedded in the textile material.
German Pat. No. 1,510,191 and British Pat. No. 1,147,374 disclose the application of a high-frequency electromagnetic field across the running textile lap for the purpose of directly eliminating metallic foreign bodies. As the foreign body passes through the high-frequency field, it is heated thereby and thus it burns its way through the textile lap and is in this manner directly eliminated therefrom. It is a disadvantage of this method that it involves a local weakening and destruction of the lap. Thus, the method disclosed in these two patents is concerned with the direct elimination of foreign bodies and gives thus no consideration to a detection that makes possible a subsequent gentle removal of foreign bodies.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus for detecting, without mechanically moving parts, the presence of metallic foreign bodies of smaller dimensions and less hard consistency than required for the effective operation of prior art arrangements.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the apparatus for detecting metallic bodies in a running textile lap performs the steps of generating a high-frequency electromagnetic field; passing the textile lap through the high-frequency electromagnetic field; and deriving a sensor signal as a function of an alteration of the high-frequency electromagnetic field caused by the presence of a metallic body in the lap.
By passing the textile web through a high-frequency electromagnetic field which, for the purposes of this disclosure is meant to be between 10 kHz and 3,000 MHz, metallic foreign bodies of all kinds and dimensions can be reliably detected. The electrically or magnetically conducting foreign bodies cause an alteration of the high-frequency electromagnetic field; this change in the field is converted into a sensor signal for further use.
By virtue of the above-outlined use of a high-frequency electromagnetic field, the detection of metallic foreign bodies is possible in a simple and operationally safe manner.
Expediently, the sensor signal controls the feed roller drive, so that in case of an alteration of the high-frequency field due to the passage of a metallic foreign body, a further advance of the textile lap is interrupted to permit a subsequent removal of the detected foreign body.
The apparatus according to the invention includes a lap feed ramp, an arrangement for generating a high-frequency electromagnetic field at a location of the ramp across its entire width and an arrangement for generating a sensor signal in response to an alteration of the electromagnetic field caused by the presence of a metallic foreign body in the lap. The output of the sensor signal generating arrangement is connected to a switch in the circuit for driving a feed roller of a carding machine. The sensor signal controls the switch and thus effects stoppage of the feed roller when a metallic foreign body is present in the high-frequency electromagnetic field.
The arrangement for generating the high-frequency electromagnetic field includes an oscillator generating a high-frequency voltage and a component, such as a coil (with or without a core), supported in the zone of the lap feed ramp and connected to the oscillator. Such an arrangement is not sensitive to external effects and needs practically no maintenance.
Advantageously, the lap feed ramp is made of a synthetic material through which the high-frequency electromagnetic field passes. Such a component is inexpensive to manufacture. In order to enhance the feed to the feed roller, the lap feed ramp slopes downwardly.
According to a feature of the invention, the high-frequency electromagnetic field is generated by a one-piece component arranged either on the underside or above the lap feed ramp.
According to a further feature of the invention, the field-generating component is formed of two parts; one part is arranged on the underside of the lap feed ramp, while the other part is supported thereabove. In this manner, a closed coil configuration and thus an intensified and long-range effect can be obtained.
According to a further advantageous feature of the invention, the proximity sensor device (that is, the arrangements for generating the high-frequency electromagnetic field and for generating the sensor signal in response to a field alteration) is formed of a transmitter part and a receiver part, whose respective transmitting and receiving antennae are preferably arranged in a frame in a parallel relationship behind one another as viewed in the direction of lap advance. The lap is passed through an opening in the frame surrounded by the loops of the two antennae.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a preferred embodiment of the invention.
FIG. 2 is a schematic side elevational view of a further embodiment of the invention.
FIG. 3 is a schematic side elevational and block diagram view of another preferred embodiment of the invention.
FIG. 4 is a schematic perspective view of the embodiment illustrated in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to FIG. 1, a textile lap is advanced on a lap feed ramp 2, made of a synthetic material (such as acrylic glass, pertinox, hard paper or hard fabric), to a feed table 3 where it is grasped by a feed roller 4 and is advanced to a lickerin 5 of a cylinder 6 of a carding machine. Along the entire width of the lap feed ramp 2, there are arranged electromagnetic field generating components 7. The latter are connected to an oscillator 9 which supplies the components 7 with a voltage of high frequency in the 10 kHz-3000 MHz range for generating the high-frequency electromagnetic field 8.
If, during operation, a metallic foreign body contained in the advancing lap passes through the high-frequency electromagnetic field 8, the latter induces eddy currents in the metallic body. The eddy currents weaken the electromagnetic field 8, drawing additional energy from the oscillator 9 to such an extent that the signal amplitude is decreased. This changed condition in the oscillator 9 causes the generation of a sensor signal which opens an on-off switch 11 in the circuit of the drive 4a of the feed roller 4. Thus, the presence of a metallic foreign body causes, by virtue of contactless detection, an automatic stoppage of the feed roller 4, whereafter the foreign body (which is still upstream of the carding machine) may be removed. After removal of the foreign body, the normal electromagnetic field 8 is re-established, causing closure of the switch 11 and thus the feed roller 4 is automatically restarted.
According to the embodiment illustrated in FIG. 2, the proximity sensor has a field generating component 7a attached to the underside of the lap feed ramp 2 and a field generating component 7b arranged above the lap feed ramp 2 in alignment with the lower component 7a. In other aspects the embodiment shown in FIG. 2 is identical to that of FIG. 1.
The signal applied to the switch 11 is generated in a manner known by itself. Thus, a high-frequency electromagnetic alternating field is built up and reduced successively and in a progressing manner in the components (proximity sensors) 7 or 7a, 7b. As long as no metallic foreign body is present in any of these alternating fields, no weakening of the field occurs. As soon as such a foreign body is present in the range of the alternating field, the latter is weakened, so that the respective proximity sensor applies a signal to the switch 11.
Turning now to the embodiment illustrated in FIGS. 3 and 4, the lap feed ramp 2 is surrounded by a rectangular frame 12, the length dimension of which is oriented transversely to the direction of lap advance on the lap feed ramp 2. Within the frame body, generally following its configuration, there are arranged a rectangular transmitting antenna 16 and, downstream thereof (as viewed in the direction of lap advance) and in a parallel relationship therewith, a rectangular receiving antenna 17. The transmitting antenna 16 is coupled to a high-frequency transmitter 18 for generating the electromagnetic field 8. The receiving antenna 17 is coupled to a receiver 19 for sensing changes in the field 8 as a result of the presence of a metallic foreign body therein.
In operation, the textile lap 1 advances on the lap feed ramp 2 and passes through the opening 14 of the frame 12 and thus passes first through the loop of the antenna 16 of the transmitter 18 and then through the loop of the antenna 17 of the receiver 19. Signals derived from the high-frequency electromagnetic field 8 emitted by the antenna 16 of the transmitter 18 are, via the antenna 17 and the receiver 19, applied to a transducer 15 which, in turn, is coupled with the switch 11 for controlling the drive of the feed roller 4 of the carding machine. In case a metallic foreign body contained in the textile lap passes the frame 12, the electromagnetic field 8 is distorted and altered by the eddy currents induced in the foreign body. These changes are sensed by the receiver 19 and are amplified by the transducer 15. The output of the transducer 15 is applied to the switch 11 which stops or, upon subsequent removal of the foreign body, restarts the feed roller 4.
A signal applied to the switch 11 is generated in a manner known by itself. For this purpose, in FIG. 1 there are arranged several proximity sensors and in FIG. 2 there are arranged several proximity sensors 7a, 7b in juxtaposition. A high-frequency electromagnetic alternating field is built up and reduced successively and in a progressing manner in these proximity sensors. As long as no foreign body is present in any of these alternating fields, no weakening of the alternating field occurs. However, as soon as such a foreign body is present in the range of the alternating field of a proximity sensor, this alternating field is weakened, so that this proximity sensor applies a signal to the switch 11. The synthetic material of which the lap feed ramp 2 is made may be, for example, acrylic glass, Pertinax, hard paper, hard fabric.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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An apparatus for detecting metallic bodies in a running textile lap performs the steps of generating a high-frequency electromagnetic field; passing the textile lap through the high-frequency electromagnetic field; and deriving a sensor signal as a function of an alteration of the high-frequency electromagnetic field caused by the presence of a metallic body in the lap.
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BACKGROUND OF THE INVENTION
The present invention is directed to an apparatus for providing constant hydraulic output pressure from a pump, more particularly, to a pressure compensation means for a piston driven hydraulic pump.
1. Field of the Invention
The use of hydraulic pumps, in particular, piston driven or rotary hydraulic pumps, to provide high pressure water is well known in the art. The hydraulic piston pumps may be driven by pneumatic pressure, internal combustion engines, electric motors, or other means. Pneumatic hydraulic pumps are often capable of developing output pressures in excess of thirty times the pneumatic pressure supplied. Thus, a hydraulic pump having a 100 psi air pressure supply may be capable of developing a hydraulic pressure of 3,000 psi or greater. However, the design of a piston driven pump includes a known problem in that the pump does not develop any significant pressure at the piston top dead point (TDP) and bottom dead point (BDP). Thus, the hydraulic pump is not working during the entire piston travel cycle.
Further, the piston hydraulic pump also suffers from a problem known as hydraulic shock when the piston face comes into contact with the water after reaching each dead point. This hydraulic shock can result in an excessive wear to the hydraulic pump and any connecting lines to the pump thereby increasing the safety risk for the pump, operator and any downstream systems.
Prior art includes various mechanisms for eliminating hydraulic shock and for regulating pump output pressures to provide for a relatively constant pressure supply. These systems include the Hydrophor water supply systems which are commonly utilized in maritime vehicles. In the Hydrophor system, a water pump fills a closed container approximately two-thirds full of water and automatically switches off. The top end of the container is connected to a compressed air supply which maintains air pressure at a set level in the container. As the hydraulic pump begins filling the container with water, the air at the top of the container is compressed. When the amount of water in the container decreases, the hydraulic pressure within the container also decreases. The compressed air within the container forces the water downwardly, thereby compensating for the loss in hydraulic pressure from the pump. Thus, the Hydrophor system utilizing compressed air and hydraulic pressure maintains a water pressure in the range of 30-80 psi.
Another known system for maintaining relatively constant output pressure is through use of a small vessel having two chambers separated by a flexible diaphragm. One chamber is filled with compressed air while the other chamber is filled with the working pressurized liquid. As in the Hydrophor system, the diaphragm is displaced by pressurized water, thereby pressurizing the air in the other chamber. As the hydraulic pressure decreases, the air pressure deforms the diaphragm into the water chamber, partially compensating for the loss in hydraulic pressure.
The above systems, however, are not suitable in high pressure hydraulic applications. In the Hydrophor system, there is direct contact between the air and the water, which absorbs the compressed air. As the water pressure increases, the absorption of air within the water is greater. To compensate for this increased absorption of air, the air pressure itself must be increased. This requires a container having a thicker wall to compensate for the increased pressure.
The second mechanism, which utilizes a diaphragm, does not have the problem of air absorption because there is no air/water interface. However, this mechanism is unsuitable for use at high hydraulic pressures. The air chamber must be filled with an air pressure almost equal to the working water pressure. This requires higher air pressure which increases energy consumption and places significant material requirements on the diaphragm itself. The diaphragm must be elastic and thin to deform sufficiently to permit the compressed air to compensate for the drop in hydraulic pressure, but at the same time, be strong enough to withstand the high pressures. Further, this second type of mechanism has limited diaphragm deformation, thus decreasing the ability of the air chamber to compensate for the drop in hydraulic pressure.
Thus, there exists a need for a high pressure output compensation system, utilizing relatively low air pressure, which is capable of maintaining relatively constant high hydraulic pressures from a piston-driven pump.
SUMMARY OF THE INVENTION
The present invention relates to a hydraulic pump output pressure compensation device for use in systems utilizing high pressure piston driven hydraulic pumps. The present invention is comprised of a high pressure cylinder having a free-floating piston therein. The one end of the cylinder is connected to the output of the hydraulic pump through an inlet valve. The same end of the cylinder further includes a high pressure outlet valve and water discharge outlet. The other end of the cylinder is connected to a compressed air source through a compressed air inlet and check valve. As the high pressure water enters the cylinder, some of the water is retained within the cylinder, displacing the free-floating piston towards the compressed air inlet, thereby further increasing the air pressure within that portion of the cylinder. As the hydraulic pump output pressure from the hydraulic pump decreases when it reaches either the TDP or BDP, the hydraulic force exerted on the free-floating piston decreases and the compressed air in the compressed air portion of the cylinder expands to move the free-floating piston to compress the water, thereby increasing the output pressure of the water from the cylinder. The present invention thus assures a continuous flow of high pressure liquid, increasing the pump's efficiency, while it absorbing the hydraulic shock effects created by the pump. Further, the present invention does not require an excessively high air pressure to compensate for the hydraulic pump output pressure variances as there is no air/water interface.
The present invention may be used in high hydraulic pressure applications such as sand blasting or cleaning. However, it will be appreciated that the present invention may be utilized in any application which requires a relatively high, constant pressure output.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be obtained when the following detailed description of the exemplary embodiments is considered in conjunction with the following drawings, in which:
FIG. 1 is a cross sectional view of the preferred embodiment of the claimed invention;
FIG. 2 is a second cross-sectional view of the preferred embodiment showing movement of the free-floating piston;
FIG. 3 is a graph of water pressure output from a hydraulic piston pump shown in relation to the pump piston position;
FIG. 4 is a cross-sectional view of a piston driven hydraulic pumping system;
FIG. 5 is a graph of the pressure output of the pump of FIG. 4 in relation to the piston position;
FIG. 6 is a cross-sectional view of a typical double-action hydraulic pump;
FIG. 7 is a diagram of the pressure output of the pump of FIG. 6 when driven by an air motor; and
FIG. 8 is a diagram of the pressure output of the pump of FIG. 6 when driven by an electric motor or internal combustion engine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is directed to an output pressure compensator means for a high pressure hydraulic pump. FIG. 1 is a cross-sectional diagram of the preferred embodiment of the claimed invention. The compensator of the preferred embodiment is comprised of a hollow cylinder 2 having external threads 4 and 6 at the cylinder 2 top and bottom. A free-floating piston 8, having two compression seal rings 10 mounted thereabout, is inserted in the cylinder 2. It will be appreciated that the number of seal rings 10 may vary within the claimed invention. The piston 8, further includes a lower pressure guide ring 12 disposed thereabout. A safety nut 14, having mating threads, is threaded onto the cylinder 2 bottom followed by a sealing gasket 16 and a bottom cap 18. The safety nut 14 is brought into abutment with the bottom cap 18, thereby providing a high pressure seal for cylinder 2. The bottom cap 18 further includes a threaded water inlet 20 and a water outlet 22 adapted to relieve hydraulic pressure lines. The outlets are in fluid communication with the water chamber 24 within cylinder 2.
The preferred embodiment further includes a safety nut 26 threaded onto the top of the cylinder 2, followed by a sealing gasket 28 and a threadedly mating top cap 30. The safety nut 26 is brought into abutment with the top cap 30 to provide a high pressure pneumatic seal. The top cap 30 further includes a threaded compressed air inlet 32 and a check valve 34, 10 comprised of a spring 36, ball 38 and body 40, adapted to be retained within the top cap 30. In the preferred embodiment of FIG. 1, a sealing gasket 42 is inserted into a threaded cavity within the top cap 30. The check valve 34, is threadedly mated with the top cap 30 to provide an air-proof seal between the check valve 34 and the cylinder 2.
A coiled piston spring 46 is inserted over and retained about check valve 34. The piston spring 46 operates to overcome initial inertia of the piston 8 and provide additional resistance to the hydraulic forces acting on the free-floating piston 8. FIG. 1 illustrates the free-floating piston 8 as having been fully indexed to the bottom of cylinder 2. This forms an air pressure chamber 48 in which compressed air entering through air inlet 32 and check valve 34 has overcome the hydraulic pressure of the water in water chamber 24.
FIG. 2 shows the preferred embodiment of FIG. I with the free-floating piston 8 indexed towards the top of cylinder 2. This occurs when the water entering through inlet 20 builds up a sufficient pressure within water chamber 24 to overcome force exerted on the piston 8 by the air pressure within air chamber 48 and the spring 46, thereby driving the piston 8 upward to the top of cylinder 2. It will be appreciated that while the preferred embodiments of FIG. 1 and 2 illustrate the free-floating piston at its extreme positions, in operation, the piston 8 would be restricted in its travel and would not reach such extreme positions.
When the hydraulic pump piston is at a top or bottom dead point, the compressed air within chamber 48 and the spring 46 operate to force the free-floating piston 8 downward, increasing the hydraulic pressure on the water in water chamber 24, thereby maintaining a relatively constant water pressure. When the hydraulic 10 pump reaches its maximum working pressure, the high pressure water entering through inlet 20 will fill water chamber 24, driving piston 8 to the top of cylinder 2, thereby further compressing the air within air chamber 48 and the spring 46. When the hydraulic piston pumps reaches a dead point, when no pressure is provided, the air pressure within chamber 48 and the spring 46 will overcome the hydraulic force exerted on piston 8, driving the piston 8 downwardly as illustrated in FIG. I. Further, the coiled spring 46, shown in compression in FIG. 2, provides additional motive force to overcome any piston 8 inertia within the cylinder 2.
FIG. 3 is a diagram which relates the typical single-action piston hydraulic pump output pressures to time and piston stroke position. A typical piston driven hydraulic pump, such as those illustrated in FIGS. 4 and 6, may begin operation at any point within the stroke length. However, for ease of illustration, the piston stoke is illustrated as beginning at the bottom dead point at time zero. On the stroke up, the working pressure increases until such time as the pump output reaches its desired working pressure. In the diagram of FIG. 3, the desired working pressure is 3,000 psi. The pump output pressure is maintained at the working pressure during the piston travel. However, as the piston begins reaching its top dead point, the working pressure begins dropping until such time as the working pressure has dropped to zero at the piston top dead point.
On the stroke down, the working pressure again begins to build until such time as it reaches its working pressure. As the piston further traverses downward in the cylinder, the pressure begins to drop until such time as the piston reaches its bottom dead point and pressure drops to zero. The piston then begins its next cycle with its upward movement and the pressure once again rises until it reaches its working pressure of 3,000 psi. The time between the drop in the working pressure and its return to the working pressure is referred to as the dead time. The period of time in which the output pressure of the pumps of FIGS. 4 and 6 is maintained at a relatively constant output pressure is referred to as the pump working time.
FIG. 4 is a cross-sectional view of a single action hydraulic piston pump of the type generally known in the art which produces the pressure output diagram of FIG. 3. The piston pump is comprised of a pump body 50, having a water inlet 52 and inlet valve 54 and a water outlet 56 and outlet valve 58. The exemplary pump of FIG. 4 further includes a check valve 60 connected to water outlet. The pressure in the hydraulic pump of FIG. 4 is generated by means of a piston P which is comprised of a piston shaft 62 and piston face 64. The piston face 64 further includes a plurality of valves 66 located in piston face 64. In the pump of FIG. 4, the piston P is drawn upwardly by a force exerted on piston shaft 62. The force may be exerted by means of an air motor, internal combustion engine or other commonly known mechanical means. As the piston P is drawn upward, the piston face 64 exerts pressure on water within chamber 68. The hydraulic pressure within chamber 68 opens valve 58, which provides an outlet for the pressurized water through outlet 56 and check valve 60. At the same time, the piston face 64 draws a vacuum, opening valve 54 and thereby drawing water through inlet 54 into chamber 70. When the piston P is at the top of its stroke, no work is being performed. As the piston P is indexed downwardly, it automatically opens the valves 66 in the piston face 64, thereby permitting the water in chamber 70 to flow into chamber 68. At the same time, the pressure in chamber 70 forces valve 54 closed.
The output from check valve 60 of FIG. 4 is connected to the compensator 72 of FIGS. 1 and 2. The compressed water pushes the free-floating piston 8 (FIGS. 1, 2) upwards which compresses the air within air chamber 48 and compresses spring 46 until the hydraulic pressure in water chamber 24 is equal to the pressure exerted on the piston by the compressed air in chamber 48 and the compressed spring 46. When pump piston 64 in FIG. 4 reaches the bottom dead point, the pressure provided by the pump of FIG. 4 is essentially zero. The compressed air within chamber 48 and the spring 46 operate to push the floating piston 8 downwardly which forces water from water chamber 24 and closes check valve 60 (FIG. 4), thereby maintaining hydraulic output pressure. The closing of the check valve 60 results in a very slight pressure loss. Thus, the compensator FIGS. 1 and 2 is capable of providing constant water pressure at 3,000 psi plus or minus 100 psi. It will be appreciated that during its operation, the floating piston 8 of FIGS. 1 and 2 never reaches the bottom dead point of cylinder 2. The length of the stroke of free-floating piston 8 depends on the water pressure created by pump of FIG. 4, the quantity of water supplied by the pump during the stroke, and the length and dead time of the hydraulic pump.
The water exiting the compensator 72 (FIG. 4) enters a pressure regulating valve V which is set to a level less than the nominal working pressure of the pump. By setting the valve V to a pressure level less than the nominal working level, the water exiting pressure regulating valve V does not see an appreciable drop in pressure from the water exiting the compensator 72. The high pressure water may be utilized for a number of applications including sand blasting applications.
FIG. 5 is a graph showing the hydraulic pressure output of the pump of FIG. 4 without and with the preferred embodiment of FIGS. I and 2. In FIG. 5, the pump of FIG. 4 begins with the piston P at its bottom dead center at times zero. As the piston P is indexed upwardly, the pressure increases until the pump reaches its working pressure, in this case 3,000 psi. The pump of FIG. 4 maintains its working pressure at 3,000 psi as the piston P continues to move upwardly. However, as the volume of water in chamber 68 decreases, the pressure output of the pump of FIG. 4 also decreases until it reaches zero at the top dead point indicated as TDP in FIG. 5 of the piston travel. As the piston P of FIG. 4 begins its downward travel, the working pressure begins to build until it reaches its desired level of 3,000 psi. As the piston is nearing its bottom dead point, the loss of water volume results in a drop-off of water pressure, as shown by line 78, until such time as the output pressure from the pump of FIG. 4 reaches zero at bottom dead point. This cycle continues to repeat as the pump piston of FIG. 4 reciprocates.
The dotted line 80 in FIG. 5 illustrates the hydraulic pressure output of the system which includes the pump of FIG. 4 and the pressure compensator of FIGS. 1 and 2. At time zero, the piston P of FIG. 4 is beginning its upward travel building the working pressure to the 3,000 psi output. As the piston P of FIG. 4 reaches its working pressure level, the free-floating piston 8 of FIG. 1 is indexed toward the top of the cylinder 2, as illustrated in FIG. 2, at which time the force of the compressed air in chamber 48 and compressed spring 46 is equal to the 3,000 psi water pressure maintained in water chamber 24. As the piston P of the pump of FIG. 4 approaches its top dead point, the output pressure from the pump of FIG. 4 begins to decrease. The force exerted by the compressed air in chamber 48 and the spring 46 on the free-floating piston 8 of FIGS. 1 and 2 is then greater than the output pressure of the pump of FIG. 4 and the free-floating piston 8 is indexed downwardly, shutting the check valve 60 (FIG. 4) and exerting pressure on the water within water chamber 24, which exits through the outlet 22 of FIGS. 1 and 2.
This is reflected in FIG. 5 in the slight drop in pressure from the 3,000 psi working pressure indicated at the top dead point in time. As the piston P of FIG. 4 begins its downward movement, the hydraulic pressure again begins to build, opening check valve 60 (FIG. 4) and water enters through inlet 20 into water chamber 24 (FIGS. 1 and 2). The hydraulic pressure in water chamber 24 continues to build until it exceeds the pneumatic pressure within chamber 48, thereby indexing the free-floating piston 8 upwardly to the top of the cylinder 2. As the piston 8 begins to reach its bottom dead center, the hydraulic output from the pump of FIG. 4 begins to drop again and the hydraulic pressure within water chamber 24 is exceeded by the combined air pressure within air chamber 48 and the compressed spring 46 . This indexes the free-floating piston 8 downward, closing check valve 60 and maintaining the working pressure for the fluid exiting outlet 22.
Thus, the hydraulic outlet of a pump of the type shown in FIG. 4 may be maintained at a relatively constant level when used in conjunction with the compensator of FIGS. 1 and 2. Further, a pressure regulator valve V (FIG. 4) may be connected to the outlet 22 of the compensator 72 and set to a pressure level lower than the pump output working pressure. The output pressure from the pressure valve V may be set to compensate for the slight pressure loss from the nominal working pressure, which occurs when the compensator piston 8 is in motion. Thus, the pressure valve may be used to maintain a consistent hydraulic pressure output from the pump of FIG. 4. The preferred embodiment of FIGS. 1 and 2 has been shown operating in conjunction with a single action hydraulic piston pump of the type shown in FIG. 4. However, it Will be appreciated that the compensator of FIGS. 1 and 2 may be used in conjunction with other types of rotary or piston pumps including, the double action piston pump as illustrated in FIG. 6.
FIG. 6 is a cross-sectional view of a double-action piston driven hydraulic pump in combination with the present invention. The pump of FIG. 6 is comprised of a pump body 100, with a pump top 102 and pump bottom 104 and having a piston 106 and piston rod 108 positioned therein. The pump of FIG. 6 includes a low pressure manifold 110 which is connected to a water supply 112 and supplies water to the pump through inlet valves 114 and 116. The pump of FIG. 6 also includes a high pressure outlet manifold 118. The low pressure water entering the valve body 100 flows into the volumes 120 and 122 above and below the piston 106, respectively. As the piston rod 108 and piston 106 are indexed upwardly, the water within volume 120 is compressed, shutting valve 116 and opening high pressure outlet valve 124, and high pressure water flows into high pressure outlet manifold 118. Simultaneously, as the piston 106 is indexed upward a pressure differential in volume 122 opens low pressure inlet valve 114 and closes high pressure outlet valve 126, permitting low pressure water to flow into volume 122.
As the piston rod 10B and piston 106 are indexed downwardly, the piston 106 creates a pressure differential in volume 120, opening valve 116 to permit low pressure water into volume 120. Simultaneously, the piston 106 is compressing the water within volume 122, closing inlet valve 114 and opening high pressure outlet valve 126 which permits high pressure water to flow into the manifold 118. High pressure water is thus supplied through the high pressure manifold 118 with each upward and downward stroke of the pump. The high pressure water passes through a check valve 128 and a conduit 130 into the compensator of the present invention 132, which regulates the output pressure of the pump of FIG. 6. Further, a pressure regulation valve V is illustrated as being connected to the output line of compensator 132. As in FIG. 4, the valve V is set to some pressure lower than the working pressure of the pump, further damping any loss of hydraulic pressure in the system.
FIG. 7 is a diagram of the water pressure created by the pump of FIG. 6 when the piston of the pump of FIG. 6 is moved by an air motor. In this instance, the time required for the upstroke of piston rod 108 and piston 106 is shorter than the downstroke time due to the different quantity of water in chamber 120 when compared with the amount of water below the piston in chamber 122. In this instance, when the compensator 132 of the preferred embodiment is connected to the output 130 of the pump of FIG. 6, it will compensate for otherwise dead spots 134 and 136 between the two different piston strokes and keep the pump output at or near the nominal working pressure (3,000 psi).
FIG. 8 is a diagram of the water pressure output created by the pump of FIG. 6 when the piston is activated by means of an electric motor or an internal combustion engine utilizing a linkage which converts the output rotation of the motor or engine into reciprocal movement. In these instances, the time required for the upward and downward strokes of the pistons are equal. However, the output pressure differs between the upward and downward strokes due to the fact that the piston speed is the same in both directions. In this instance, when the compensator of the preferred embodiment is connected to the output of the pump of FIG. 6, it will compensate for the dead spots which result in a drop in pressure 138 and 140 as the piston approaches the top and bottom dead points.
Having described the invention above, various modifications of the techniques, procedures, material and equipment will be apparent to those in the art. It is intended that all such variations within the scope and spirit of the appended claims be embraced thereby.
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A high pressure hydraulic pump output compensator which utilizes a free-floating piston in a closed cylinder forming a lower and an upper chamber. One end of the cylinder is connected to the input of a hydraulic pump operating in excess of 1,000 psi. The lower chamber further includes a hydraulic input and an output port. Compressed air is provided to the free-floating piston at the opposite end of the chamber which exerts a force downwardly on the free-floating piston. The output pressure from the hydraulic pump compresses the air within the cylinder until such time as the compressed air and water pressure are equalized. As the output from the hydraulic pump drops during its working cylinder, the compressed air forces the piston downward to maintain the hydraulic output pressure.
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BACKGROUND OF THE INVENTION
This invention relates to a method for detecting/processing color image information which is capable of precisely and automatically detecting the image information in color registration on a color original film without positional adjustment of image sensors even if the sensors are provided separately for each of plural colors.
In a photograhic printing system, it is necessary to photometrically measure the density of an original film (i.e. a film negative formed by developing a film negative) to determine its exposure amount or correction amount for printing. The density of the film negative is conventionally measured in LATD (Large Area Transmittance Density) with photosensors such as photodiodes provided near the optical path of a printing optical system. However, since the LATD image detection is a method for measuring the average density of the film negative in average but not for accurately measuring it across a frame, the printing exposure or correction is not quite precisely determined.
FIG. 1 shows a system which is proposed by this applicant to solve such problems encountered in the prior art.
A film negative 2 is conveyed by a conveying mechanism 9 to a position on a film negative carrier 1. The film negative 2 is illuminated with the light from a light source 4 via a color compensation means 3 which comprises 3 color filters of yellow (Y), magenta (M) and cyan (C). The light transmitted through the film negative 2 is directed to reach a photographic paper 7 via a lens unit 5 and a black shutter 6. The photographic paper 7 is wound around a supply reel 7A and reeled on a take-up reel 7B in synchronism with the movement and suspension of movement of the film negative 2. Photosensors 8 such as photodiodes are provided near the lens unit 5 of the film negative 2 in order to detect image density information of the three primary colors. Utilizing the detection signals from such photosensors 8, picture printing is carried out. An image information detecting apparatus 10 comprising a two-dimensional image sensor 11 is operatively positioned near the film negative 2 at a position inclined from an optical axis LS of the light source 4 and the film negative 2. A lens unit 12 is provided in front of the two-dimensional image sensor 11 to substantially focus the center area of the film negative 2. On the back of the image information detecting apparatus 10 is attached a substrate board 13 for mounting a processing circuit comprising integrated circuits and so on.
The two-dimensional image sensor 11 comprises, as shown in FIG. 2, an image pickup section 101 for optically picking up an image, a storage section 102 for storing charges transmitted from the image pickup section 101, and an output register 103 for outputting the charges stored in the storage section 102. By controlling driving signals 101S through 103S from a driving circuit, the image information in two-dimensions (area) is photo-electrically converted and outputted serially from the output register 103 in the form of an analog image signal PS. The circuit mounted on the substrate board 13 has, for example, a circuit structure shown in FIG. 3. The image sensor 11 is driven by driving signals 101S through 103S supplied from the driving circuit 20. The light illuminating the image pickup section 101 of the image sensor 11 is outputted from the output register 103 as a picture signal PS, sampled and held by a sample-and-hold circuit 21 at a predetermined sampling cycle. The sample value thereof is converted by an analog-to-digital (A/D) converter 22 into digital signals DS. The digital signals DS from the A/D converter 22 are inputted into a logarithmic converter 23 for logarithmic conversion, then converted to density signals DN, passed through a write-in control circuit 24 and finally written in a memory 25.
A reading speed signal RS from the driving circuit 20 is inputted into the write-in control circuit 24 in order to read out image information at a predetermined speed when the image sensor 11 is driven. The write-in control circuit 24 writes in the density signals DN at predetermined positions of a memory sequentially and corresponding with the driving speed (i.e.--the scanning speed across the face thereof) of the image sensor 11. In other words, the reading speed of the image sensor 11 is determined by the driving speed. The reading speed in turn determines the segmentation number of picture elements with respect to an image area. The memory 25 should therefore store the detected information in correspondence with the number of pixels, too.
When a picture is printed in a conventional manner in the above mentioned structure, the light transmitted through one frame of a film negative 2 which has been conveyed to and standing still at a printing position is detected by photosensors 8. Then, the filters in the color compensation means 3 are adjusted in response to the picture signals for each of the primary RGB colors and the black shutter 6 is opened to expose a photographic paper 7 with the determined exposure amount.
An image information detecting apparatus 10 comprising a two-dimensional image sensor 11 of area scanning type such as a CCD is mounted at a position near the film negative 2 at an inclined angle with respect to the optical axis LS to facilitate mounting operation. The whole frame of the film negative 2 is segmented into a large number of arrayed pixels for detecting image information. In other words, when predetermined driving signals 101S through 103S are fed from the driving circuit 20 to the image sensor 11, the two-dimensional image sensor 11 is adapted to receive the light transmitted through the film negative 2 on the printing section via the lens unit 12. The two-dimensional image sensor 11 can therefore scan the whole surface of a frame of the film negative 2 along scanning lines SL sequentially by segmenting the whole area into a large number of small pixels 2A as shown in FIG. 4A. After the whole area has been scanned, the output register 103 of the image sensor 11 outputs picture signals PS sequentially, then the picture signals PS are sampled and held by a sample-and-hold circuit 21 and the sampled values thereof are converted by an A/D converter 22 into digital signals DS. The digital signals DS from the A/D converter 22 are logarithmically converted by a logarithmic converter 23 to density signals DN. The density signals DN are input to a write-in control circuit 24 to be stored in a memory in the arrays corresponding to the pixels 2A shown in FIG. 4B and in terms of the density digital values of the film negative 2.
If the digital values for respective pixels of the film negative 2 or the density values for respective pixels with respect to the three primary colors RGB are stored in the memory 25, it is possible to read out the digital values for any particular pixel of the film negative 2 out of the memory 25. If the density values for the respective three primary colors of R, G and B, which are obtained using mosaic filters (not shown) are stored as shown in FIG. 4B, it is possible to read out such values from the memory for processing (which will be described hereinafter) in order to determine the exposure or correction amount for photographic printing in the same manner as in the prior art.
In such a method for measuring the density of the film negative 2, accurate image processing cannot be conducted unless each imaged frame corresponds to an image sensor area or unless the center of each imaged frame coincides with the center of the image sensor 11 constantly; FIG. 5 shows the state where the center SAC of the sensor area SA of the image sensor 11 coincides with the center PAC of the image area PA in a frame of the film negative 2. However, in practice they are often deviated (by the distance λ) from each other even though they remain within the scope of mechanical tolerance or the sensor area SA of the image sensor 11 is inclined from the image area PA (by the angle θ). In the prior art system, it is necessary to positionally adjust the attachment of the image information detecting device 10 minutely to cause the center SAC of the sensor area SA to coincide with the center PAC of the image area PA (in other words to make the distance λ zero) and the angle θ zero. The attachment and adjustment of the device requires much labor and further, since it needs an additional system for mechanical minute adjustment, it becomes a factor to push up the costs. There has long been awaited a solution for the problem.
In the operation of detecting color image information from a color film negative as shown in FIG. 7, the light of the primary color B out of the light which is transmitted through a film negative 30 is focused on an image sensor 35 by a lens unit 32, and dichroic filter mirrors 33 and 34 are operatively provided in the optical path between the lens unit 32 and the image sensor 35 so that the light of the primary color R which is the light reflected from the dichroic filter mirror 33 is received by an image sensor 37. The light of the primary color G which is the light reflected from the dichroic filter mirror 34 is received by an image sensor 36. When the light from the film negative 30 in three primary color separations is received respectively by one of the three image sensors 35 through 37 (i.e.--sensor 35 is for B, 36 for G, and 37 for R) and stored in a memory in pixels for each of the three primary colors, the sensor address of the image sensors 35 through 37 should be made to precisely coincide with the position of frame images of the film negative 30. For instance, as shown in FIG. 8, if it is assumed that the image sensor 35 of the primary color B has the scope BMA for receiving light, when the scope of the image sensor 36 of the color G is deviated from the scope BMA laterally by a and vertically by b to become situated as RMA, the image sensors 35 through 37 scan different locations on the same film to store them in digital form in a memory. Since these stored images are not aligned positionwise in detection, colors do not come to be in registration to disturb image processing. The positions of two-dimensional image sensors 35 through 37 which receive the image light in three color separation should be aligned to correspond to the same location on images of the film negative 30. The detection areas thereof are aligned by minute positional adjustment in the prior art. This adjustment involves not only cumbersome works but requires also complicated mechanical systems.
Moreover, in the photographic printing system where the direction in the feeding of photographic paper is switched between longitudinal and lateral directions, the sensor area should be adjusted to have its center coincide with the center of image area in both directions.
SUMMARY OF THE INVENTION
This invention was conceived in order to obviate aforementioned problems encountered in the prior art, and aims to provide a method for detecting/processing image information which is capable of automatically correcting mechanical deviation in position by means of software without the necessity of positional adjustment mechanism or positional adjustment of image sensors, by detecting deviation amount between the sensor addresses of image sensors and the frame addresses of detected frames and converting the sensor addresses in pixel data detected by image sensors into frame addresses.
Another object of this invention is to provide a method for detecting/processing color image information which is capable of detecting color images in color registration by detecting deviation amounts between the respective sensor addresses of image sensors which are provided to separate color images into plural colors and the frame addresses of detected images and converting the sensor addresses in pixel data detected by respective image sensors into frame addresses thereby to obviate mechanical deviation in positions of the image sensors.
Still another object of this invention is to provide a method for detecting/processing image information which is capable of automatically correcting mechanical deviation of image sensors in position by means of software but without the necessity of positional adjustment mechanism by detecting the amount of deviation between the sensor addresses of image sensors and frame addresses of a detected frame, calculating data to obtain a start address where data on a specific point (for instance, the spot to be scanned first in an effective frame) of respective effective frames both in longitudinal and lateral directions are stored and processing the data for both directions and sizes.
According to one aspect of this invention, for achieving the objects described above, there is provided a method for detecting/processing image information comprising the steps of receiving light from images with an image sensor, digitally detecting for each pixel the image information of the whole area through which said image sensor receives light, storing the information in a memory and processing said stored data, in which memory addresses on data tables are corresponded with sensor coordinate of said image sensor, a reference film negative having a mark at a reference position is photometrically measured by said image sensor, the amount of deviation between a position on the sensor coordinate corresponding to said reference position of said reference film negative when there is no deviation between said sensor coordinate and frame coordinate and said reference position on said sensor coordinate, if deviated, is calculated, values on said frame coordinate corresponding to each pixel point on said sensor coordinate are calculated to be written in said data tables, and said detected images are photometrically measured with said image sensor to be stored in said memory and simultaneously are processed in accordance with the memory addresses on said frame coordinate obtainable by referring to said data tables.
According to another aspect of this invention, there is provided a method for detecting/processing color image information comprising the steps of separating the light from color images which contains all colors into separate monochromatic beams of plural colors, respectively receiving the separated lights with plural image sensors, digitally detecting, or a pixel by pixel basis, the image information of the whole area where said image sensors receive the light and storing the digitally detected image information in a memory and processing said stored data, in which memory addresses on data tables of plural colors correspond to sensor coordinates of respective image sensors, a reference film negative having a mark at a reference position is photometrically measured respectively by said image sensors, the amount of deviation between a position on the sensor coordinate corresponding to said reference position of said reference film negative when there is no deviation between said sensor coordinate and frame coordinate and said reference position on said sensor coordinate if deviated, is calculated, values on said frame coordinate corresponding to each pixel point on said sensor coordinate are calculated to write in said data tables, said detected images are photometrically measured respectively by said image sensors and stored in said memory, and color images are processed in accordance with the memory address on said respective frame coordinate obtainable by referring to said data tables.
Furthermore, according to still another aspect of this invention, there is provided a method for detecting/processing image information comprising the steps of receiving light from images with an image sensor, digitally detecting for each pixel the image information of the whole area through which said image sensor receives light, storing the information in a memory and processing said stored data, in which memory addresses on a first data table correspond to sensor coordinates of said image sensor, a reference film negative having a mark at a reference position is photometrically measured by said image sensor, the amount of deviation between a position on the sensor coordinate corresponding to said reference position of said reference film negative when there is no deviation between said sensor coordinate and frame coordinate and said reference position on said sensor coordinate if deviated is calculated, positional data on said size information is read out from said first data table for each feeding direction and for each size, start addresses where a specific point on the effective area for each case is stored is obtained from said calculated amount of deviation written in a second data table, images are photometrically measured by said image sensor and stored in said memory in the case of ordinary measurement, and images are processed in accordance with the start addresses on said frame coordinate obtainable by referring to said second data table.
The nature, principle and utility of the invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a structural view which shows an embodiment of a two-dimensional image sensor applied for image information detection in a photographic printing system;
FIG. 2 is a structural view which explains the function of the two-dimensional image sensor;
FIG. 3 is a block diagram of the control system of the two-dimensional image sensor;
FIGS. 4A and 4B are explanatory diagrams which describe the correspondence between pixel segmentation of the original film and stored data thereof;
FIG. 5 is an explanatory diagram of the relationship between a sensor area and a frame area;
FIG. 6 is a diagram which explains the deviation therebetween;
FIGS. 7 and 8 are diagrams which explain color registration;
FIGS. 9A and 9B are explanatory diagrams for explaining the deviation between sensor coordinates and frame coordinates;
FIG. 10 is a flow chart which shows an example of operation according to this invention;
FIG. 11 is an explanatory chart of a data table;
FIG. 12 is an explanatory diagram which shows the detection of the reference position;
FIG. 13 is a diagram which shows another example of the data table;
FIGS. 14 and 15 are a diagram and a flow chart which explain the operation of another embodiment according to this invention;
FIGS. 16A and 16B are flow charts which show an example of operation according to this invention;
FIG. 17 is a chart which shows an example of data table;
FIG. 18 is an explanatory diagram of a start address; and
FIG. 19 is a diagram which explains the reference position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to this invention, a reference position is determined in advance for a color image area by means of a reference film negative, for example, detected images on the film negative are photometrically measured by respective image sensors of plural colors such as the three primary colors to detect the positional deviation at a particular position from the reference position, and the positional deviation on each sensor area is corrected for color registration. Data tables are prepared for each color in advance in order to indicate which sensor address of a pixel position on each two-dimensional image sensor corresponds to a position on a frame (frame coordinates). When a film negative is photometrically measured, it is at the same time processed according to the address on the frame coordinate obtainable by referring to such data tables. The number of reference positions may be one (for example, at the center point of the frame) if there are deviations only in the longitudinal and lateral directions but not angular. But if there is an angular deviation, too, the number of reference positions must be two or more. A description is provided below for the case where two reference positions are needed.
When the reference positions on the film negative or actual images are photometrically measured with two-dimensional image sensors, and if the sensor coordinates x-y coincides with the frame coordinates X-Y as shown in FIG. 9A, the obtained data are used in processing as is. If the sensor coordinates x-y are deviated from the frame coordinates X-Y as shown in FIG. 9B, the amount of deviation (deviation λ in both longitudinal and lateral directions of X and Y, and inclination angle θ) is obtained to re-write the data table so that the image data may be processed in the position as shown in FIG. 9A. By processing it for all the three primary colors, scanning areas are made to be coincidental to each other over the whole frame.
If the sensor coordinate and the frame coordinate are deviated by the angle θ (for the point α1, β1) as shown in FIG. 9B, the relationship below holds between a point (Xi, Yi) on the frame coordinate X-Y and a point (xi, yi) on the sensor coordinate x-y; ##EQU1## and the inclination angle θ is expressed as ##EQU2## and therefore, each measured data for respective pixels can be transformed from the sensor coordinates to frame coordinates. If there is no deviation in inclination, θ is simply set equal to 0 such that cos θ=1, sin θ=0, and the expression (1) can be calculated.
The present invention will now be explained by referring to the flow chart with FIG. 10. The operation will be described in respect to one color herein.
First of all, the memory address of the data table (1,2, . . . , n×m) is corresponded with the sensor coordinate on the image sensor 11 ((1,1), (1,2), (1,3), . . . , (n,m)) as shown in FIG. 11 for each pixel (Step S1). A reference film negative 40 having reference positions marked at the locations SP1 and SP2 (see FIG. 2) is mounted at a predetermined position and photo-metrically scanned (i.e.--measured), and the measured data is stored in a memory A (Steps S2 and S3). In this case, the reference positions are set at the center SP1 of the reference film negative 40 and at a point SP2 where a line passing through the center SP1 crosses a side line. The reference points SP1 and SP2 are marked so as to be detected by the image sensor 11 when it photometrically measures the film in the above mentioned manner. Then the deviation between the position "0" (refer to FIG. 9B) on the sensor coordinate which corresponds to the reference position SP1 on the reference film negative 40 and a reference position (α1,β1) on the deviated sensor coordinates is calculated (Step S4). The deviation (α2,β2) from the other reference point SP2 is calculated (Step S5) and the inclination θ of the sensor coordinate from the frame coordinate is calculated in accordance with the above mentioned expression (2) (Step S6). In this manner, the deviation between the sensor coordinate and the frame coordinate is obtained, coordinates on the frame coordinate for each pixel on the sensor coordinate are calculated by the expression (1) and the thus obtained values are written in the memory B of the data table (Steps S7 and S8). The data table is written-in with frame coordinates corresponding to the memory address as shown in FIG. 11. Such a data table should be prepared in advance.
A film negative 2 is mounted at a predetermined position and measured photometrically with the image sensor 11 (Step S9), and the measured data is written-in the memory A (Step S10). The address on the frame coordinate can be learned from the data table and the image data is processed in accordance with the obtained data (Step S11). Such processing is conducted for each of the colors R(red), G(green) and B(blue). Even if an image sensor of a color is deviated from a frame of the film negative as shown in FIG. 6, such a deviation can be automatically corrected in the processing procedure to achieve color registration.
Although the data table is re-written for each pixel in the above statement, a data table may be given different numbers for each block (LU, RU, LD, RD, CN) if images are processed in the unit of a block or a segmented unit as shown in FIG. 13. The processing is conducted in this case by transforming the sensor coordinate to the frame coordinate in the same manner as above, and coordinating the values on the frame coordinate to that of block segments.
In the case where the reference film negative is marked at its center for photometric measurement of a reference position, deviation of the mark may make accurate re-writing of data tables impossible. Moreover, the reference film negative should be marked in advance. The aforementioned method may be realized by photometrically measuring an aperture on a film negative carrier with a two-dimensional image sensor, and calculating the reference position automatically. Such an example is shown in FIGS. 14 and 15.
Since the aperture of the film negative carrier is completely included within the area of the two-dimensional image sensor, the four points A(ai,aj), B(bi,bj), C(ci,cj) and D(di,dj) which define four corners of the aperture shown in FIG. 14 are obtained in the following manner. The area is scanned first in the direction of N1 and then in the direction of N2, and the point at which the light is first detected is designated as A(ai,aj) (Step S20). Then it is scanned in the directions N2 and N3, the point at which the light is deflected first is designated as B(bi,bj) (Step S21). It is then scanned in the directions N3 and N4, the point at which the light is first detected is designated as C(ci,cj). Lastly, it is scanned in the directions of N4 and N1, the point at which the light is first detected is designated as D(di,dj) (Step S23). Such a detection of the four points A through D can be obtained by calculation after all the data on the two-dimensional image sensor has been stored in the memory and then read out for calculation. After having obtained the four points A through D, for instance the distances from A to B, C, D are calculated and the longest distance is made a diagonal, the second longest line a longitudinal line and the shortest line a short side line of the aperture (Step S24). The coordinates ai and bi on two points A and B corresponding the longitudinal line are compared and the smaller one is made the point left top of the frame while the bigger one the point right top thereof (Step S25). The two points obtained at the step S20 are made the two points on the top corners of the frame as well as the reference points (Step S26). The sensor addresses of the two reference points on the film negative are detected from the data table (Step S27). The inclination angle θ is detected in accordance with the above expression (2) (Step S28). The deviation and inclination θ from the reference position obtained at the above Step S25 are detected, the contents of the frame coordinate of the data table which have been prepared in advance are converted by the above expression (1) (Step S29). The image information of a film negative is then detected (Step S30) followed by processing of the image information in accordance with the re-written content of the data table. Since the content of the data table has already been converted to the address without inclination nor deviation, even if image sensors are deviated or inclined from the film negative, the images can be constantly processed in the right relation shown in FIG. 9A. In photometrically measuring the aperture of the film negative carrier with the image sensor 11, since the direction of the film negative carrier is already in correspondence with both of the feeding directions of the film, the data table can be re-written and at the same time, the feeding direction of the film is automatically detected for appropriate processing. The size of the aperture on the film negative carrier can be detected to discriminate the size of the film negative automatically.
Although the above description was made for detection of images on the film negative, the same method is applicable for a positive film. The two-dimensional image sensors are described in the foregoing statement, but a line sensor may be used and moved relative to the film.
According to this invention as described in detail in the above statement, since the deviation between image sensor coordinate and actual frame coordinate is detected in preparing a data table, and since the sensor address of pixel data detected with the image sensor is converted to the frame address with the thus prepared data table to automatically correct the positional deviation of the image sensor, minute mechanical adjustments and an adjustment mechanism become unnecessary so as to thereby simplify the system as well as to reduce the cost. Even if the image sensor of one or more colors are positionally deviated or inclined from the film negative, image processing can be conducted in the proper relationship shown in FIG. 9A according to this invention method for color registration.
The aforementioned statement concerned the case where an image sensor is inclined by the angle θ from a film negative. If there is no inclination, the operation will be conducted as below; a reference position is determined at an appropriate location in the image area by means of a reference film negative. The images on the film are photometrically measured by a two-dimensional image sensor to automatically correct the positional deviation of the sensor area from the amount of deviation in the XY-directions (longitudinal/lateral) on the location corresponding to the reference position. A data table is prepared in advance to indicate the start address where the data on a point which is to be scanned first or a specific point such as the left top point of an effective frame area of all the types of frames including those for longitudinal and lateral feedings. When the film negative is photometrically measured, images are processed in accordance with the start address on the frame coordinates obtained by referring to the data table. The number of reference position may be one as in this case (such as in the center of frame), the deviation in the directions X and Y (longitudinal and lateral) alone should be corrected. The invention will now be explained in reference to the flow charts in FIGS. 16A and 16B.
An image sensor (image information detecting device) is adjusted so as not to cause deviation from the film negative at the printing section (Step S40). Effective areas are determined on the frame coordinate in directions X and Y for respective sizes of the film negative, and a data table A with memory address and sensor coordinate is prepared as shown in FIG. 17 (Step S41). The effective areas correspond to the lengths in directions X and Y (longitudinal and lateral directions) of the film negative. Since there is no inclination from the image sensor, a point to the left and above the scanning lines SL, for instance, is designated as start addresses SAT and SAW as shown in FIG. 18. The areas both for longitudinal and lateral feeding can be determined for each size on the sensor area SA of the image sensor. As shown in FIG. 17, the memory address on the data table A (1,2,3, . . . ,nxm ) corresponds to the sensor coordinate of the image sensor 11 ((1,1), (1,2), (1,3), . . . , (n,m)) for each pixel (Step S42). A reference film negative 30 having a mark SPM at the central reference position as shown in FIG. 19 is mounted at a predetermined position and photometrically measured with the image sensor and the obtained data thereof is stored in a memory (Steps S43 and S44). Then, the deviation between a position on the reference film negative 30 corresponding to the sensor coordinate on the reference position SPM if there is no deviation between the sensor coordinate and the frame coordinate and corresponding to the reference position on the sensor coordinate, if there is a deviation, is calculated (Step S45). By this processing, the deviation amount in the directions X and Y between the image sensor and the film negative is obtained and based upon the thus obtained deviation amount, the start address as shown in FIG. 18 is set for the lateral and longitudinal feeding of the film negative for each size. More particularly, the printer is set in the lateral feeding mode first (Step S46), and size information of the film negative is inputted in an appropriate sequence (Step S47). Size information may be inputted from a keyboard in a predetermined sequence such as 135 size→110 size→126 size→disc. Since the size or the effective area of the film negative of the size inputted just now is known, the XY data on the inputted size from the data table A is read out (Step S48), and the start address of this inputted size is obtained due to the read out data and calculated deviation in the lateral feeding and then stored in a memory (Step S49). The start address is set for all the sizes in lateral mode repeatedly (Step S50). Similar processing is repeated for longitudinal feeding (Steps S51 through S55). Start addresses for all the sizes are written in the memory (Step S56) to prepare the data table B as shown in FIG. 17. The data table B thus stores the start addresses for each size and for both longitudinal and lateral feeding. Once an appropriate start address is detected, the lateral feeding area WT and longitudinal feeding area LT can be obtained based upon the input size as shown in FIG. 18.
A sheet of film negative 2 is mounted at a predetermined position to be photometrically measured with the image sensor 11. At the same time, size information and mode information on the direction of feeding are manually inputted from outside (Step S57). This information on the size and the direction of feeding may be detected by photometrically measuring the unexposed areas of the film negative or the film negative carrier with the image sensor (by the methods disclosed in Japanese Pat. Application Nos. 7534/1984 and 79407/1985), and automatically inputted. The number of pixels in the longitudinal and lateral directions on the film negative is calculated by referring to the data table A (Step S58), then the film negative is photo-metrically measured as above (Step S59) and the obtained data is stored in a memory (Step S60). Then, the start address data (positional information) corresponding thereto is read out from the data table B (Step S61), and the data on the effective area on the memory is extracted from the number of pixels obtained at the step S58 (Step S62) and the read-out start address to carry out the processing of the image data (Step S63). Thanks to these processing, even if the image sensor program deviates from the film negative frame in the directions of XY, the data can be processed in a manner so to automatically correct such deviation.
According to this invention, the amount of deviation between the image sensor coordinate and the frame coordinates is detected, and the data tables are prepared with start addresses set respectively for each size and each feeding direction to automatically and rapidly correct positional deviation of the image sensor based upon the start addresses presently set on the data tables for both longitudinal and lateral sizes. Since fine mechanical adjustment becomes unnecessary, the method does not need an adjustment mechanism and can be conveniently reduced in cost.
It should be understood that many modifications and adaptations of the invention will become apparent to those skilled in the art and it is intended to encompass such obvious modifications and changes in the scope of the claims appended hereto.
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In photographic printing systems, it is necessary to detect image information of an original film to determine printing exposure amount for optimum prints. When an image sensor is used as a detector or for detecting image information, the detection area in the image sensor should correspond exactly with the detected area on the film. Particularly, when images are measured by separation into three colors of RGB (Red, Green, Blue), color registration among RGB should be attained. Image information can be automatically and accurately detected and processed without needing mechanical positional adjustment of the image sensor(s).
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This is a division of our copending application Ser. No. 603,080, filed Aug. 8, 1975, now U.S. Pat. No. 3,968,096, which in turn is a division of our prior application, Ser. No. 543,706, filed Jan. 23, 1975, now U.S. Pat. No. 3,929,723.
DESCRIPTION OF THE INVENTION
The invention relates to and has among its objects the provision of novel plastic compositions capable of photodegradation. Further objects of the invention will be evident from the following description wherein parts and percentages are by weight unless otherwise specified.
Plastics have become an important part of the American way of life. Innumerable articles of manufacture are made of plastics. One of the main uses thereof is in the manufacture of containers for liquids and solids of all kinds, particularly foods. Another important use is the manufacture of plastic sheet materials such as films and foils. For example, plastic films are used in agriculture for covering the soil between plants, thereby to prevent the growth of weeds.
One problem with plastics is that they are not easily decomposed. Thus, for example, plastic food containers thrown by the roadside do not decompose but remain until collected, thereby polluting the environment. Similarly, plastic films used as soil coverings must be removed from the fields prior to initiating a new crop.
The invention described herein concerns a means for obviating the above problems in that it provides polyolefin platics which are capable of photodegradation. Containers fabricated from the plastics of the invention when exposed to sunlight will gradually decompose and eventually crumble away. Thus, such containers when thrown along the roadside will eventually become part of the soil. Films prepared from the plastics of the invention when used for agricultural purposes will gradually become friable by the action of sunlight so that they can be readily plowed into the soil.
The benefits of the invention are realized by incorporating into a polyolefin any of the compounds described below.
GROUP I
Cyanohalomethanes of the structure
C(CN).sub.R X.sub.q
wherein:
X is chlorine, bromine, or iodine
R IS 1, 2, OR 3
Q IS 4-R
Illustrative examples of compounds included in Group I are:
Trichloroacetonitrile
Tribromoacetonitrile
Triiodoacetonitrile
Dichloromalononitrile
Dibromomalononitrile
Diiodomalononitrile
Chlorotricyanomethane
Bromotricyanomethane
Iodotricyanomethane
Group II.
Nitrobenzenesulfenyl halides of the structure ##STR1## WHEREIN:
X is chlorine, bromine, or iodine
N IS 1 OR 2
Illustrative examples of compounds included in Group II are:
2,4-Dinitrobenzenesulfenyl chloride
2,4-Dinitrobenzenesulfenyl bromide
2,4-Dinitrobenzenesulfenyl iodide
Group III
Haloalkylsulfenyl halides of the structure
X-S-(CH.sub.b X.sub.a).sub.c -R
wherein:
X is chlorine, bromine, or iodine
R is hydrogen, chlorine, bromine, iodine, or an alkyl radical containing 1 to 6 carbon atoms
a is 1 or 2
b is 2-a
c is 1 or 2
Illustrative examples of compounds included in Group III are:
Trichloromethylsulfenyl chloride
Tribromomethylsulfenyl chloride
Triiodomethylsulfenyl chloride
Trichloromethylsulfenyl bromide
Trichloromethylsulfenyl iodide
Tribromomethylsulfenyl bromide
Tribromomethylsulfenyl iodide
Triiodomethylsulfenyl bromide
Triiodomethylsulfenyl iodide
1,1,2,2-Tetrachloroethylsulfenyl chloride
1,1,2,2-Tetrachloroethylsulfenyl bromide
1,1,2,2-Tetrachloroethylsulfenyl iodide
1,1,2,2-Tetrabromoethylsulfenyl chloride
1,1,2,2-Tetrabromoethylsulfenyl bromide
1,1,2,2-Tetrabromoethylsulfenyl iodide
1,1,2,2-Tetraiodoethylsulfenyl chloride
1,1,2,2-Tetraiodeothylsulfenyl bromide
1,1,2,2-Tetraiodoethylsulfenyl iodide
Group IV
Halobenzenesulfonly halides of the structure -- ##STR2## wherein:
X is chlorine, bromine, or iodine
p is an integer from 1 to 5
Illustrative examples of compounds included in Group IV are:
2-Chlorobenzenesulfonyl chloride
2-Chlorobenzenesulfonyl bromide
2-Chlorobenzenesulfonyl iodide
2,4,5-Trichlorobenzenesulfonyl chloride
2,4,5-Trichlorobenzenesulfonyl bromide
2,4,5-Trichlorobenzenesulfonyl iodide
Pentabromobenzenesulfonyl chloride
Pentabromobenzenesulfonyl bromide
Pentabromobenzenesulfonyl iodide
Group V
Haloalkylsulfonyl halides of the structure
X--SO.sub.2 --(CH.sub.b X.sub.a).sub.c --R
wherein:
X is chlorine, bromine, or iodine
R is hydrogen, chlorine, bromine, iodine, or an alkyl radical containing 1 to 6 carbon atoms
a is 1 or 2
b is 2-a
c is 1 or 2
Illustrative examples of compounds included in Group V are:
Trichloromethanesulfonyl chloride
Tribromomethanesulfonyl chloride
Triiodomethanesulfonyl chloride
Trichloromethanesulfonyl bromide
Trichloromethanesulfonyl iodide
Tribromomethanesulfonyl bromide
Tribromomethanesulfonyl iodide
Triiodomethanesulfonyl bromide
Triiodomethanesulfonyl iodide
1,1,2,2-Tetrachloroethanesulfonyl chloride
1,1,2,2-Tetrachloroethanesulfonyl bromide
1,1,2,2-Tetrachloroethanesulfonyl iodide
1,1,2,2-Tetrabromoethanesulfonyl chloride
1,1,2,2-Tetrabromoethanesulfonyl bromide
1,1,2,2-Tetrabromoethanesulfonyl iodide
1,1,2,2-Tetraiodoethanesulfonyl chloride
1,1,2,2-Tetraiodoethanesulfonyl bromide
1,1,2,2-Tetraiodoethanesulfonyl iodide
Group VI.
Haloalkyl disulfides of the structure
R--(CH.sub.b X.sub.a).sub.c --S--S--(CH.sub.b X.sub.a).sub.c --R
wherein:
X is chlorine, bromine, or iodine
a is 1 or 2
b is 2-a
c is 1 or 2
R is hydrogen, chlorine, bromine, iodine, or an alkyl radical containing 1 to 6 carbon atoms
Illustrative examples of compounds included in Group VI are:
Bis-(trichloromethyl) disulfide
Bis-(tribromomethyl) disulfide
Bis-(triiodomethyl) disulfide
Bis-(1,2,2,2-tetrachloroethyl) disulfide
Bis-(1,2,2,2-tetrabromoethyl) disulfide
Bis-(1,2,2,2-tetraiodoethyl) disulfide
Bis-(1,1,2,2-tetrachloroethyl) disulfide
Bis-(1,1,2,2-tetrabromoethyl) disulfide
Bis-(1,1,2,2-tetraiodoethyl) disulfide
Group VII.
Halonitroalkanes of the structure
O.sub.2 N--(CH.sub.b X.sub.a).sub.c --R
wherein:
X is chlorine, bromine, or iodine
R is hydrogen, chlorine, bromine, iodine, or an alkyl radical containing 1 to 6 carbon atoms
a is 1 or 2
b is 2-a
c is 1 or 2
Illustrative examples of compounds included in Group VII are:
Chloropicrin
Bromopicrin
Iodopicrin Perchloronitroethane
Perbromonitroethane
Periodonitroethane
Polyolefins containing any of the above compounds (or additives as they are often referred to herein) decompose readily when exposed to sunlight. The decomposition, however, is not instantaneous but is gradual, and the rate thereof depends on such factors as the type of polyolefin, the amount of the compound added, and the activity of the latter. The reaction which takes place can be described as a photodepolymerization in which the polymeric chains are reduced to lower molecular weight under the influence of sunlight.
The amount of additive to be incorporated with the polyolefin depends on the activity of the additive, and upon the desired rate of photodecomposition. In general, one may use about 0.1 to 10% of the additive, based upon the weight of polyolefin. For most purposes, about 1 to 5% of the additive is sufficient to obtain a reasonable and useful rate of photodegraduation.
The polyolefin to which the invention is applied includes, for example, high and low density polyethlene, polypropylene, polybutylene, polystyrene, mixtures of polyethylene and polypropylene, vinyl acetate/ethylene copolymers, and the like. The incorporation of the additive with the polyolefin may be carried out in any of the ways known in the art of compounding plastics. For example, intimate mixing of the polyolefin and additive may be effected by melting and mixing the polyolefin with the additive by any suitable means such as a mixer of the Banbury or Werner type or in a screw extruder. The compositions of polyolefin and additive can be formed into any desired articles such as films, tubular sheets, foils, bags, bottles, or other containers by application of well-known molding and fabricating techniques.
It is within the compass of the invention to use known photosensitizing compounds such as dibenzoyl peroxide, azo-bisisobutyronitrile, and the like in conjunction with the additives of the invention. In some instances such photosensitizers increase the activity of the additives of the invention. Thus, polyolefins containing an additive in accordance with the invention and a photosensitizer will exhibit an enhanced rate of photodegradation.
EXAMPLES
The invention is further demonstrated by the following illustrative examples.
EXAMPLE 1
Photodegradable Polypropylene Films
A. To 0.6 gram of powdered polypropylene resin was added a solution of 0.006 gram of additive in 0.6 ml. of acetone. The mixture was stirred to evenly distribute the additive solution over the particles of polypropylene. The mixture was spread as a thin layer on a Mylar sheet supported by a ferrotype chrome plate. After allowing the acetone to evaporate, the said layer was covered with another Mylar sheet and chrome plate. This assembly was heated for 30 sec. at 350° F. and then pressed at 370 psi. for 30 sec. The assembly was then transferred to an unheated press and pressed at 4000 psi. while cooling. A film of polypropylene and 1% additive having a thickness of 0.003 to 0.004 inch was thus obtained.
A similar procedure was employed for the preparation of polypropylene films containing other additives. In cases wherein the melting point of the additive was above 350° F., the temperature of the press was maintained at about 10° F. above this melting point and within the range of 350°-412° F. A piece, 3/4 × 13/8 , was cut from each film and its infrared spectrum was taken.
B. Test procedure: The films prepared as above described were placed in a stainless steel rack exposed to sunlight. This rack was mounted on a building located at Albany, Cal., and was positioned facing south and at an angle of 45° to the horizontal. The films were thus exposed continuously for a period of approximately 1 month, that is, from Sept. 14 to Oct. 11 of one calendar year. After this exposure, an infrared spectrum of the sample was again determined. The extent of photooxidation was taken as a measure of the photodegradability of the irradiated material. Photooxidation was determined by measuring the increase in the carbonyl absorption band of the exposed sample over that of an irradiated sample containing no additive.
C. Specific additives used: The sequence described above in parts A and B was performed with the following additives, each in the amount of from 3 to 5%, based on the weight of polypropylene:
__________________________________________________________________________a. Dibromomalononitrile Br.sub.2 C(CN).sub.2b. Trichloromethanesulfonyl chloride ClSO.sub.2CCl.sub.3c. 2,4,5-Trichlorobenzenesulfonyl chlorided. Chloropiorin O.sub.2 NCCl.sub.3e. 1,1,2,2-Tetrachloroethylsulfenyl chloridef. Bis-(1,2,2,2-tetrachloroethyl) disulfide Cl.sub.3 CCH(Cl)SSCH(Cl)CCl.sub.3__________________________________________________________________________
The results are summarized below.
Table 2__________________________________________________________________________Polypropylene and Additive Increase in Additive Amount of carbonyl, ab- effectivenessRun Additive additive, % sorbance units ratio*__________________________________________________________________________a. Dibromomalononitrile 3 0.234 31.2b. Trichloromethanesulfonyl chloride 3 0.044 5.9c. 2,4,5-Trichlorobenzenesulfonyl chloride 5 0.158 21.1d. Chloropicrin 5 0.023 3.1e. 1,1,2,2-Tetrachloroethylsulfenyl chloride 5 0.175 23.3f. Bis-(1,2,2,2-Tetrachloroethyl) disulfide 5 0.031 4.1Control 10 None used 0.008 1.0__________________________________________________________________________ *Additive effectiveness ratio is equal to the increase in carbonyl for a particular additive divided by the increase in carbonyl obtained without additive (control). Thus, for example, polypropylene containing dibromomalononitrile is oxidized photochemically 0.234/0.008 0r 31.2 time more than polypropylene without an additive.
EXAMPLE 2
Photodegradable Polyethylene Films
Polyethylene films containing 2 to 5% of additive were prepared by the same procedure described in Example 1. Photodegradability of the resulting films was determined as described in Example 1.
The following additives were used:
Runs a to f: Some additives as Example 1
______________________________________g. Trichloromethylsulfenyl chloride ClSCCl.sub.3h. 2,4-Dinitrobenzenesulfenyl chloride ##STR5##______________________________________
The results are summarized below.
Table 2__________________________________________________________________________Polyethylene and Additive Increase in Additive Amount of carbonyl, ab- effectivenessRun Additive additive, % sorbance units ratio__________________________________________________________________________a. Dibromomalononitrile 5 0.056 4.3b. Trichloromethanesulfonyl chloride 5 0.021 1.6c. 2,4,5-Trichlorobenzenesulfonyl chloride 5 0.052 4.0d. Chloropicrin 5 0.037 2.8e. 1,1,2,2-Tetrachloroethylsulfenyl chloride 5 0.071 5.5f. Bis-(1,2,2,2-tetrachloroethyl) disulfide 5 0.067 5.2g. Trichloromethylsulfenyl chloride 2 0.021 1.6h. 2,4-Dinitrobenzenesulfenyl chloride 5 0.020 1.5Control None used 0.013 1.0__________________________________________________________________________
EXAMPLE 3
Photodegradable Polystyrene Films
A. Commercial polystyrene powder was first purified as follows: The powder (90 g.) was placed in a 2-liter Erlenmeyer flask togeher with 510 ml. of chloroform and the mixture was shaken until dissolved. The solution was poured slowly with vigorous stirring into a 1-gallon Waring Blendor containing 2 liters of methanol. The finely precipitated powder was filtered, washed with methanol, air-dried, and finally dried in a vacuum oven at 52° C. and 30 p.s.i. This procedure was repeated for a total of three times and a polystyrene containing no styrene odor was obtained.
B. Incorporation of additive: A wide-mouth jar was charged with 3 g. of the purified polystyrene powder, 0.15 g. of additive, and 17 ml. of chloroform, then shaken on a wrist-action shaker until solution was obtained. The solution was allowed to stand for a few minutes to remove entrapped air bubbles. Afterward, the solution was spread on a 4 × 8 inch glass plate with a film-casting knife with a setting of 0.038 inch. The plate was suspended above chloroform in a covered tray to retard evaporation of the solvent. After the plate had dried overnight, it was placed in a tray containing distilled water, which floated the film away from the glass. This film of polystyrene plus the incorporated additive was about 0.004 to 0.005 inch thick. A piece, 3/4 × 13/8 was cut from the film and its infrared spectrum was taken.
C. Test procedure: The said piece of film was then irradiated for 66 hours by maintaining it on a revolving table 9 in. in diameter with the film sample 6 in. from a 275-watt RS sunlamp. After irradiation, an infrared spectrum of the sample was again determined. The extent of photooxidation was taken as a measure of the photodegradability of the irradiated material. Photooxidation was determined by measuring the increase in the carbonyl absorption band of the irradiated sample over that of an irradiated sample containing no additive.
D. Specific additives used: The sequence described above in parts A, B, and C was perfomed with all of the additives mentioned in Example 2.
The results are tabulated below:
Table 3__________________________________________________________________________Polystyrene and Additive Increase in Additive Amount of carbonyl, ab- effectivenessRun Additive additive, % sorbance units ratio__________________________________________________________________________a. Dibromomalononitrile 5 0.334 3.0b. Trichloromethanesulfonyl chloride 5 1.012 9.0c. 2,4,5-Trichlorobenzenesulfonyl chloride 5 0.735 6.6d. Chloropicrin 5 0.137 1.2e. 1,1,2,2-Tetrachloroethylsulfenyl chloride 5 0.414 3.7f. Bis-(1,2,2,2-tetrachloroethyl) disulfide 5 0.510 4.6g. Trichloromethylsulfenyl chloride 3 0.422 3.8h. 2,4-Dinitrobenzenesulfenyl chloride 5 0.227 2.0ControlNone used 0.112 1.0__________________________________________________________________________
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Polyolefins capable of photodegradation are prepared by incorporating in the polyolefin an additive containing chlorine, bromine, or iodine and either a nitrogen or a sulfur group.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a power control method used in a code-division multiple access (CDMA) format communication system, which is particularly suitable for application to a communication system having a multiple access interference (MAI) canceller capability.
[0002] Generally, in CDMA radio communication formats such as wideband CDMA (W-CDMA), each uplink from a mobile station (MS) to a base station (BS) has two power control systems known as the outer loop and the inner loop. The outer loop is a higher layer control for independently adjusting the target for uplink power control in each cell in an active group. Since the outer loop is based on measurement results of a block error rate (BLER) of decoded data, the control response is delayed by the transmission time interval (TTI) required for calculating the block error rate.
[0003] The inner loop, to which the present invention is primarily directed, makes minor adjustments of the mobile station transmission power to hold the signal-to-interference ratio (hereinafter referred to as SIR) of the uplink at a specific target. The inner loop power control of the uplink is performed by the following method (see 3rd Generation Partnership Project (3GPP) TS 25.214, v1.1.0, UTRA FDD Physical Layer Procedures):
[0004] (1) The base station receives a dedicated physical control channel (DPCCH) of an uplink, and measures the SIR value of the received signal.
[0005] (2) Next, the base station compares the measured SIR value to a target value for the signal-to-interference power ratio (hereinafter referred to as SIR target value), and determines a transmission power control (TPC) command for the uplink in order to control the transmitting power of the mobile station.
[0006] (3) The transmission power control command which has been determined in this way is next inserted into a predetermined position in the slot of the downlink (the communication in the direction from the base station to the mobile station) transmitted immediately after the slot which is currently being transmitted, and transmitted to the mobile station.
[0007] (4) The mobile station adjusts the transmission power of the uplink in accordance with the received transmission power control command.
[0008] Since response delays of the power control degrade the system performance, the inner loop of the power control format was performed for each slot period and SIR measurement was performed in real-time in conventional methods.
[0009] The interference canceller (IC) has been proposed as art for increasing system capacity by eliminating multiple access interference which occurs in CDMA communications. In base stations having such interference canceling capabilities, the multiple access interference components are subtracted from the received CDMA signals by means of an interference canceling unit (ICU) of each uplink channel. When a desired dedicated physical data channel (DPDCH) is demodulated at the base station, the multiple access interference components can be substantially removed from the received signal by means of an iterative interference subtractive operation of a multistage interference canceling unit. As a result, it is possible to improve the SIR vale of a desired dedicated physical data channel, thus further increasing the system capacity. This is explained in many technical papers and articles such as A. Duel-Hallen et al., “Multiuser Detection for CDMA Systems,” IEEE Personal Communications, pp. 46-58, April 1995 and S. Moshavi, “Multi-user Detection for DS-CDMA Communications,” IEEE Communications Magazine, pp. 124-136, October 1996 .
[0010] In normal base stations having an interference canceling capability, SIR measurements of the dedicated physical control channel are made prior to interference cancellation. As a result, the measured SIR value is smaller than the SIR value of the dedicated physical data channel after interference cancellation, which is demodulated and decoded. For this reason, if transmission power control of the uplink is performed based on the SIR value prior to interference cancellation in accordance with the transmission power control method described above, there is a risk of the transmission power of the uplink being unnecessarily raised. In order to avoid this, one might conceive of performing transmission power control based on the SIR value after interference cancellation, but in this case, the power control is delayed because of the time required for the interference cancellation operation.
[0011] Additionally, the SIR target value used to determined the transmission power control command is determined by the outer loop based on the block error rate as described above. Since the block error rate is calculated from the results of a cyclic redundancy check (CRC), it cannot be calculated until the decoding operation (rate de-matching de-interleaving, channel decoding and CRC judgment) is completed with respect to the entire frame. Furthermore, in order to measure the block error rate (e.g. 20 ms−2 s), it is necessary to perform cyclic redundancy checks of a plurality of frames. Therefore, the SIR target values from the outer loop are delayed by the block error rate measurement.
[0012] This response delay in the power control is one factor in the degradation of the system capacity. This effect is particularly apparent when the state of the communication path suddenly changes, such as when connecting or terminating new channels (calls) or due to fast fading effects.
BRIEF SUMMARY OF THE INVENTION
[0013] The object of the present invention which has been made in view of the above considerations is to offer CDMA control method and a CDMA system structure having an interference canceller which can effectively increase the system capacity while simultaneously being capable of handling sudden changes in the communication path, and more specifically, to achieve a quickly responding power control method capable of suppressing unneeded increases in the transmission power (and multiple access interference) of the uplink by reflecting the SIR values after interference cancellation in the generation of power control command information.
[0014] According to a first aspect of the present invention, a communication system for performing code-division multiple access communications between a mobile station and a base station is such that the base station comprises base station receiving means for receiving signals from the mobile station and outputting a first reception signal; interference canceling means for canceling a multiple access interference signal contained in the first reception signal; interference cancellation effect estimating means for estimating a post-interference cancellation signal-to-interference power ratio of the first reception signal which is currently being received; control command generating means for generating a power control command by comparing the post-interference cancellation signal-to-interference power ratio determined by the interference cancellation effect estimating means with a target value for power control; and base station transmitting means for transmitting the power control command to the mobile station; and the mobile station comprises mobile station receiving means for receiving a signal from the base station and outputting a second reception signal; and mobile station transmitting means which adjusts the power of the transmission signal transmitted to the base station based on the power control command contained in the second reception signal.
[0015] According to a second aspect of the present invention, a communication system for performing code-division multiple access communications between a mobile station and a base station is such that the base station comprises base station receiving means for receiving signals from the mobile station and outputting a first reception signal; interference canceling means for canceling a multiple access interference signal contained in the first reception signal; error rate calculating means for decoding the first reception signal after interference cancellation by the interference canceling means and determining an error rate of the decoded data; first target value setting means for determining a target value for power control based on the error rate determined by the error rate calculating means; interference cancellation effect estimating means for estimating the effects of interference cancellation by the interference canceling means; second target value setting means for updating the target value depending on the interference cancellation effects estimated by the interference cancellation effect estimating means; control command generating means for generating a power control command by comparing the target value outputted from the second target value setting means with the signal-to-interference power ratio of the first reception signal which is currently being received; and base station transmission means for transmitting the power control command to the mobile station; and the mobile station comprises mobile station receiving means for receiving a signal from the base station and outputting a second reception signal; and mobile station transmitting means which adjusts the power of the transmission signal transmitted to the base station based on the power control command contained in the second reception signal.
[0016] According to a third aspect of the present invention, a base station device in a communication system for performing communications with a mobile station by code-division multiple access comprises base station receiving means for receiving signals from the mobile station and outputting a reception signal; interference canceling means for canceling a multiple access interference signal contained in the reception signal; interference cancellation effect estimating means for estimating a post-interference cancellation signal-to-interference power ratio of the reception signal which is currently being received; control command generating means for generating a power control command by comparing the post-interference cancellation signal-to-interference power ratio determined by the interference cancellation effect estimating means with a target value for power control; and base station transmitting means for transmitting the power control command to the mobile station.
[0017] According to a fourth aspect of the present invention, a base station device for a communication system for performing communications with a mobile station by code-division multiple access comprises base station receiving means for receiving signals from the mobile station and outputting a reception signal; interference canceling means for canceling a multiple access interference signal contained in the reception signal; error rate calculating means for decoding the reception signal after interference cancellation by the interference canceling means and determining an error rate of the decoded data; first target value setting means for determining a target value for power control based on the error rate determined by the error rate calculating means; interference cancellation effect estimating means for estimating the effect of the interference cancellation by the interference canceling means; second target value setting means for updating the target value depending on the interference cancellation effects estimated by the interference cancellation effect estimating means; control command generating means for generating a power control command by comparing the target value outputted from the second target value setting means with the signal-to-interference power ratio of the first reception signal which is currently being received; and base station transmitting means for transmitting the power control command to the mobile station.
[0018] According to a fifth aspect of the present invention a power control method in a communication system for performing communications by code-division multiple access between a mobile station and a base station comprises canceling a multiple access interference signal contained in a reception signal from the mobile station; estimating a post-interference cancellation signal-to-interference power ratio of the reception signal which is currently being received; generating a power control command by comparing the estimated post-interference cancellation signal-to-interference power ratio and a target value for power control; and controlling the transmission power of the mobile station by transmitting the power control command to the mobile station.
[0019] According to a sixth aspect of the present invention, a power control method in a communication system for performing communications by code-division multiple access between a mobile station and a base station comprises canceling a multiple access interference signal contained in a reception signal from the mobile station; decoding the reception signal after the interference cancellation and determining the error rate of the decoded data, determining a target value for power control based on the determined error rate, estimating the interference cancellation effect due to the interference cancellation, and updating the target value depending on the estimated interference cancellation effect; generating a power control command based on a comparison between the target value and the signal-to-interference power ratio of the reception signal which is currently being received; and transmitting the power control command to the mobile station to control the transmission power of the mobile station.
[0020] According to the present invention, in a CDMA system having power control and interference cancellation capabilities, the power control target values are set based both on values reflecting the interference cancellation effect due to the interference canceling units in addition to values set by the outer loop as conventional. Additionally, the determination of the power control command information is performed by first estimating the post-interference cancellation signal-to-interference power ratio of the current received signal, and then using this value. Consequently, the power control system reflects the effect of the interference cancellation function. Furthermore, this power control system has a fast response with respect to changes on the radio communication path in comparison to conventional power control systems. As a result, unnecessary increases in the transmission power of the uplink can be avoided, thus stressing multiple access interference as compared with conventional systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a drawing showing a conventional CDMA receiving apparatus.
[0022] [0022]FIG. 2 shows the frame structure of a dedicated physical data channel/dedicated physical control channel of an uplink.
[0023] [0023]FIG. 3 shows the structure of a multi-stage sequential interference canceling demodulator.
[0024] [0024]FIG. 4 shows the structure of an interference canceling unit of a multi-stage serial interference canceller.
[0025] [0025]FIG. 5 shows the structure of a transmission power control command generator.
[0026] [0026]FIG. 6 shows the operation timing of a transmission power control command generator.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Here, the present invention shall be described with reference to the attached drawings. While a W-CDMA signal format is used as an example in the following description, the present invention shall not be construed as being so restricted.
[0028] [0028]FIG. 1 shows an example of the structure of a base station 100 provided with an interference canceller, for performing power control. In FIG. 1, a single antenna 160 is shown along with an interference canceller corresponding to that single antenna in order to simplify the structure, but the present invention is also applicable to array antennas, and array antennas are in fact more commonly used. FIG. 2 is a diagram showing the frame structure of an uplink in which a dedicated physical data channel and a dedicated physical control channel are I/Q multiplexed.
[0029] The procedure for processing received signals shall be explained with reference to FIG. 1. A signal received by the antenna 160 passes through a high-frequency radio portion (RF) 165 and is supplied to a matched filter (MF) 110 and an interference canceling demodulator 130 . The received signal is first despread by the despreading code of the dedicated physical control channel in the matched filter 110 to obtain a synchronization timing. While the detailed description shall be omitted here, a plurality of users (user number K) are actually accommodated, so that this synchronization timing acquiring process is performed for K channels corresponding to the respective users.
[0030] Using the results of the matched filter 110 , the SIR values are determined in real-time by the dedicated physical control channels in the SIR measuring portion 120 . Then, the measured SIR values are transmitted to the transmission power control command generator 170 .
[0031] In the present embodiment, the interference canceling demodulator 130 despreads and demodulates both the dedicated physical data channel and dedicated physical control channel using an interference canceling capability. The interference canceling demodulator 130 outputs SIR values and interference-cancelled demodulated signals for K channels with respect to K users. Here, the SIR values are measured for each interference canceling unit of each stage as shall be explained in detail in FIG. 3. With regard to SIR measurements, they are measured on the basis of the dedicated physical control channel for each user.
[0032] The demodulated signal is transmitted to the communication path decoder 140 for each user, where rate de-matching, de-interleaving, channel decoding and cyclic redundancy checks are performed for each user. Using the results of the cyclic redundancy check, a block error rate is measured in units of transmission time interval TTI with respect to the decoded data for each user in the block error rate measuring portion 150 , and the block error rate is sent to the transmission power control command generator 170 . The SIR information measured at each stage of the interference canceling unit 130 is supplied to the transmission power control command generator 170 which receives the values of the block error rate as described above.
[0033] In the transmission power control command generator 170 , the SIR information of each stage supplied from the interference canceling demodulator 130 , the block error rate supplied from the block error rate measuring portion 150 and the real-time SIR values of the dedicated physical control channels supplied from the SIR measuring portion 120 are used to generate transmission power control commands for the uplinks with respect to each user.
[0034] The generated transmission power control commands of the uplinks are sent to the frame (slot) generator 190 for each user, where they are multiplexed with coded signals by a channel coder 192 by being inserted at suitable positions in the transmission slot, and after being modulated by the CDMA modulator 180 , are transmitted through the antenna 160 to the respective mobile stations as downlink transmission signals.
[0035] [0035]FIG. 2 shows the frame structure of a dedicated physical data channel and a dedicated physical control channel in the uplink. Whereas the dedicated physical data channel on the I channel is composed of only data, the dedicated physical control channel on the Q channel is composed, e.g. 10 ms-long frames having 15 slots (slot # 1 , slot # 2 , . . . , slot #i, . . . , slot # 15 ), each 0.625 ms-long slot being composed of a channel estimation pilot signal, a TFCI (transport format combination indicator), FBI (feedback information) and a transmission power control command (TPC).
[0036] [0036]FIG. 3 shows an example of an interference canceling demodulator 130 . In this example, a multi-stage (n-stage) serial subtractive interference canceller is shown, but it is also just as possible to use other types of interference cancellers such as multi-stage parallel subtractive type interference cancellers in the present invention.
[0037] In the drawing, from left to right in a horizontal direction, there is a total of K interference canceling units 135 corresponding to each channel, in other words, to each user, for each stage from a first stage to an n-th stage. In each stage 131 , 132 and 133 , the operations of the interference canceling units 135 are performed consecutively. For example, the interference canceling unit 135 for channel j in stage i receives a respread replica signal from channel j of the (i−1)-th stage and a residual signal after an interference canceling operation to channel j−1 in the i-th stage, performs despreading, channel estimation, channel correction and detection, and respreading to generate a respread replica signal which is outputted to channel j of the (i+1)-th stage, performs an interference canceling operation by subtracting this respread replica signal from a residual signal received from channel j−1, then sends the residual signal after the interference canceling operation to the next channel j+1. Additionally, the interference canceling unit 135 of channel j of the i-th stage simultaneously measures the SIR value for channel j of the i-th stage, which is then sent to the transmission power control command generator 170 .
[0038] An example of the structure of each interference canceling unit 135 is shown in FIG. 4. The interference canceling units 135 of the present embodiment are composed of a portion corresponding to the dedicated physical control channel and a portion corresponding to the dedicated physical data channel, and as is clear from FIG. 4, these have roughly identical structures and perform the same operations. Explaining the operations taking as an example the portion corresponding to the dedicated physical control channel, the input signal caused by the received signal is inputted to the channel estimating portion 200 and the despreading portion 210 . In the interference canceling units of the second and subsequent stages, a signal obtained by adding the respread replica signal received from the previous stage to the residual signal received from the previous stage or previous channel is inputted to the channel estimating portion 200 and the despreading portion 210 .
[0039] The channel estimating portion 200 estimates the fluctuations (of amplitude and phase) occurring on the transmission path of the channel, and sends the results of the estimate to the channel correcting portion 220 . The despreading portion 210 despreads the input signal using the despreading code of that channel, and outputs the resulting demodulated signal to the channel correcting portion 220 . The channel correcting portion 220 adds corrections to the demodulated signal based on the results of the channel estimates so as to cancel out the channel fluctuations received on the transmission path, and outputs the result to the SIR measuring portion 230 and the detector (symbol determining portion) 225 .
[0040] The detector (symbol determining portion) 225 determines the received symbols from the demodulated signal after channel correction, and outputs the results of the determination to the respreading portion 240 . In the interference canceling unit 135 of the final stage, as indicated by the dotted line, the determined received symbols are outputted to the channel decoder 140 . At the respreading portion 240 , the received symbols are respread using the same spreading codes as used for despreading, and at the channel reshaping portion 250 , the opposite of the channel correction performed in the channel correcting portion 220 is performed on the respread signal, as a result of which a respread replica signal which is the replica of the spread signal on that channel is generated. At the interference canceling unit 135 , an interference canceling operation is performed by subtracting this respread replica signal from the input signal. The signal which has undergone an interference canceling operation of the dedicated physical control channel is next inputted to a processing unit for the dedicated physical data channel, and an interference canceling operation is performed in a similar manner.
[0041] For the present example, a case has been explained wherein the processing unit for the dedicated physical control channel and the processing unit for the dedicated physical data channel are connected serially, but the present invention is also applicable to cases where these processing units have a parallel connection as well.
[0042] On the other hand, the SIR measuring portion 230 measures SIR values based on demodulated signals received from the channel correcting portion 220 of the dedicated physical control channel.
[0043] While not shown in FIG. 4 for the purpose of convenience of explanation, the demodulating process for the dedicated physical control channel and the dedicated physical data channel may be performed by applying a RAKE receiving system which separates and combines multiple transmission paths.
[0044] [0044]FIG. 5 and FIG. 6 respectively show an example of the structure of the transmission power control command generator 170 and the timings for the operation thereof. FIG. 5 shows the structure for a single user, and in actuality, there are as many parts having the same structure as there are users K in the transmission power control command generator 170 , to generate transmission power commands for each user.
[0045] The SIR values which are supplied from the interference canceling units 135 of each stage of the interference canceling demodulator 130 , along with the pre-cancellation SIR values supplied from the SIR measuring portion 120 , are inputted to the interference cancellation effect estimating portion 300 . The interference cancellation effect estimating portion 300 stores the inputted information, estimates post-interference cancellation SIR values for the current received signals prior to interference cancellation using an algorithm to be described later on the information it currently holds, and outputs the estimated values (hereinafter referred to as SIR estimates) to the comparator 320 . In this case, the outputted estimates are SIR values which will presumably be obtained after passing through the interference canceling units of the n-th stage.
[0046] Additionally, the interference cancellation effect estimating portion 300 estimates an average signal-to-interference power ratio (hereinafter referred to as average estimated SIR value) with respect to the current received signal based on the SIR values actually measured after interference cancellation already acquired from the interference canceling demodulator 130 and SIR values obtained by the above-described estimate, and outputs the result to the target value setting portion 310 . This average estimated SIR value corresponds to the block error rate of the transmission time interval TTI in which the current received signal is contained.
[0047] The outer loop SIR target value setting portion 330 has the same function as that of setting the SIR target value which is the reference when generating a transmission power control command in a conventional system, and tentatively determines SIR target values based on the block error rate supplied from the block error rate measuring portion 150 . Since this decision making process is the same as the outer loop system of conventional transmission power control methods, its detailed description shall be omitted here, but put simply, the algorithm is such as to set the SIR target value high if the block error rate is high, and to set the SIR target value low if the block error rate is low, a computation method of which may involve prestoring a correspondence table between block error rates and SIR target values, and reading out the SIR target values corresponding to the inputted block error rates.
[0048] The target value setting portion 310 uses the tentative SIR target value acquired from the outer loop SIR target value setting portion 330 and the average estimated SIR value of the transmission time interval TTI in which the current pre-interference cancellation received signal is contained to update the target SIR value for power control when, for example, the difference therebetween is larger than a threshold value. At this time, information indicating how many mobile stations are currently connected (channel connection information) can be used as auxiliary information. As the updating algorithm, a method of simply replacing with the estimated average SIR value as the updated value, a method of taking the product of a first coefficient responsive to the average estimate SIR value and a second coefficient responsive to the channel connection information with the tentative SIR target value as the updated value, or a method of taking a value obtained by inputting the average estimated SIR value, the channel correction information and tentative SIR target value to a predetermined function as the updated value may be conceivably used. Additionally, if the difference between the tentative SIR target value and the average estimated SIR value is smaller than the threshold value, the target value setting portion 310 determines that correction of the target value is not required, and outputs the tentative SIR target value as is.
[0049] The comparator 320 compares the SIR target value for the power control obtained from the target value setting portion 310 and the post-interference cancellation estimated SIR value estimated for the pre-interference cancellation received signal currently received, and based on the results of the comparison, generates a transmission power command indicating transmission power up or down, and transmits it through the frame generator 190 to the mobile station.
[0050] As is clear from the above, the controlled change in the transmission power based on the estimated SIR value considering interference cancellation effects replaces conventional inner loop control, while the setting and updating of the SIR target value for control using the average estimated SIR value corresponding to the block error rate in consideration of the interference cancellation effect corresponds to the conventional outer loop control.
[0051] Here, the algorithm for estimating the post-interference cancellation SIR with respect to the current received signal performed in the interference cancellation effect estimating portion 300 and the algorithm for computing the average estimated SIR value corresponding to the error rate relating to the current received signal shall be explained using FIG. 6.
[0052] In the SIR measuring portion 120 , the SIR values of the received signals are measured in real-time, so that the interference cancellation effect estimating portion 300 can easily obtain a pre-interference cancellation SIR value of the received signal received at the time t. However, since some time is required for the interference cancellation, it is impossible to obtain at the time t the actual measurements of the post-interference cancellation SIR value of the received signal received at the time t.
[0053] However, even at the time t, it is of course possible to obtain actual measurements of the post-interference cancellation SIR value of a received signal received in the past. For example, if the delay time required for an n-stage interference cancellation operation is taken as τt, then the post-interference cancellation SIR value for the n-th stage can be obtained for a received signal received at the time t−τt . Accordingly, it is possible to estimate how much the SIR value has improved due to the interference cancellation by using the pre-interference cancellation SIR values and the actually measured post-interference cancellation SIR values relating to past received signals, whereby it is possible to obtain a function f_IC 0 representing the effect of the interference cancellation. This function f_IC 0 indicates the relationship between a signal-to-interference power ratio SIR_ 0 ( 96 ) of a signal received at the time τ and the signal-to-interference power ratio SIR_n(τ) after the n-th stage interference cancellation of the same received signal, this being expressible as SIR_n(τ)=f_IC(SIR_ 0 (τ)). Thus, at the current time t, it is possible to obtain an estimated SIR value as SIR_n(t)=f_IC(SIR_ 0 (t)). When determining this function f_IC 0 , it is possible to use the post-interference cancellation SIR values of each of a plurality of stages (or all stages), or to use the post-interference cancellation SIR values of a specified n-th stage (for example, the final stage).
[0054] Additionally, with regard to the pre-interference cancellation SIR value, values up to the time t have been obtained. Therefore, it is also possible to obtain the function f_SIRt(k, τ2−τ1) which expresses the change in the SIR value in the k-th stage due to the time change from the time τ2 to the time τ1. For example, at the current time t, it is possible to readily determine f_SIRt(0, t−τt) from actually measured values. Furthermore, it is possible to obtain a function F_IC 0 expressing the interference cancellation effect considering the time-varying element based on these functions f_IC 0 and f_SIRt 0 .
[0055] The interference cancellation effect estimating portion 300 inputs the pre-interference cancellation SIR value for the time t into this interference cancellation effect function F_IC 0 , and estimates the post-interference cancellation SIR value of the received signal received at the time t. Consequently, it is possible to obtain at the time t the post-interference cancellation SIR value of he received signal received at the time t without having to wait for the processing delay of the interference cancellation operation.
[0056] Additionally, as is clear from FIG. 6, SIR values after n-stage interference cancellation are obtained as the actually measured values with respect to the received signals received until the time t−τt. Furthermore, due to the above-described estimation SIR values after n-stage interference cancellation are obtained as the estimated values with respect to the received signals received from the time t−τt to the time t. The interference cancellation effect estimating portion 300 uses the post-interference cancellation estimated SIR value for the signal received at the time t and the post-interference cancellation SIR value up to a predetermined time prior to then to determine the post-interference cancellation average estimated SIR value, takes this as the average estimated SIR value of the transmission time interval TTI in which the received signal received at the time t is contained, and outputs this to the target value setting portion 310 . As mentioned above, this average estimated SIR value corresponds to the block error rate of the transmission time interval TTI in which the received signal received at the time t is contained. While the example described here is one wherein the post-interference cancellation SIR value for the received signal received at the time t and the average estimated SIR value calculated based on the estimated SIR value are taken as the average estimated SIR value of the transmission time interval TTI in which the received signal received at the time t is contained, but as with the above-described SIR estimation algorithm, it is also possible to perform corrections taking into account the time varying element of the computed average estimated SIR values.
[0057] In this way, the present invention predicts the post-interference cancellation SIR value for the current received signal, and reflects this in the transmission power control, so that transmission power control is performed more precisely than when using the actual values, thus enabling unnecessary increases of the transmission power as occurred conventionally to be avoided before they happen, and enabling real-time transmission power control with a fast response to be performed by absorbing processing delays due to interference cancellation operations. Furthermore, an average estimated SIR value corresponding to the block error rate of the current received signal is determined, and this is reflected in the target value for transmission power control, thus enabling processing delays due to calculation of the block error rate to be absorbed and enabling real-time transmission power control to be performed with a fast response. Since it is thus possible in the present invention to effectively perform the conventional outer loop and inner loop control in a system using interference cancellers without changing the existing outer loop control signal generating portion, the adaptability to systems with standard specifications can be considered to be high.
[0058] In the above-described embodiment, only a serial interference canceller structure is shown in the drawings, but the present invention is also applicable to parallel interference cancellers or serial-parallel hybrid interference canceller structures.
[0059] Additionally, in the above-described embodiment, an average estimated SIR value corresponding to the block error rate taking into account the interference cancellation effect for the current received signal is estimated, this value is reflected in the target SIR value and corrected, and the transmission power control command is determined based on the instantaneous SIR value taking into account the interference cancellation effect on the current received signal and the corrected target SIR value, but the present invention is based on the generation of a transmission power control command signal for the uplink in consideration of the interference cancellation effect without being affected by delays due to interference cancellation, so that other methods can be conceived for achieving the generation of the transmission power control command. For example, by using an estimated value of the interference canceling effect, it is possible to update the target SIR values every SIR measurement period during control corresponding to the inner loop as well, and to determine the transmission power control command based on the corrected target SIR value and the SIR value of the current received signal. Furthermore, the target SIR value correcting method corresponding to the outer loop can be such as to estimate the post-interference cancellation block error rate itself and performed on the basis thereof. In either case, the effects indicated below are similar.
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The purpose of the present invention is to offer a structure of a CDMA system having a power control method and interference cancellers which can effectively increase the system capacity and is resistant to sudden changes on the communication path, and to achieve a power control method with a fast response capable of preventing unnecessary increases in the transmission power (and multiple access interference) of the uplink by reflecting the values of the post-interference cancellation signal-to-interference power ratio in the generation of power control command information. The invention is directed to a power control method in a communication system for performing communications by code-division multiple access between a mobile station and base station, wherein a multiple access interference signal contained in a reception signal from the mobile station is cancelled, a post-interference cancellation signal-to-interference power ratio of the reception signal currently received is estimated, a power control command is generated by comparing the estimated post-interference cancellation signal-to-interference power ratio and a target value for power control, and transmitting this power control command to the mobile station to control the transmission power of the mobile station.
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RELATED APPLICATIONS
This application is a continuation-in-part of Brunck, Pepe and Webb, entitled "Trypsin Inhibitors", filed Jan. 30, 1992, U.S. Ser. No. 07/828,388, now abandoned and hereby incorporated by reference herein, including the drawings attached thereto.
FIELD OF THE INVENTION
This invention relates to inhibitors of trypsin useful for treatment of pancreatitis.
BACKGROUND OF THE INVENTION
In a healthy mammal, the pancreas produces and secretes enzymes that digest carbohydrates, fats and proteins in the gastrointestinal tract. They are produced in inactive form (termed proenzyme) and subsequently are converted to an active form in the small intestine giving rise to a cascade of amylolytic, lipolytic and proteolytic activity. The cascade is thought to begin with the conversion of pancreatic trypsinogen to trypsin catalyzed by enterokinase, a proteolytic enzyme associated with the small intestine. The newly-formed trypsin then converts the other pancreatic proenzymes into their active forms to trigger a burst of enzymatic activity characterized as digestion. Greenberger et al., Diseases of the Pancreas, "Harrison's Principles of Internal Medicine," 11th Edition, p. 1372, McGraw-Hill, (E. Brunewald et al. edit, 1987).
In the absence of perturbing factors, the pancreas is able to protect itself from the autodigestion which could result from the digestive enzymes it produces. The pancreatic acinar cells (where the digestive enzymes are synthesized and stored) provide three control mechanisms to prevent their own destruction. First, the enzymes are produced as catalytically inactive proenzymes. Second, after their synthesis, but before secretion into the digestive system, the enzymes are segregated from the acinar cell cytoplasm in lysosomes (membrane-bound intracellular organalles). Third, the lysosomes containing the enzymes contain potent protein inhibitors of trypsin which prevent premature activation of other hydrolyric proenzymes. Steer el al., New England Journal of Medicine, 316:144 (1987).
In the presence of perturbing factors, a disorder of the pancreas termed pancreatitis (either acute or chronic) may result. Acute pancreatitis can manifest itself as a mild and self-limiting disorder (termed edematous pancreatitis), or in a more severe form (termed necrotizing pancreatitis) where permanent damage to pancreatic tissue occurs. Chronic pancreatitis results in extensive and permanent destruction of the pancreas. Greenberger et al., supra, at 1372.
Acute pancreatitis is usually associated with biliary tract stones, while chronic pancreatitis is often associated with chronic alcohol abuse. Steer et al., supra, at 144. Pancreatitis may also arise as a complication of cardiac surgery involving cardiopulmonary bypass procedures, and is reported to follow all types of open-heart surgery, including cardiac transplantation. Castillo et al., New England Journal of Medicine, 325:382 (1991). Moreover, bouts of acute pancreatitis are occasionally induced following gastrointestinal diagnostic and surgical procedures, such as bile duct exploration, sphincteroplasty, distal gastrectomy, splenctomy, and endoscopic retrograde cholangiopancreatography. Bardenheier et al., Am. J. Surg. 116:773 (1968); Cotton, Gut, 18:316 (1977). Significant pancreatic injury has been reported in 1 to 3% of patients suffering from abdominal trauma which occasionally results in obstructive chronic pancreatitis.
Pancreatitis is characterized by damage to the pancreas and surrounding tissues which arises from autodigestion of the cells by the various digestive enzymes activated by trypsin. Animal studies of chemically-induced pancreatitis suggest that the disorder is rooted in the inability of pancreatic acinar cells to excrete the digestive proenzymes. This results in the activation of trypsinogen to trypsin by lyosomal hydrolases within the cell, with the amount produced exceeding protective levels of protease inhibitor normally available. Steer et al., supra, at 148; Gabryelewicz, Digestion, 40:19 (1988). This results in the subsequent activation of the other digestive enzymes co-localized with trypsin in the lysosome. These activated digestive enzymes cause edema, interstitial hemorrhage, vascular damage, coagulation necrosis, fat necrosis and parenchymal cell necrosis, Greenberger et al., supra, at 1372.
The activated digestive enzymes may subsequently enter the blood and the peritoneal cavity and can lead to secondary multiple organ damage. Although the blood contains trypsin inhibitors, it has been reported that trypsin complexed with one such inhibitor, alpha-2-macroglobulin, remains active. Rinderknecht et al., Biochim. Biophys. Acta, 295:233 (1973); Harpel et al., J. Clin. Invest., 52:2175 (1975); Rinderknect et al., Biochim. Biophys. Acta, 377:158 (1975). This active complex is thought to contribute in part to the metastatic proteolytic damage observed in pancreatitis. Jones, et al., Gut, 23:939 (1982).
A number of compounds have been examined for treatment of pancreatitis. Specifically, aprotinin, Futhan, Foy, Foy-305 and the leupeptins.
Aprotinin is a polypeptide of 58 amino acids and is reported to be a potent inhibitor of trypsin, with a dissociation constant (K d ) of 3×10 -11 M. Jones, supra, at p. 939. However, it is also reported to be ineffective in the treatment of human acute pancreatitis. Imrie et al., Br. J. Surg., 65:337 (1978); M.C.R. Working Party, Lancet, ii: 632 (1977); Niederau et al., J. Clin. Invest., 78:1056, 1061 (1966). Aprotinin is also an inhibitor of the coagulation factors, kallikrein and plasmin with a K d of 1×10 -7 M and 2×10 -10 M respectively. Kassell et al., Biochem. Biophys. Res. Commun., 18:225 (1965); Fritz el al., Arzneim. Forsch. 33:479 (1983); Lazdunski et al., Proteinase Inhibitors, p 420, Springer Verlag (H. Fritz et al. ed. 1974); Trautschold et al., Biochem. Pharmacol., 16:59 (1967).
Futhan is a nonpeptidyl low molecular weight protease inhibitor first synthesized by Fuji et al., Biochim. Biophys. Acta, 661:342 (1981). It is also known as nafamstat mesilate, FUT-175, and 6-amidino-2-naphthyl-4-guanidino benzoate dimethanesulfonate. It is reported to be effective in the treatment of acute pancreatitis induced in animal models. Iwaki et al., Jap. J. Pharmac. 41:155 (1986); Gabryelwicz et al., supra, at p 22. It is a potent inhibitor of trypsin, as well as the coagulation enzymes, kallikrein, factor Xa, and thrombin. Aoyama et al., Japan J. Pharmacol., 35:203 at 209 (1984); Hitomi et al., Hemostasis, 15:164 (1985).
Foy (also known as gabexate mesilate) and Foy-305 (also known as camostate) are also nonpeptidyl low molecular weight protease inhibitors. Both are reported to be effective to varying degrees in the treatment of acute pancreatitis induced in animal models. Niederau, supra, at 1061; Lankisch et al., Gastroenterology, 96:193 (1989). Both compounds are reported to be effective inhibitors of trypsin, as well as the coagulation/fibrinolysis enzymes, kallikrein, thrombin, plasmin and Clr complement system enzyme. Muramutu et al., Biochim. Biophys. Acta, 268:221 (1972); Takasugi et al., J. Med. Sci., 29:188 (1980); Tamura et al., Biochim. Biophys. Acta, 484:417 (1977).
The leupeptins are low molecular weight peptidyl aldehydes consisting of N-acetyl-L-leucyl-L-leucyl-L-argininal, N-propionyl-L-leucyl-L-leucyl-L-argininal and their analogs which contain L-isoleucine or L-valine in place of L-leucine. Aoyagi et al., "Structures and Activities of Protease Inhibitors of Microbial Origin", Proteases and Biological Control, pp. 429-454, Cold Spring Harbor Laboratory. Press (Reich et al. edit. 1975). They are reported to prolong the survival of rats in which acute pancreatitis has been induced. Jones, supra, at p. 939. They are potent inhibitors of trypsin and other serine proteases. Chiet al., J. Antibiotics, XLII: 1506 (1989).
Various derivatives of the leupeptins have been disclosed which are also potent inhibitors of trypsin. N-benzyloxycarbonyl-L-pyroglutamyl-L-leucyl-L-argininal was shown to be a potent inhibitor of trypsin (with an IC 50 about 7 times lower than than that for N-acetyl-L-leucyl-L-leucy-L-argininal) (Saino et al., J. Antibiotics, XLi: 220 (1988)).
U.K. Patent Application 2,153,825 and Japanese Application 60-163815 describe naphthalene derivatives of arginine as trypsin inhibitors useful for treatment of pancreatitis; and Niederau et al., Gastroenterology 88:1192 (1985) describe proglumide, benzotript and secretin as protective agents against caerulein-induced pancreatitis in mice.
Abbreviations
The following abbreviations are used in this application.
"Bn" refers to benzyl.
"Boc" refers to t-butoxycarbonyl.
"BOP" refers to benzotriazol-1-yloxy-tris-(dimethylamino)-phosphonium-hexafluorophosphate.
"CDI" refers to carbonyldiimidazole.
"DCM" refers to dichloromethane.
"DIEA" refers to diisopropylethylamine.
"DMF" refers to N,N-dimethylformamide.
"Fm" refers to 9-fluorenemethyl.
"IPA" refers to isopropanol.
"MeOH" refers to methanol.
"NaOAc" refers to sodium acetate.
"NMM" refers to 4-methylmorpholine. "Ph" refers to phenyl group.
"Ppa" refers to protected peptide or analog.
"TBS" refers to 0.1M Tris, 0.14M sodium chloride, pH 7.4.
"TEA" refers to triethylamine.
"TFA" refers to trifluoroacetic acid.
"THF" refers to tetrahydrofuran.
SUMMARY OF THE INVENTION
Applicants have discovered that compounds having the general structure:
Pr-A.sub.1 -A.sub.2 -A.sub.3,
where Pr is a hydrophobic group; A 1 is glutamic acid (Glu) or aspartic acid (Asp), or an equivalent of Glu or ASp; A 2 is proline (Pro) or an equivalent of Pro having a 4- or 5-membered ring structure; A 3 is Argininal (Arg-aldehyde or Arg-al) or an equivalent thereof are very specific and active trypsin inhibitors. In contrast to previously described trypsin inhibitors these compounds show potency and selectivity. That is, the described compounds have little to no inhibitory activity [i.e., have an IC 50 value substantially greater (i.e., more than ten fold greater) than that with trypsin] against one or more other serine proteases with physiologically significant activities, including those involved in blood clotting, e.g., kallikrein, thrombin and the activated coagulation factors XII, XI, IX, VII, X, and II; serine proteases involved in clot dissolution e.g., plasmin, tissue plasminogen activator (tPA), and urokinase (UK); serine proteases involved in clot prevention e.g., Protein C; and serine proteases involved in complement mediated cell lysis, e.g., Clr and Cls. See, Colman et al., "Overview of Hemostasis" at pp 3-15, Bachmann, "Plasminogen activators", at pp 318-339, Owen, "Protein C", at 235-241 in Hemostasis and Thrombosis, Basic Principles and Clinical Practice, 2nd Edition, J. B. Lippincott Company (Colman et al. edit., 1987), and Eisen, "Complement", Microbiology, 3rd Edition, p. 456, Harper & Row (Davis et al., 1980). Because of their unexpected selectivity, these compounds will be advantageous over other trypsin inhibitors known in the art because they will not have undesirable side effects resulting from inhibiting other useful and necessary protease activities in the body. This property also permits the compounds to be administered intravenously and orally with few side effects.
By "equivalent" is meant to include variations in the general structure of one or more amino acids or hydrophobic groups which have little if any deleterious affect on the inhibitory activity of the compound compared to the use of the designated amino acid or hydrophobic group. Such variations are well known in the art and can be determined without undue experimentation. They include those variations in the general formula shown below. For example, the hydrophobic group is hydrophobic enough to provide a potent inhibitory activity. Arginine equivalents will function to direct the inhibitor to the active site of trypsin. Examples of such equivalents include an L-or D-isomer of argininal, homoargininal, guanidinoaminobutyral, guanidinoaminopropional, (Me 2 )Arg, (Et 2 )Arg, p-aminomethyl-phenylalaninal, p-amidinophenylalanine, p-guanidinophenylalanine, a conformationally constrained arginine analog as described by T. R. Webb and C. Eigenbrot, J. Org. Chem. 56:3009 (1991), or mono- or di-substituted N-alkyl derivative thereof wherein alkyl means a lower alkyl, preferably methyl. The Glu or Asp is a carboxylated non-cyclic amino acid and equivalents thereof. Such equivalents would include γ-R' esters of glutamic acid, β-R' esters of aspartic acid, or R'-substitituted tetrazoles where the tetrazole substituted for the carboxylic acid group of Glu or Asp. R' in these equivalents is H, lower alkyl of 1 to 6 carbons, or aralkyl of about 6 to about 15 carbon atoms; and the Pro is a cyclic (preferably 4 or 5 membered ring) compound, not including a hydroxy group in the ring, examples include D- or L-isomers of proline, β-methylproline, β,β-dimethylproline; dehydroproline, azetidine carboxylic acid.
This invention also provides a pharmaceutical composition for the prevention and treatment of pancreatitis, which includes one of the above compounds formulated as a pharmaceutically acceptable salt combined with a pharmaceutically acceptable carrier. The invention also provides a method for prevention of, or treatment of, pancreatitis.
Thus, in various aspects, the invention features novel peptide aldehydes, their pharmaceutically acceptable salts, and therapeutic compositions comprising these pharmaceutically acceptable salts in a suitable pharmaceutical diluent for use in the prevention and treatment of pancreatitis, or other diseases characterized by an elevated level of trypsin activity. The novel compounds include those having the general formula: ##STR1## where R 1 is a branched alkyl, a cyclic or polycyclic alkyl (which may be substituted with one or more alkyl groups, preferably of 1 to 5 carbon atoms) of 4 to 10 carbons, n is 1, 2 or 3; A is a group having the formula: ##STR2## where Y, and Z are independently selected from a direct link, oxygen atom and methylene group where only one of Y and Z can be a direct link or an oxygen atom and each R is independently H or an alkyl group with 1 or 2 carbon atoms; B is selected from a group consisting of --CO 2 H, --CO 2 R', ##STR3## wherein R' is as defined above; x is --(CH 2 ) 3 --NH--C(═NH)--NH 2 , --(CH 2 ) 4 --C(═NH)--NH 2 , 4-amidinophenylmethyl, 4-guanidinylphenylmethyl, or 4aminomethylphenylmethyl, and their mono- and di-substituted N-alkyl derivatives, wherein the alkyl group is methyl, ethyl, propyl, isopropyl, butyl or isobutyl; and R 2 is oxygen or N--NR 3 --C(═O)--NR 4 , where R 3 is hydrogen, an alkyl group of 1 to 6 carbons, a phenyl group, an aralkyl group of 7 to 9 carbons, and R 4 is hydrogen, an alkyl group of 1 to 6 carbons, a phenyl group, an aralkyl group of 7 to 9 carbons, or a peptide or peptide analog, provided that N--NR 3 --C(═O)--NHR 4 is readily hydrolyzed at low pH to give the derivative with an oxygen atom. By such peptide analog derivatives having R 2 as N--NR 3 --C(═O)--NHR 4 is meant to include prodrug forms of inhibitors of this invention which can be orally administered, and which in the low pH (e.g., 6.0 or less) of the stomach are cleaved to produce a potent trypsin inhibitor of the invention.
It is known that peptidyl arginine aldehydes exist in equilibrium structures in aqueous solutions. See, Bajusz, S., et al., J. Med. Chem., 33:1729 (1990). These structures, as shown below, include the arginine aldehyde, A, aldehyde hydrate, B, and two amino cytol forms, C and D. The R group would represent the remainder of a given compound embodied in the present invention. The peptide aldehydes of the present invention include within their definition all their equilibrium forms. ##STR4##
"Hydrophobic group" refers to a group which, when attached to molecules, would cause them to have an aversion to water and cluster together in order to avoid contact with water in an aqueous media. Typically, these include groups containing four or more carbon atoms, as a branched alkyl or alkenyl, and polycyclic alkyl substituents.
In preferred embodiments A is azetidine carboxylic acid, L-proline, β-methyl-L-proline, β,β-dimethyl-L-proline or 3,4-dehydro-L-proline.
In another aspect, the invention features a method for synthesis of a peptide aldehyde. The method includes reacting a semicarbazide having the formula: ##STR5## where Ar is optionally substituted phenyl or an equivalent thereof, with an N-protected amino acid aldehyde to produce a protected semi-carbazone, deprotecting the N-terminus of the protected semi-carbazone, and reacting the deprotected semi-carbazone with an N-protected amino acid to produce an N-protected peptide.
In preferred embodiments, the Ar is phenyl; the amino aldehyde is chosen from the group consisting of argininal and lysinal; the deprotecting and reacting the deprotected semi-carbazone steps are repeated a plurality of times with either the same N-protected amino acid or a different N-protected amino acid; the Ar has the formula: ##STR6## where each R" is selected independently from the group consisting of hydrogen, methyl, methoxy, halogen, ethyl and ethoxy.
In yet another aspect, the invention features a protected semi-carbazone formed by reacting a semicarbazide having the formula III above with an α-N-protected amino aldehyde to produce a protected semi-carbazone.
Examples of methods useful for making these semi-carbazides and resulting semi-carbazones are described in Webb, "Reagents for Automated Synthesis of Peptide Analogues, U.S. Ser. No. 07/627,753, filed Dec. 14, 1990 assigned to the same assignee as the present invention, and hereby incorporated by reference herein. See also, Murphy et al., J. Am. Chem. Soc. 114:3156-3157 (1992).
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a scheme illustrating a process for making a solid phase reagent which is subsequently used to make one or more compounds of the present invention, wherein "Bn" refers to benzyl, "t-Bu" refers to t-butyl, and "Boc" refers to t-butoxycarbonyl.
FIG. 2 is a scheme illustrating a process for synthesis of compound 21, wherein "i" refers to pTsOH/FmOH, tolulene/reflux, "ii" refers to Boc-Asp-β-benzyl ester/BOP/NMM/DMF and "iii" refers to triethylamine/reflux.
FIG. 3 is a scheme illustrating a process for synthesis of compound 24, wherein "i" refers to CDI/13 followed by 14, "ii" refers to TFA/DCM, "iii" refers to 1/sodium acetate, "iv" refers to a protected peptide or analog as free acid (Ppa), e.g., 21 of FIG. 2/BOP/NMM/DMF, "v" refers to H 2/ Pd, and "vi" refers to H 3 O + .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Trypsin Inhibitors
Inhibitors of this invention are generally described above. Below are provided examples of such inhibitors. These examples are not limiting in the invention; those in the art will readily recognize that equivalent inhibitors are synthesized by similar methods to those provided below. For example, one preferred embodiment is the compound, t-butyloxycarbonyl-L-aspartyl-L-prolinyl-L-argininal, which is both a potent and specific inhibitor of trypsin. The inhibitor constant (K i ) for this compound against trypsin is 4.5×10 -10 M. Moreover, surprisingly little or no inhibition of other serine proteases was found (see Table 2, infra). Another preferred embodiment is the compound of Example 8 which is advantageously specific for inhibiting trypsin.
The specificity of compounds of this invention is unprecedented in the art. For example, McConnell et al., J. Med. Chem., 33:86 (1989) and Bajusz, Symposia Biologica Hungarica, 25:277 (1984) report that substitution of the N-terminal acetyl group or hydrogen of leupeptin with a more hydrophobic group, e.g., benzyloxycarbonyl (Cbz) or t-butyloxycarbonyl (Boc) has little effect on trypsin inhibitory activity and specificity or even results in a less potent and nonspecific trypsin inhibitor. Compounds of this invention are generally at least one hundred (100) fold and up to one thousand (1,000) fold or greater, more potent inhibitors of trypsin than the known leupeptin analogs, and show substantially greater specificity.
Synthesis
Compounds of the present invention may be synthesized by either solid or liquid phase methods. The functional groups of the amino acid derivatives used in such syntheses are protected by blocking groups, as described herein, to prevent undesired side-reactions during the coupling procedure. The solution-phase starting materials used are readily available from commercial chemical vendors including Aldrich, Sigma, Nova Biochemicals and the like.
The peptide aldehydes can be synthesized by sequential chemical attachment of amino acid derivatives using the solid phase synthesis reagents and methods disclosed by Webb, U.S. patent application, Ser. No. 627,753, filed Dec. 14, 1990, entitled "Reagents for Automated Synthesis of Peptide Analogues," assigned to the same assignee as the present invention, the disclosure of which is incorporated herein by reference. FIG. 1 illustrates the synthesis of a solid phase reagent to which subsequent amino acid derivatives are attached, details of which are provided in the examples, infra.
The present invention also features semicarbazone derivatives discussed above, prepared from the above peptide aldehydes. The semicarbazones are derivatives of the peptide aldehydes which protect the aldehyde functionality of the peptide aldehyde. Unlike the compounds described by McConnell et al., supra, at p. 88, such semicarbazone derivatives are soluble in organic solvents, are crystalline, and couple in high yield, which makes them useful for efficient synthesis of desired peptide aldehydes.
There have been reports of various methods for the solution synthesis of peptide aldehydes (see Bajusz et al., J. Med. Chem. 33:1729-1735 (1990); McConnell et al., J. Med. Chem. 33:86-93 (1990) and references cited therein; Kawamura et al., Chem. Pharm. Bull., 17;1902 (1969); Someno et al., ibid, 34, 1748 (1986); Westerik and Wolfenden, J. Biol. Chem., 247:8195 (1972); and Ito et al., Chem. Pharm. Bull. 23, 3081, (1975)). McConnell et al., supra have used the unsubstituted semicarbazide as an aldehyde protecting reagent for the solution synthesis of peptide aldehydes. Galpin et al., Pept. Struct. Funct., Proc. Am. Pept. Symp., 9th, 799-802 (Edited by: Deber, C. M., Hruby, V. J., Kopple, K. D., Pierce Chem. Co., Rockford, Ill.) have reported on the use of a soluble semicarbazide functionalized polymer which they have used for the manual preparation of some peptide aldehydes.
The methods cited above have significant limitations in scope and practical utility. Only a few of these methods have been shown to be applicable to the synthesis of peptide argininals. The procedures that use lithium aluminum hydride to generate the peptide aldehyde at a late stage in the synthesis (see Bajusz et al., supra) are not applicable to the synthesis of derivatives containing ester protecting groups or other functional groups sensitive to lithium aluminum hydride (LiAlH 4 ). Therefore the hydride procedure is not suited for the synthesis of derivatives containing, for example, aspartic acid or glutamic acid when this reaction sequence is used. Procedures that use the unsubstituted semicarbazide group as a protecting group for the argininal (see McConnell et al., cited above) suffer from low yields and significant solubility problems. The procedures for the solid phase automated synthesis of peptide aldehyde analogs described in the commonly assigned U.S. patent application, Ser. No. 07/627,753, filed Dec. 14, 1990, has overcome many of these problems. However, under certain circumstances, for example, in the case of large scale synthesis, due to cost considerations, the use of the solution phase methods described herein may be particularly advantageous.
We have therefore devised a new protecting group that has many advantages over the existing aldehyde protecting group. The procedure for the synthesis of this protecting group (the 4-diphenylmethyl-semicarbazide group or DPS group) and its use for the preparation of peptide aldehydes, is illustrated in FIG. 3. The DPS group has many advantages over the simple semicarbazide group; including the much greater solubility of the resulting DPS semicarbazone derivatives; also, many of the intermediates are crystalline and can be purified by simple recrystallization. The intermediates also give good yields on coupling and deprotection, etc.
The commercially available 4-phenylsemicarbazide was also investigated by us as a potential aldehyde protecting group reagent. Using this reagent some protected argininals were converted to the corresponding 4-phenylsemicarbazones. Although these derivatives do not have sufficient solubility to be a practical alternative to the DPS derivatives, the 4-phenylsemicarbazones do offer some advantages over the simple semicarbazones.
Formulations
The present invention also includes the pharmaceutically acceptable salts of the compounds disclosed. These salts include acid addition salts, for example, salts of hydrochloric, hydrobromic, acetic acid, and benzene sulfonic acid; other suitable acid addition salts are considered to be within the scope of this invention.
The present invention also includes compositions prepared for storage or adminstration which include a pharmaceutically effective amount of the disclosed compounds in a pharmaceutically acceptable carrier or diluent. Acceptable carriers or diluents for therapeutic use are well known in the pharmaceutical art, and are described, for example, in Remington's Pharmeceutical Sciences, Mack Publishing Co. (A. R. Gennaro edit. 1985) hereby incorporated by reference herein. For example, preservatives, stabilizers, dyes and even flavoring agents may be provided. Id. at 1449. These include sodium benzoate, sorbic acid and esters of p-hydroxybenzoic acid. In addition, antioxidants and suspending agents may be used. Id.
A pharmaceutically effective dose of the composition required for the prevention or treatment of pancreatitis will depend on the route of administration, the type of mammal being treated, and the physical characteristics of the specific mammal under consideration. The compositions of the present invention may be formulated and used as tablets, capsules or elixirs for oral adminstration; suppositories for rectal administration; sterile solutions, suspensions for injectable adminstration, and the like. The dose and method of adminstration can be tailored to achieve optimal efficacy but will depend on such factors as weight, diet, concurrent medication and other factors which those skilled in the medical arts will recognize. Generally, an amount between 0.1 mg/kg and 100 mg/kg body weight/day is administered dependent upon potency of the inhibitor.
The potency and specificity of the compounds of the present invention are determined by in vitro assay methods well known in the art. Potency is assessed from the concentration of compound required to substantially inhibit the enzymatic action of trypsin. Specifically, the inhibitor constant, K i , of the compounds can be determined by the method of Dixon, Biochem. J. 55:170 (1953). The specificity is assessed by determination of the concentration, IC 50 , of compound required to give 50% inhibition of the enzymatic activity of the coagulation enzymes, kallikrein, factor XIa, factor VIIa, factor Xa, thrombin; the fibrinolysis enzymes, plasmin, tissue plasminogen activator (tPA), and urokinase (UK), and the anticoagulation enzyme, protein C. Specificity is found when the concentration of compound giving 50% inhibition of trypsin is low relative to the concentration required to give like inhibition of the other enzymes. That is, the IC 50 for trypsin should be less than about 0.1, preferably 0.01 μM, while the IC 50 for the other enzymes is at least 10-1000 fold (preferably 10-100 fold) greater, e.g., greater than 1 μM.
The efficacy of the compounds of the present invention as a prophylactic treatment for pancreatitis is assessed in vivo using the chemically-induced animal model of Niederau et al., Gastroenterology 88:1192-1204 (1985).
The compounds of the present invention, as selected by the in vitro and in vivo methods disclosed, are potent and highly specific inhibitors of trypsin and thus are useful for the prevention and treatment of pancreatitis in mammals.
The invention will now be further illustrated by the following examples. Unless otherwise specified, the procedures described in the following examples are conducted at ambient temperature and pressure. The first seven examples are illustrated in FIG. 1.
EXAMPLE 1
Preparation of α-N-t-butoxycarbonyl-N g -nitro-argininal ##STR7##
The following procedure for the synthesis of alpha-t-butoxycarbonyl-N g -nitro-argininal 1 is an example of a general procedure for the preparation of Boc-amino acid aldehydes. See Patel et al., Biochim. Biophys. Acta, 748, 321-330 (1983). 12.7 g Boc-N g -nitro-arginine (40 mmoles) and 7.0 g carbonyldiimidazole (CDI; 43 mmoles) were added at room temperature (between 20° and 25° C.) to 200 mL dry tetrahydrofuran (THF) and allowed to stir for 30 minutes. The reaction mixture was cooled to -78° C. and 35 mL LiAlH 4 (1M in THF) was added dropwise over thirty minutes. The reaction was allowed to stir for an additional 1 hour at -78° C. Next, 18 mL acetone was added and the mixture quickly added to 400 mL 1N HCl. The mixture was extracted twice with 100 mL ethyl acetate. The ethyl acetate washes were combined and then washed two times each with 100 mL water, 100 mL saturated NaHCO 3 and 100 mL saturated NaCl (brine). The solution was dried using MgSO 4 and concentrated to a foam. The crude weight of the alpha-t-butoxycarbonyl-N g -nitro-arginal was 6.36 g (21 mmole; yield 52%).
The following alternative procedure for the synthesis of alpha-t-butoxycarbonyl-N g -nitro-argininal 1 is a modification of the procedure of Fehrentz and Castro, Synthesis, 676 (1983).
Boc-N g -nitro-arginine was obtained from Calbiochem. N-methyl piperidine, N,O-dimethlyhydroxylamine hydrochloride and isobutylchloroformate, and lithium aluminum hydride were obtained from Aldrich Chemical Company, Inc. Dichloromethane, ethyl acetate, methanol and tetrahydrofuran may be obtained from Fisher Scientific Company.
11.4 mL N-methyl piperidine was slowly added to a stirred suspension of 8.42g (94 mmole) N,O-dimethylhydroxylamine in 75 mL dichloromethane which had been cooled to about 0° C. The solution was allowed to stir for 20 minutes to give the free hydroxylamine, and then was kept cold for use in the next step.
In a separate flask, 30.0 g (94 mmole) Boc-N g -nitroarginine was dissolved by heating in about 1400 mL tetrahydrofuran and cooled under nitrogen to 0° C. 11.4 mL N-methylpiperidine and 12.14 mL (94 mmole) isobutylchloroformate was added and the mixture stirred for 10 minutes. The free hydroxylamine prepared above was added all at once, the reaction mixture allowed to warm to room temperature, and then stirred overnight.
The resulting precipitate was filtered off, then washed with 200 mL tetrahydrofuran. After concentrating the filtrates to about 150 mL under vacuum, 200 mL ethyl acetate was added, followed by ice to cool the solution. The cooled solution was washed with two 75 mL portions of 0.2N hydrochloric acid, two 75 mL portions 0.5N sodium hydroxide, and one 75 mL portion brine, and then dried over anhydrous magnesium sulfate. Upon concentration in vacuum, 22.7 g (70% yield) of solid Boc-N g -nitro-arginine N-methyl-O-methylcarboxamide was recovered. Thin layer chromatographic analysis in 9:1 dichloromethane/methanol (silica gel) showed one spot.
A flask was placed under a nitrogen atmosphere and cooled to -50° C., then charged with 70 mL (70 mmole) 1N lithium aluminum hydride (in tetrahydrofuran) and 500 mL dry tetahydrofuran. 50 mL of a solution containing 66 mmole Boc-N.sup. g -nitroarginine N-methyl-O-methylcarboxamide in dry tetrahydrofuran was slowly added while the temperature of the reaction mixture was maintained at -50° C. After allowing the reaction mixture to warm to 0° C. by removal of the cooling, it was recooled to -30° C., at which temperature 100 mL (0.2 mole) 2N potassium bisulfate was added with stirring over about a 10 to 15 minute period. The reaction mixture was then allowed to stir at room temperature for 2 hours. After filtering off the precipitate, the filtrate was concentrated to 100 mL under vacuum. The concentrate was poured into 800 mL ethyl acetate, then was washed successively with two 50 mL portions 1N hydrochloric acid, two 50 mL portions saturated sodium bicarbonate, one 50 mL portion brine. The combined aqueous extracts were extracted with 3-100 mL portions of ethyl acetate. All of the ethyl acetate washes were combined and then dried over anhydrous magnesium sulfate. The mixture was concentrated under vacuum to yield 18.5 g (95%) compound 1.
EXAMPLE 2
Preparation of Trans-4-(aminomethyl)-cyclohexane Carboxylic Acid Benzyl Ester Para-touluenesulfonate Salt ##STR8##
50 g (0.318 moles) trans-4-(aminomethyl)-cyclohexane carboxylic acid, 61.7 g (0.324 moles) p-toluenesulfonic acid, 250 mL (2.4 moles) benzyl alcohol, and 250 mL toluene were combined and stirred at room temperature. The mixture was refluxed for 24 hours and the liberated water removed azeotropically by means of a Dean and Stark apparatus. A clear solution was obtained after 5 hours of refluxing. The solution was allowed to cool to room temperature and the product crystallized. The mixture was vacuum filtered, washed with ether and dried in a vacuum oven to give 128.12 g (96% yield). 1 H NMR (CD 3 OD) δ1.05 (m, 2H), 1.43 (m, 2H), 1.59 (m, 1H) 1.85 (m, 2H), 2.03 (m, 2H), 2.33 (m, 1H), 2.35 (s, 3H), 2.75 (d, 2H), 5.09 (s, 2H), 7.23 (d, 2H), 7.32 (m, 5H), 7.69 (d, 2H). M.P. 154°-156° C. See, Greenstein and Winitz, Chemistry of the Amino Acids. 2:942 (1986).
EXAMPLE 3
Preparation of 1-t-butoxycarbonyl-semicarbazidyl-trans-4-methyl Cyclohexane Carboxylic Acid Benzyl Ester ##STR9##
3.24 g (0.02 moles) carbonyldiimidazole (CDI) was dissolved in 45 mL of dimethylformamide (DMF) at room temperature under nitrogen. A solution of 2.48 g (0.02 moles) t-butyl carbazate in 45 mL DMF was added dropwise. 8.38 g (0.02 moles) solid benzyl ester 2 was added, followed by the dropwise addition of 3.06 mL triethylamine (TEA) over a 30 minute period. The reaction was allowed to stir at room temperature under nitrogen for one hour. Water (100 mL) was added and the mixture extracted three times with 50 mL ethyl acetate. The ethyl acetate layers were combined and extracted two times each with 75 mL 1N HCl, H 2 O, NaHCO 3 , NaCl and dried with MgSO 4 . The mixture was filtered and the solution was concentrated to give an oil. This material could be purified by recrystallization from ethyl acetate/hexanes (M.P.=106°-108° C.) or used directly in the next step. 1H NMR (CDCl 3 ) δ0.94 (m, 2H), 1.42 (m, 2H), 1.45 (s, 9H), 1.81 (m, 2H), 2.02 (m, 2H), 2.27 (m, 1H), 3.17 (t, 2H), 5.09 (s, 2H), 5.51 (t, 1H), 6.46 (s, 2H), 7.34 (m, 4H).
EXAMPLE 4
Preparation of 1-(t-butoxycarbonyl)-3-semicarbazidyl-trans-4-methyl-cyclohexane Carboxylic Acid ##STR10##
To the crude Boc-benzyl ester 3 from Example 3 above, 250 mL of methanol (MeOH) and 500 mg of 10% palladium on activated carbon were added. After shaking on the hydrogenator for one hour at 5 psig H 2 , the mixture was filtered with Celite through a fine fritted filter. The solution was concentrated to a foam, methylene chloride added, and a precipitate formed. The mixture was kept at 5° C. for 65 hours. The crystallized material was filtered with ether and 4.0 g of crude product obtained (12.7 mmoles; yield 62% overall yield from compound 2.) 1 H NMR (CD 3 OD), δ0.96, (m, 2H), 1.42 (m, 2H), 1.46 (s, 9H), 1.82 (m, 2H), 1.97 (m, 2H), 2.18 (m, 1H), 3.0 (t, 2H). M.P.=185°-189° C.
EXAMPLE 5
Preparation of Semicarbazidyl-trans-4-methylcyclohexane Carboxylic Acid Trifluoroacetate Salt ##STR11##
315 mg (1 mmole) of compound 4 was added to 10 mL trifluoroacetic acid (TFA) at 0° C. and the resulting solution stirred for 30 min. After this time the solution was added dropwise to 75 mL ether. A precipitate formed, and the mixture was filtered and washed with ether. Weight of crude product was 254 mg, 0.77 mmoles; yield (77%). 1 H NMR (CD 3 OD), δ1.0 (m, 2H), 1.38 (m, 2H), 1.43 (m, 1H), 1.84 (m, 2H), 2.01 (m, 2H), 2.22 (m, 1H), 3.04 (d, 2H). M.P.=154°-156° C.
EXAMPLE 6
Preparation of A-(t-butoxycarbonyl)-N g -nitro Argininal-semicarbazonyl-trans-4-methylcyclohexane Carboxylic Acid ##STR12##
A solution of 13.7 g (41.6 mmoles) compound 5, 18.0 g ˜59 mmoles) crude compound 1 in 135 mL ethanol containing 45 mL water, was treated with 9.41 g (69 mmoles) NaOAc and refluxed for one hour. This solution was allowed to cool and then poured into 0.1N HCl and extracted three times with ethyl acetate. The combined organic phase was washed with water, then brine, dried with MgSO 4 and concentrated to a small volume. This cloudy mixture was allowed to set overnight at 5° C. to precipitate the product, which was isolated by filtration and dried under vacuum. This gave 9.9 g, 47% yield based on 5. 1 H NMR (CD 3 OD), δ1.0 (m, 2H), 1.43 (s, 9H), 1.45-2.20 (m, 13H), 3.09 (d, 2H), 3.30 (m, 2H), 4.18 (bs, 1H), 7.10 (d, 1H). M.P.=162°-163° C.
EXAMPLE 7
Synthesis of Semicarbazide Solid Support ##STR13##
Solid phase reagent 7 was prepared by placing 0.8 g (0.5 mmoles, 0.62 g/mol) methyl-benzhydrylamine (MBHA) resin in a reaction vessel and washing 1 time with dichloromethane (DCM) (all washes require 10 mL of solvent with agitation for 1-2 minutes), 3 times with dimethylformamide (DMF), 2 times with 10% diisopropylethylamine (DIEA)/DMF, and 4 times with DMF. 5 mL DMF, 1 mmole 4-methylmorpholine (NFM) (102 μl), 1 mmole benzotriazol-1-yloxy-tris-(dimethylamino)-phosphonium-hexa-fluorophosphate (BOP reagent) (443 mg), and 1 mmole compound 6 (500 mg) was added, mixed on a rotating wheel for 16 hours, and washed 3 times with DMF, 2 times with 10% DIEA/DMF and 3 times with DMF. The resin was then washed successively with DCM, methanol, and ether.
The resulting resin 7 shows 98-99% coupling yield by ninhydrin.
This resin was then extended at the N-terminus, with amino acids or amino acid analogs, on a conventional peptide synthesizer using standard t-Boc methodology as shown in the examples which follow.
The automated synthesis of peptide aldehydes was performed on an Applied Biosystems model 430A peptide synthesizer using the t-Boc chemistry conditions in the 430A user's manual. The resulting protected peptide aldehyde can be cleaved from support with formaldehyde and deprotected with hydrogen/Pd. The nitro group can be removed from the guanidine group without reduction of the aldehyde.
EXAMPLE 8
Preparation of N-t-butyloxycarbonyl-L-Glu-L-Pro-L-argininal ##STR14##
The peptide aldehyde 8 was synthesized using an Applied Biosystems Model 430A peptide synthesizer as discussed above. The t-Boc chemistry conditions utilized were as provided in the instrument user's manual.
0.500 g resin 7 was made ready for use by removing the t-Boc protecting groups by treatment with 50% trifluoroacetic acid (in dichloromethane). After washing and neutralizing the acidity by treatment with 10% diisopropylethylamine (in dichloromethane), commercially available t-Boc-protected amino acids were coupled to the support reagent (and the growing amino acid support chain) in a sequential manner.
Thus, N-Boc-L-proline was attached to the resin using dicyclohexylcarbodiimide and 1-hydroxybenztriazole in dimethylformamide, followed by treatment with 50% trifluoroacetic acid (in dichloromethane) to remove the t-Boc protecting group, a wash step and a wash with 10% diisopropylethylamine (in dichloromethane) to neutralize acidity. N-Boc-L-glutamic acid-γ-benzyl ester was coupled in the same manner, except that treatment with 50% trifluoroacetic acid was omitted.
The peptide aldehyde was removed from the solid phase by treatment with a mixture of 5 mL tetrahydrofuran, 1 mL acetic acid, 1 mL formaldehyde and 0,100 mL 1N HCl for 1 hour with stirring. After filtering this mixture, the resin was washed with 10 mL of tetrahydrofuran. The combined filtrates were diluted with 100 mL water and extracted with ethyl acetate. The ethyl acetate phase was then washed with saturated NaCl, dried over magnesium sulfate, and concentrated under vacuum.
To remove the nitro and benzyl protecting groups of the peptide aldehyde, the concentrated peptide aldehyde was taken up in a mixture comprising 10 mL of 10% water in methanol, 0.300 mL 1N HCl and 0.200 g palladium on carbon, and then treated with hydrogen at 5 psi for 45 minutes. The mixture was filtered through a fine fritted filter with Celite, washed with 10% water in methanol, and concentrated to give the crude peptide aldehyde.
The resulting peptide aldehyde was then purified using reverse phase HPLC on a 10 micron particle size, 300 angstrom pore size C-18 column, eluting with a water-acetonitrile (both containing 0.1% trifluoroacetic acid) gradient, where the gradient ran from 5% to 40% acetonitrile. The column fractions were analyzed by analytical HPLC and fractions containing pure product were pooled and lyophilized to yield product 8. Fast atom bombardment mass spectrometry gave observed molecular weight of 484 a.m.u.; calculated molecular weight was 484 a.m.u.
EXAMPLE 9
Preparation of N-t-butyloxycarbonyl-L-Asp-L-Pro-L-argininal ##STR15##
Peptide aldehyde 9 was synthesized and purified in the same manner as described in Example 8. Here, N-BoC-L-proline was first attached to resin 7 followed by N-Boc-L-aspartic acid-beta-benzyl ester (in the place of N-Boc-L-glutamic acid-γ-benzyl ester). Again, treatment with 50% trifluoroacetic acid was omitted after the last coupling. Fast atom bombardment mass spectrometry gave observed molecular weight of 470 a.m.u.; calculated molecular weight was 470 a.m.u.
EXAMPLE 10
Preparation of N-isobutyloxycarbonyl-L-Asp-L-Pro-L-argininal ##STR16##
Peptide aldehyde 10 was synthesized and purified in the same manner as described in Example 8. Here, N-Boc-L-proline was first attached to resin 7 followed by N-isobutoxycarbonyl-L-aspartic acid-beta-benzyl ester (in the place of N-Boc-L-glutamic acid-γ-benzyl ester). Again, treatment with 50% trifluoroacetic acid was omitted after the last coupling. Fast atom bombardment mass spectrometry gave observed molecular weight of 470 a.m.u.; calculated molecular weight was 470 a.m.u.
EXAMPLE 11
Preparation of N-adamantyloxycarbonyl-L-AsP-L-Pro-L-argininal ##STR17##
2.5 g (12.6 mmole) adamantyloxycarbonyl fluoride was added to a mixture of 2.2 g (10 mmole) α-N-(t-butoxycarbonyl-L-aspartic acid-beta-(benzyl ester) in 50 mL saturated NaHCO 3 and 30 mL tetrahydrofuran. After stirring for 2 hours at room temperature, the reaction mixture was poured into 100 mL 1N hydrochloric acid, and extracted with ethyl acetate. The combined extracts were washed with water, dried over MgSO 4 , and concentrated to an oil. The oil was taken up in ether, then precipitated by addition of hexanes. The supernatant was decanted and the liquid concentrated in vacuum to give a white foam. 1.8 g (45% yield) N-adamantyloxycarbonyl-L-aspartic acid-gamma-benzyl ester was recovered.
Peptide aldehyde 11 was synthesized and purified in the same manner as described in Example 8.
Here, N-Boc-L-proline was first attached to resin 7 followed by N-adamantyloxycarbonyl-L-aspartic acid-gamma-benzyl ester (in the place of N-Boc-L-glutamic acid-γ-benzyl ester). Again, treatment with 50% trifluoroacetic acid was omitted after the last coupling. Fast atom bombardment mass spectrometry gave observed molecular weight of 548 a.m.u.; calculated molecular weight was 548 a.m.u.
EXAMPLE 12
Preparation of N-t-buyloxycarbonyl-D-Asp-L-Pro-L-argininal ##STR18##
Peptide aldehyde 12 was synthesized and purified in the same manner as described in Example 8. Here, N-Boc-L-proline was first attached to resin 7 followed by N-Boc-D-aspartic acid-beta-benzyl ester (in the place of N-Boc-L-glutamic acid-γbenzyl ester). Again, treatment with 50% trifluoroacetic acid was omitted after the last coupling. Fast atom bombardment mass spectrometry gave observed molecular weight of 470 a.m.u.; calculated molecular weight was 470 a.m.u.
In the following examples the 1 H NMR is consistent with the desired product in every case. The following examples are illustrated in FIGS. 2 and 3.
EXAMPLE 13
Preparation of 1-t-butoxycarbonyl-semicarbazidyl-4-diphenylmethane ##STR19##
A solution of 16.2 g (0.10 mole) carbonyldiimidazole (CDI) in 225 mL dimethylformamide (DMF) was prepared at room temperature and allowed to stir under nitrogen. A solution of 13.2 g (0.100 moles) t-butyl carbazate (13) in 225 mL DMF was then added dropwise over a 30 min. period. Next a solution of 18.3 g (0.10 moles) diphenylmethylamine 14 in 100 ml DMF was added over a 30 min. period. The reaction was allowed to stir at room temperature under nitrogen for one hour. Water (10 mL) was added and the mixture concentrated to about 150 mL under vacuum. This solution was poured into 500 mL water and extracted with 400 mL ethyl acetate. The ethyl acetate phase was extracted two times each with 75 mL 1N HCl, H 2 O, saturated NaHCO 3 , and brine, and dried with MgSO 4 . The mixture was filtered and the solution was concentrated to give 29.5 g (85% yield) of a white foam. This material could be purified by recrystallization from ethyl acetate/hexane, but was pure enough to use directly in the next step: mp 142°-143° C. Anal. Calcd. for C 19 H 23 N 3 O 3 : C, 66.84; H, 6.79; N, 12.31. Found: C, 66.46; H, 6.75; N; 12.90.
EXAMPLE 14
Preparation of Semicarbazidyl-4-diphenylmethane Trifluoroacetate Salt ##STR20##
A solution of 3.43 g (10 mmole) compound 15 in 12.5 mL dichloromethane was treated with 12.5 mL of trifluoroacetic acid (TFA) at 0° C. and allowed to stir for 30 min at this temperature. After this time the solution was added dropwise to 75 mL ether. A precipitate formed, and the mixture was filtered and washed with ether. Weight of crude product was 2.7 g (80% yield): mp 182°-184° C.
EXAMPLE 15
Preparation of α-N-(t-butoxycarbonyl-N g -nitro-argininal-semicarbazonyl-4-N-diphenylmethane ##STR21##
A solution of 2.65 g (7.8 mmoles) compound 16, and 2.36 g (7.8 mmoles) of 1 (alpha-N-(t-butoxycarbonyl)-N g -nitro-argininal) in 20 mL ethanol containing 6 mL of water, was treated with 1.2 g (8.8 moles) of sodium acetate and refluxed for one hour. This solution was allowed to cool and then poured into water and extracted three times with ethyl acetate. The combined organic phase was washed with water, 0.1N HCl, and brine, dried with MgSO 4 , and concentrated to a small volume. The white solid residue was recrystallized from acetonitrile/ether. This gave 3.2 g (78% yield base on 16): mp 78°-79° C.
EXAMPLE 16
Preparation of N g -nitro-argininal-semicarbazonyl-4-N-diohenvlmethane Trifluoroacetate Salt ##STR22##
A solution of 0.53 g (1.0 mmole) compound 17 in 5 mL dichloromethane was treated with 5 mL trifluoroacetic acid (TFA) at 0° C. and allowed to stir for 30 minutes at this temperature. After this time the solution was added dropwise to 40 mL ether. A precipitate formed, and the mixture was filtered and washed with ether. This gave 0.51 g of a pure white solid (97% yield): mp 159°-160° C.
EXAMPLE 17
Preparation of L-proline-9-fluorenemethyl Ester p-toluenesulfonic Acid Salt ##STR23##
A solution of L-proline 15.99 g (139.0 mmole), 9-fluorenemethanol 30.0 g (152.9 mmole), and p-toluenesulfonic acid in 600 mL of toluene was refluxed and water was removed with a Dean-Stark trap. After 26 hours, the reaction was concentrated to give 64 g (99% crude yield) of an oil which was used directly in the next step.
EXAMPLE 18
Preparation of α-N-(t-butoxycarbonyl)-L-aspartyl-beta-(benzyl ester)-L-proline-9-fluorenemethyl Ester ##STR24##
A solution of L-proline-9-fluorenemethyl ester p-toluenesulfonic acid salt 19 (15.44 g, 33.2 mmole), butoxycarbonyl)-L-aspartic acid-beta-(benzyl ester) (9.35 g, 41.9 mmole), benzotriazol-1-yloxy-tris-(dimethylamino)-phosponium-hexafluorophosphate (BOP reagent) 18.6 g (42.0 mmole) in 100 mL DMF was allowed to stir in an ice-bath. This solution was treated with 1-hydroxybenzotriazole hydrate (0.45 g, 3.34 mmole), diisopropylethylamine (19.0 mL, 198 mmole) and the reaction allowed to stir at 0°-5° C. for 1.5 hours. After this time the reaction mix was poured into 600 mL of ethyl acetate and extracted successively with saturated aqueous citric acid, water, saturated sodium bicarbonate, and finally brine. The organic phase was dried with MgSO 4 and concentrated under vacuum to give 18 g (91% crude yield) of an oil, which was used directly in the next step.
EXAMPLE 19
Preparation of α-N-(t-butoxycarbonyl)-L-aspartyl-beta-(benzyl ester)-L-proline ##STR25##
The crude oil from above, α-N-(t-butoxycarbonyl)-L-aspartyl-beta-(benzyl ester)-L-proline 9-fluorenemethyl ester 20 (17.5 g, 29.2 mmole) was suspended in 250 mL triethylamine and allowed to reflux for 1 hour. This mixture was concentrated to an oil, dissolved in 600 mL of ethyl acetate. The ethyl acetate phase was washed once with citric acid, once with brine, dried with MgSO 4 , and concentrated to give an oil. This material was purified by column chromatography (silica gel, 10-20% THF/DCM) to give 7.5 g (38% overall from 19).
EXAMPLE 20
Preparation of α-N-(t-butoxycarbonyl)-L-aspartyl-beta(benzyl ester)-L-prolyl-L-N g -nitro-argininal-semicarbazonyl-4-N-diphenylmethane ##STR26##
α-N-(t-butoxycarbonyl)-L-aspartyl-beta-(benzyl ester)-L-proline 21 (11.29 g, 26.9 mmole) was dissolved in 60 mL DMF. This solution was treated with N-methylmorpholine (NMM, 11.9 mL, 108 mmole), BOP (11.9 g, 27 mmole) and 18 (14.64 g, 28 mmole), then allowed to stir for 2h. This mixture was poured into 700 mL ethyl acetate and washed with 1N citric acid, saturated NaHCO 3 , water, and brine, dried with MgSO 4 , and concentrated to give a foam. This material was purified by column chromatography (silica gel, 6-20% IPA/DCM) to give 12.5 g (38% overall from 21).
EXAMPLE 21
Preparation of α-N-(t-butoxycarbonyl)-L-aspartyl-L-prolyl-L-argininal ##STR27##
A solution of 22 (4.4 g, 5.1 mmole) in 85 mL methanol was treated with 20 mL water, 10.5 mL glacial acetic acid, 44 mL 1N HCl, and 2.2 g 10% Pd on carbon. This was hydrogenated at 11 psi with shaking for 70 min. The mixture was filtered and concentrated to a small volume. The resulting peptide aldehyde was then purified using reverse phase HPLC on a 10 micron particle size, 300 Å pore size C-18 column, eluting with a water-acetonitrile (both containing 0.01% trifluoroacetic acid) gradient, where the gradient ran from 5% to 40% acetonitrile. The column fractions were analyzed by analytical HPLC and fractions containing pure product were pooled and lyophilized. This gave 400 mg of pure 23, which was identical to the product from Example 9, along with 1.2 g of debenzylated starting material. The yield was 25% based on consumed starting material.
EXAMPLE 22
Preparation of N-t-butyloxycarbonyl-L-(β-methyl ester)-Asp-L-Pro-L-argininal ##STR28##
Peptide aldehyde 24 is synthesized and purified in the same manner as described in Example 8. Here, N-BOC-L-proline is first attached to resin 7 followed by N-Boc-L-(β-methyl ester) aspartic acid in the place of N-Boc-L-glutamic acid-γ-benzyl ester. Again, treatment with 50% trifluoroacetic acid is omitted after the last coupling.
EXAMPLE 23
Preparation of N-t-butyloxycarbonyl-L-(β-t-butyl ester)-ASP-L-Pro-L-argininal ##STR29##
Peptide aldehyde 25 is synthesized and purified in the same manner as described in Example 8. Here, N-Boc-L-proline is first attached to resin 7 followed by N-Boc-L-(β-t-butyl ester) aspartic acid in the place of N-Boc-L-glutamic acid-γ-benzyl ester. Again, treatment with 50% trifluoroacetic acid is omitted after the last coupling.
EXAMPLE 24
Preparation of 3-Cyano-2-(1,1-dimethylethoxy) methanamidopropionic Acid ##STR30##
20.0 g (86 mmol, 1 equiv.) of Boc-L-Asparagine (from Bachem or Sigma) was dissolved in 120 mL of dry pyridine and 20.0 g (97 mmol, 1.3 equiv. ) of dicyclohexylcarbodiimide dissolved in 60 mL of dry pyridine was added dropwise over a period of 30 minutes. The reaction was stirred for 3 hours at 23° C. and filtered through a 2 μm nylon filter. The filtrate was concentrated in vacuo on a rotary evaporator and 100 ml of water was added. The pH was adjusted to 10 with 40% sodium hydroxide (aq.) and the solution filtered through a 2 μm nylon filter once again. The filtrate was passed through a 120 mL bed of Dowex 50X8-400 ion exchange resin and the resin washed with four column volumes of 1:1 methanol:water. The filtrate was concentrated in vacuo to yield 17.5 g (95% yield) of product as a white solid. 1 H-NMR (CD 3 OD): 4.40 p.p.m (m, 1H); 2.95 p.p.m. (m, 2H); 1.40 p.p.m. (s, 9H).
EXAMPLE 25
Preparation of 3-Tetrazolyl-2-(1,1-dimethylethoxy) methanamidopropionic Acid ##STR31##
17.5 g (82 mmol, 1 equiv. ) of 3-cyano-2- (1,1-dimethylethoxy) methanamido-propionic acid 26 was dissolved in 125 mL of tetrahydrofuran and 40.5 g (129 mmol, 1.5 equiv. ) tributyltin azide was added. The reaction mixture was brought to reflux and held there for 3 days. The reaction mixture was cooled and the volatiles removed in vacuo on a rotary evaporator. The residue was dissolved in 300 mL of 0.5M sodium hydroxide and this aqueous solution was washed with ethyl acetate (4×100 mL). The aqueous layer was passed through a 125 mL bed of Dowex 50X8-400 ion exchange resin and the resin washed with four column volumes of 1:1 methanol:water. The volatiles were removed in vacuo on the rotary evaporator to yield 17.9 g of the product as a white solid (85% yield). 1 H-NMR (CD 3 OD): 4.55 p.p.m (m, 1H); 3.40 p.p.m. (m, 2H); 1.40 p.p.m. (s, 9H). This material is suitable for use in solid-phase peptide synthesis.
EXAMPLE 26
Preparation of 3-(N-2-methyl)tetrazolyl-2-(1,1-dimethylethoxy)methanamidopropionic Acid, Methyl Ester and 3-(N-3-Methyl)tetrazolyl-2-(1,1-dimethylethoxy)methanamidopropionic Acid, Methyl Ester ##STR32##
1.5 g (5.8 mmol, 1.0 equiv.) of 3-tetrazolyl-2-(1,1-dimethylethoxy)methan-amidopropionic acid 27 was dissolved in 13 mL of dry dimethylformamide and 3.9 g (12.0 mmol, 2.1 equiv.) of cesium carbonate was added. This was followed by the addition of 930 μL (14.5 mmol, 2.5 equiv.) of methyl iodide via syringe. The reaction mixture was stirred at 23° C. for 3 hours and poured into 50 mL of 0.5M hydrochloric acid. The resulting mixture was extracted with ethyl acetate (3×50 mL). The combined organics were washed with 50 mL 0.5M hydrochloric acid, 50 mL saturated sodium bicarbonate, and 50 mL brine. After drying over sodium sulfate, the organics were decanted and the volatiles removed in vacuo on the rotary evaporator to yield a mixture of the title compounds as a yellow oil. The isomers were separated by chromatography on silica gel (50% ethyl acetate/hexane) with one isomer eluting first (Rf= 0.3 vs. Rf=0.15 of the other isomer on silica gel developing in 50% ethyl acetate/hexane). Fractions containing pure product were combined and the volatiles removed on the rotovap to yield 0.60 g of pure product for each of the title compounds. 1 H-NMR (CDCl 3 ): The second-eluting isomer gave 5.8 p.p.m (d, 1H); 4.75 p.p.m (m, 1H); 4.05 p.p.m (s, 3H); 3.75 p.p.m. (s, 3H); 3.4 p.p.m (m, 2H); 1.5 p.p.m. (s, 9H). The first-eluting isomer gave: 5.75 p.p.m (d, 1H); 4.75 p.p.m (m, 1H); 4.30 p.p.m (s, 3H); 3.75 p.p.m. (s, 3H); 3.65 p.p.m (m, 2H); 1.7 p.p.m. (s, 9H).
EXAMPLE 27
Preparation of 3-(N-2-methyl)tetrazolyl-2-(1,1-dimethylethoxy)methanamidopropionic Acid or 3-(N-3-methyl)tetrazolyl-2-(1,1-dimethylethoxy)methanamidopropionic ##STR33##
0.5 g (1.75 mmol, 1.0 equiv.) of 3-(N-2-methyl)tetrazolyl-2-(1,1-dimethylethoxy)methanamidopropionic acid methyl ester or 3-(N-3-methyl)tetrazolyl-2-(1,1-dimethylethoxy)methanamidopropionic acid methyl ester is dissolved in 12 mL of methanol and 2.3 mL (1.3 equiv.) of 1.0M lithium hydroxide (aq.) is added. The reaction is stirred for 2 hours at 23° C. when starting material can no longer be seen by TLC analysis (1:1 ethyl acetate/hexane). The reaction mixture is passed through a 10 mL bed of Dowex 50X8-400 ion exchange resin and the resin is washed with four column volumes of 1:1 methanol:water. The solvents are removed in vacuo to yield the appropriate title product.
EXAMPLE 28
Preparation of L-3-tetrazolyl-2-(1,1-dimethylethoxy)methanamidopropionyl-L-Pro-L-argininal ##STR34##
Peptide aldehyde 30 is synthesized and purified in the same manner as described in Example 8. Here, N-Boc-L-proline is first attached to resin 7 followed by 3-tetrazolyl-2-(1,1-dimethylethoxy)methanamidopropionic acid 27 (in the place of N-Boc-L-glutamic acid-γ-benzyl ester). Again, treatment with 50% trifluoroacetic acid is omitted after the last coupling.
EXAMPLE A
Potency--Determination of Inhibitor Contant, K i
The potency of peptide aldehydes, 8, 9, 11 and 12, as inhibitors of bovine and human pancreatic trypsin was quantified in vitro by determination of their inhibitor constants, K i . Enzyme activity was determined using as substrate S-2222 [N-benzoyl-L-isoleucyl-L-glutamyl-glycyl-L-arginine-p-nitroanilide hydrochloride where glutamyl side chain is 50% carboxylic acid and 50% methyl ester], purchased from Kabi Diagnostica. The substrate was made up in deionized water prior to use.
A 96-well microtiter plate was prepared for use in the assay by incubating each well with 300 μL of 1% bovine serum albumin (in deionized water) for 30 minutes at 37° C., and washing three times with deionized water.
To each well was added 50 μL TBS (0.1M Tris, 0.14M NaCl, pH 7.4), 50 μL 2.5 nM trypsin and 50 μL peptide aldehyde in TBS or TBS alone. After incubating for 15 minutes at 37° C., 50 μL of S-2222 (at 37° C.) at a specified concentration was added to each well. After mixing, the rate of substramte turnover at 37° C. was measured for 30 minutes at 405 nm (generation of p-nitroaniline). The initial S-2222 concentrations in the assay mixture were 0.45, 0.23, 0.11, 0.056, and 0.028 mM.
K i was determined graphically using a Dixon plot, as described in Dixon, Biochem. J. 55:170 (1953). Results are shown in Table 1 below.
TABLE 1__________________________________________________________________________K.sub.i For Peptide Aldehydes Against Trypsin.Peptide Aldehyde Structure K.sub.i (μM)__________________________________________________________________________N-t-butoxycarbonyl-L--Glu--L--Pro--L-Argininal 8 0.0014N-t-butoxycarbonyl-L--Asp--L--Pro--L-Argininal 9 0.00045N-adamantyloxycarbonyl-L--Asp--L--Pro--L-Argininal 11 0.0002N-t-butoxycarbonyl-D--Asp--L--Pro--L-Argininal 12 0.045__________________________________________________________________________
EXAMPLE B
Specificity--Determination of IC 50
The specificity of the peptide aldehydes (8 through 12) was determined in vitro by measurement of their IC 50 against other enzymes involved in hemostasis. A specific concentration of enzyme and its substrate were challenged with varying concentrations of inhibitor. IC 50 is that concentration of inhibitor giving 50% inhibition of substrate turnover, under the assay conditions. Specific assay procedures used are presented below. Tables 2a and 2b below show the results of the specificity assays. ">25" means less than 50% inhibition observed at highest concentration of inhibitor tested, 25 μM inhibitor; "<0.025" means greater than 50% inhibition observed at lowest concentration of inhibitor tested, 0.025 μM; "Inact." means no inhibition observed at highest concentration of inhibitor tested; and "ND" means not determined.
Table 2c and 2d shows % selectivity relative to trypsin for each compound and commercial inhibitor tested. For each compound, % selectivity is equal to [IC 50 for Trypsin)/IC 50 for other enzyme)]×100. The lower the numerical value of % selectivity, the more selective the compound is as a trypsin inhibitor.
TABLE 2a______________________________________IC.sub.50 for Peptide Aldehydes and Commercial Inhibitors.Compound IC.sub.50 (μM)Tested Kallikrein XIa VIIA Xa Thrombin______________________________________8 6 4 >25 Inact. 149 17 12 Inact. >25 1710 8 13 Inact. 2 911 2 6 >25 0.3 1012 >25 >25 Inact. >25 Inact.Aprotinin 0.2 2 >25 Inact. Inact.Futhan <0.025 <0.025 1.2 6.0 0.21FOY 1 1 >25 8 6Leupeptin 4 11 >25 25 20______________________________________
TABLE 2b______________________________________IC.sub.50 for Peptide Aldehydes and Commercial Inhibitor.Compound IC.sub.50 (μM)Tested Protein C Plasmin tPA UK Trypsin______________________________________8 Inact. 0.6 Inact. 9 0.0069 Inact. 1.4 Inact. 25 0.01410 >25 1.2 >25 >25 <0.02511 >25 1.1 >25 19 <0.02512 >25 1.2 >25 17 0.084Aprotinin 2 0.008 Inact. ND 0.019Futhan 0.084 <0.025 0.37 ND <0.025FOY 15 1.6 9 ND 0.25Leupeptin >25 8 Inact. Inact. 1.7______________________________________
TABLE 2c______________________________________Calculated % Selectivity for Peptide Aldehydes andCommercial Inhibitors.Compound % SelectivityTested Kallikrein XIa VIIa Xa Thrombin______________________________________8 0.10 0.15 <0.02 0 0.049 0.08 0.12 0 <0.06 0.0810 <0.3 <0.19 0 <1.3 <0.2811 <1.3 <0.42 <0.1 <0.83 <0.2512 <0.34 <0.34 0 <0.34 0Aprotinin 9.5 0.95 <0.08 0 0Futhan 100 100 <2.1 <0.42 <0.12FOY 25 25 <1.0 3.1 4.2Leupeptin 43 15 <6.8 6.8 8.5______________________________________
TABLE 2d______________________________________Calculated % Selectivity for Peptide Aldehydes andCommercial InhibitorsCompound % SelectivityTested Protein C Plasmin tPA UK Trypsin______________________________________8 0 1 0 0.07 1009 0 1 0 0.06 10010 <0.1 <2 <0.1 <0.1 10011 <0.1 <2 <0.1 <0.1 10012 <0.3 7 <0.3 0.5 100Aprotinin 1 237 0 -- 100Futhan <30 100 <6.8 -- 100FOY 1.7 16 2.7 -- 100Leupeptin <6.8 21 0 0 100______________________________________
(a) Preparation of Microtiter Plates
96-well microtiter plates were prepared for use in these assays by incubating each well with 300 μL 1% bovine serum albumin (in deionized water) for 30 minutes at 37° C., then washing three times with deionized water.
(b) Factor VIIa Assay
Enzyme activity was determined using as substrate, S-2288 [D-isoleucyl-L-prolyl-L-arginine-p-nitroanilide dihydrochloride], purchased from Kabi Diagnostica. The substrate was made up in deionized water prior to use.
Factor VIIa:rTF complex was prepared by adding to a polypropylene test tube 5 mL 25 nM recombinant human tissue factor (rTF), 2.5 ml 400 nMhuman Factor VIIa (in 0.4% bovine in TBS) and 2.5 mL 20 mM CaCl 2 . Background control was prepared by adding to a second polypropylene test tube 1 mL 25 nM rTF, 0.5 mL 0.4% bovine serum albumin in TBS, and 0.5 mL 20 mM CaCl 2 . Both solutions were then incubated for 30 minutes at room temperature before use in the assay.
The assay was run by combining in appropriate wells 50 μL inhibitor in TBS or TBS alone and 100 μL of Factor VIIa:rTF complex or background control, incubating this mixture for 30 minutes at room temperature, adding 50 μL of 2 mM S-2288, incubating for an additional 30 to 60 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
(c) Factor Xa Assay
Enzyme activity was determined using as substrate, Pefachrome Xa [N-methoxycarbonyl-D-cyclohexylalanyl-L-glycyl-L-arginine p-niroanilide acetate], purchased from Centerchem, Inc. The substrate was made up in deionized water prior to use.
The assay was run by combining in appropriate wells 50 μL of inhibitor in TBS or TBS alone and 50 μL 30 nM human Factor Xa (or TBS as background control) and 50 μL TBS, incubating this mixture for 30 minutes at room temperature, adding 50 μL of 1 mM Pefachrome Xa, incubating for an additional 30 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
(d) Factor XIa Assay
Enzyme activity was determined using as substrate, S-2366 [L-pyroglutamyl-L-prolyl-L-arginine-p-nitroanilide hydrochloride], purchased from Kabi Diagnostica. The substrate was made up in deionized water prior to use.
The assay was run by combining in appropriate wells 50 μL of inhibitor in TBS or TBS alone and 50 μL of 5 nM human Factor XIa (or TBS as background control) and 50 μL TBS, incubating this mixture for 30 minutes at room temperature, adding 50 μL of 2 mM S-2366, incubating for an additional 30 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
(e) Thrombin Assay
Enzyme activity was determined using as substrate, S-2238 [D-phenylalanyl-L-pipecolyl-L-arginine-p-nitroanilide dihydrochloride], purchased from Kabi Diagnostica. The substrate was made up in deionized water prior to use.
The assay was run by combining in appropriate wells 50 μL TBS and 50 μL inhibitor in TBS or TBS alone and 50 μL 20 nM bovine thrombin (or TBS as background control), incubating this mixture for 30 minutes at room temperature, adding 50 μL 1 mM S-2238, incubating for an additional 30 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
(f) Plasmin Assay
Enzyme activity was determined using as substrate, S-2251 [D-valyl-L-leucyl-L-lysine-p-niroanilide dihydrochloride], purchased from Kabi Diagnostica. The substrate was made up in deionized water prior to use.
The assay was run by combining in appropriate wells 50 μL of inhibitor in TBS or TBS alone and 50 μL 25 nM human plasmin (or TBS as background control) and 50 μL TBS, incubating this mixture for 30 minutes at room temperature, adding 50 μL 2 mM S-2251, incubating for an additional 60 to 120 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
(g) Protein C Assay
Enzyme activity was determined using as substrate, Pefachrome PC [δ-carbobenzoloxy-D-lysyl-L-prolyl-L-arginine-p-nitroanilide], purchased from Centerchem, Inc. The substrate was made up in deionized water prior to use. Protac used to activate Protein C was obtained from American Diagnostics.
Activated human Protein C was prepared by adding to a polypropylene test tube 5 mL of pooled human plasma diluted 1:8 with TBS and 5 mL of 0.117 Units/mL Protac, then incubating for 60 minutes at 37° C.
The assay was run by combining in appropriate wells 50 μL of inhibitor in TBS or TBS alone and 100 μL activated Protein C, incubating this mixture for 30 minutes at room temperature, adding 50 μL 2 mM Pefachrome PC, incubating for an additional 60 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
(h) Tissue Plasminogen Activator Assay
Enzyme activity was determined using as substrate, S-2288, purchased from Kabi Diagnostica. The substrate was made up in deionized water prior to use.
The assay was run by combining in appropriate wells 50 μL of inhibitor in TBS or TBS alone and 50 μL 50 nM recombinant tissue plasminogen activator (or TBS as background control) and 50 μL TBS, incubating this mixture for 30 minutes at room temperature, adding 50 μL 2 mM S-2288, incubating for an additional 60 to 120 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
(i) Trypsin Assay
Enzyme activity was determined using as substrate S-2222, purchased from Kabi Diagnostica. The substrate was made up in deionized water prior to use.
The assay was run by combining in appropriate wells 50 μL TBS and 50 μL inhibitor in TBS or TBS alone and 50 μL of 40 nM bovine trypsin (or TBS as background control), incubating this mixture for 30 minutes at room temperature, adding 50 μL 1.8 mM S-2222, incubating for an additional 30 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
(j) Kallikrein Assay
Enzyme activity was determined using as substrate S-2302 [D-prolyl-L-phenylalanyl-L-arginine-p-nitroanilide dihydrochloride], purchased from Kabi Diagnostica. The substrate was made up in deionized water prior to use.
The assay was run by combining in appropriate wells 50 μL TBS and 50 μL of inhibitor in TBS or TBS alone and 50 μL of 4 to 9 nM human kallekrein (or TBS as background control), incubating this mixture for 30 minutes at room temperature, adding 50 μL of 1 mM S-2302, incubating for an additional 30 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
(k) Urokinase Assay
Enzyme activity was determined using as substrate S-2444 [L-pyroglutamyl-L-glycyl-L-arginine-p-nitroanilide hydrochloride], purchased from Kabi Diagnostica. The substrate was made up in deionized water prior to use.
The assay was run by combining in appropriate wells 50 μL inhibitor in TBS or TBS alone and 50 μL of 270 U/mL human urokinase (or TBS as background control) and 50 μL TBS, incubating this mixture for 30 minutes at room temperature, adding 50 μL 1 mM S-2444, incubating for an additional 30 minutes at room temperature, then reading the absorbance of the wells at 405 nm on a microtiter plate reader set with background substraction at 650 nm.
EXAMPLE C
Animal Model for Pancreatitis
Niederau et al., Gastroenterology, 88:1192-1204 (1985) showed that acute necrotizing pancreatitis can be induced in mice by intraperitoneal (IP) injections of caerulein. When so induced, serum amylase levels were found to rise and fall with the severity and course of inflammatory process.
Pancreatitis was induced in fasting male balb/c mice weighing between 18 to 20 g by giving them three IP injections of caerulein, with each dose at 100 μg/kg body weight. The injections of each were given at two hour intervals over a 6 hour period. The ability of N-Boc-L-Asp-Pro-Arg-al (compound 9) to inhibit the induced pancreatitis was tested by injection into caerulein-treated mice. The inhibitor was dissolved into TBS, then injected IP into the mice. The first injection was given 1/4 hour prior to the caerulein treatment, then one hour after each caerulein injection. Inhibitor dose tested was 50 mg/kg body weight.
A blood serum sample was drawn and tested for amylase concentration. The blood sample was obtained by periorbital bleeding into heparized tubes 4 hours after the last injection of inhibitor. After centrifuging to remove the blood cells, the serum was the diluted 1:10 in TBS and assayed with Sigma Diagnostics Amylase reagent. The kinetic change in absorbance was measured at 405 nm for 1 minute, then was convereted into U/ml amylase activity.
TABLE 3______________________________________(Amylase Activity (U/ml) Mean ± S.D n______________________________________Saline + caerulein 64.4 ± 14.4.sup.a 7N--Boc--L--Asp--Pro--Arg-al + 40.8 ± 5.2.sup.a,b 8caeruleinControl (no caerulein) 10.4 ± 1.6 5______________________________________ .sup.a p < 0.01 vs control by NewmanKeuls test .sup.b p < 0.01 vs saline + caerulein by NewmanKeuls test
These data show the protective effect of inhibitors of this invention in vivo.
Having described the invention, it will be apparent to one of ordinary skill in the art that changes and modifications can be made without departing from the spirit and scope of the invention as set forth herein. Other embodiments are within the following claims.
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Novel compounds having activity against trypsin are disclosed. Specifically, novel peptide aldehyde analogues that have substantial potency and specificity as inhibitors of mammalian pancreatic trypsin are presented. The compounds are useful in the prevention and treatment of the tissue damage or destruction associated with pancreatitis.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority from a U.S. Provisional Application Serial No. 60/077,028, filed Mar. 6, 1998, entitled, “One-Piece Pintle Hitch.”
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a one-piece pintle hitch assembly. Conventional pintle hitches utilize a flange or mounting plate, usually integral with a hitch, that is bolted or otherwise secured to another mounting plate on a vehicle or towbar assembly. The present invention provides a one-piece hitch assembly that avoids the necessity of providing mounting plates. In addition, the pintle hitch assembly of the present invention provides an improved design that provides significant advantages over currently known pintle hitch assemblies.
[0004] 2. Description of Related Art
[0005] Pintle hitch assemblies are known in the art. For example, U.S. Pat. Nos. 5,332,250 to Thornwall et al.; 4,568,098 to Landrey Jr.; and 5,106,114 to Haupt, all of which are herein incorporated by reference, disclose various pintle hitch assemblies. However, all of these pintle hitch assemblies utilize a mounting plate that must be attached to a corresponding mounting plate on the tow vehicle. Typically, the plates are bolted to one another to secure the pintle hitch to the vehicle. It is cumbersome and burdensome to align and bolt or otherwise attach the mounting plate of the pintle hitch assembly to a mounting plate that has been previously installed on the vehicle, and/or to remove and unbolt the hitch assembly from the vehicle mounting plate. And, as will be appreciated, it is often difficult to install a mounting plate to the vehicle since the plate must be securely affixed to the vehicle frame. Accordingly, there is a need for a pintle hitch assembly that avoids the use of mounting plates and the problems associated with such plates.
[0006] Moreover, there are significant safety concerns relating to the use of currently available pintle hitch assemblies that utilize mounting plates which bolt to one another. There are hazards associated with the use of bolts or threaded fasteners. Bolts are susceptible to being under torqued during installation which may lead to the bolt(s) becoming loose, and eventually separating from the assembly. Also, bolts may fracture or otherwise fail. And, it is well known that the threads and/or the corresponding threaded fastener, i.e., the nut, may become corroded and rust, thereby further increasing the difficulty of removing and re-attaching a pintle hitch to the tow vehicle. As a result, there is a need for a pintle hitch assembly that is not susceptible to these types of safety concerns.
[0007] Currently known pintle hitch assemblies are relatively heavy in view of the significant amount of metal used to form the bar portion of the assembly. The resulting weight increases the difficulty in mounting the pintle hitch assembly to the vehicle, and further increases costs associated with the manufacture of such assembly, primarily due to the increase in the amount of materials that are necessary. Accordingly, there is a need for an improved pintle hitch assembly, one which is lighter in weight and which is less expensive to manufacture.
SUMMARY OF THE INVENTION
[0008] The present invention achieves all of the foregoing objectives and provides, in a first aspect, a pintle hitch comprising a bar and a lower jaw that is integral with an end of the jaw. The pintle hitch further comprises an upper jaw hingedly attached to the bar end at which is disposed the lower jaw. The upper jaw is movable between a closed position and an open position. The other end of the bar, opposite the end at which is disposed the lower jaw, is adapted to engage a receiver assembly. The use of conventional mounting plates and associated threaded fasteners is entirely avoided.
[0009] In another aspect, the present invention provides a pintle hitch comprising a longitudinal bar member and a pintle hook and latch assembly disposed at an end of the bar. The bar defines two oppositely directed, narrowed regions along the side of the bar. The resulting pintle hitch is relatively light in weight and more economical to manufacture than conventional pintle hitches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is an elevational view of a first preferred embodiment of the pintle hitch assembly according to the present invention.
[0011] [0011]FIG. 2 is a top view of the first preferred embodiment pintle hitch assembly according to the present invention, the assembly having an upper latch component removed.
[0012] [0012]FIG. 3 is an elevational view of a partially disassembled first preferred embodiment pintle hitch assembly, the assembly having a latch component removed.
[0013] [0013]FIG. 4 is a cross-sectional view of the first preferred embodiment pintle hitch assembly shown in FIG. 3, the cross-section taken across line IV-IV in FIG. 3.
[0014] [0014]FIG. 5 is an elevational view of a second preferred embodiment pintle hitch assembly according to the present invention.
[0015] [0015]FIG. 6 is an elevational view of a third preferred embodiment pintle hitch assembly according to the present invention.
[0016] [0016]FIG. 7 is an elevational view of a fourth preferred embodiment pintle hitch assembly according to the present invention in which the latch component has been removed.
[0017] [0017]FIG. 8 is a top view of the fourth preferred embodiment pintle hitch assembly illustrated in FIG. 7.
[0018] [0018]FIG. 9 is an elevational view of a fifth preferred embodiment pintle hitch assembly according to the present invention.
[0019] [0019]FIG. 10 is an elevational view of a sixth preferred embodiment pintle hitch assembly according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention provides a one-piece pintle hitch assembly. Conventional pintle hitches utilize a flange or mounting plate, usually integral with the hitch, that is bolted or otherwise secured to another mounting plate on a vehicle or towbar assembly. The present invention provides a one-piece hitch assembly that avoids the necessity of providing mounting plates and the requisite mechanical fasteners such as threaded bolts and nuts. The pintle hitch assembly of the present invention includes a pintle hook that is formed or otherwise integrally attached at the end of a drawbar or other member. The drawbar may be engaged with a vehicle or conventional hitch assembly. Preferably, the drawbar and pintle hook assembly of the present invention may be received in a conventional square or round receiver tube. Typical receivers include Class II receivers available from Draw-Tite™. Accordingly, the term “receiver” or “receiver assembly” as used herein refers to these and similar assemblies that receive, and are engageable with, a drawbar.
[0021] In another aspect, the present invention provides a unique cross-sectional configuration utilized along one or more regions of the bar component of the preferred embodiment pintle hitch assembly. The unique configuration reduces the amount of material otherwise necessary, and thus, the weight of the assembly.
[0022] In yet another aspect, the present invention assembly provides a bar member in which the end of the bar, at which is located the pintle hitch, is offset from the longitudinal axis of the remaining portion of the bar. The present invention provides other preferred versions and configurations described herein.
[0023] Generally, the present invention relates to a one-piece pintle hitch that installs in conventional square or round receiver tubes. This one-piece hitch incorporates an upper hinged jaw or latch as generally referred to herein, a jaw locking device and a lower hook or jaw, and/or a combination ball lower jaw. The one-piece hitch preferably utilizes a bar having a square, rectangular, or circular cross section that is sized to fit common receivers. The device can be produced by welding, casting, or forging of iron, steel, etc. All of these aspects are described in greater detail below.
[0024] Referring to FIGS. 1 - 4 , a first preferred embodiment pintle hitch assembly 1 according to the present invention is illustrated. It is to be understood that the referenced drawings are not to scale. In most applications, the bar portion of the pintle assembly will be significantly longer than shown. The pintle assembly 1 comprises a longitudinal bar 2 , a lower hook or jaw 50 , and a neck 30 extending between the hook 50 and the bar 2 . The bar defines an aperture 4 proximate or near a bar end 20 as shown. The aperture 4 serves to receive a pin (not shown) that extends through the aperture 4 when the assembly 1 is engaged to the vehicle, i.e. a tow bar receiver typically installed along the rear underside of the vehicle. The bar 2 further defines a medial narrowed region 6 extending between the aperture 4 and the neck 30 . Preferably, the bar 2 defines two narrowed regions 6 , each on opposite sides of the bar 2 . Each narrowed region 6 is defined by a recessed surface 10 and a transition surface 8 extending around the recessed surface 10 . The bar 2 further defines a distal narrow regioned 12 generally located between the aperture 4 and the bar end 20 . Preferably the bar 2 defines two narrowed regions 12 , each on opposite sides of the bar 2 . Each distal narrow regioned 12 defines a transition surface 14 that extends around a recessed surface 16 . The narrowed regions 6 and 12 are described in greater detail in conjunction with FIG. 2. The bar 2 has a bar outer surface 22 as shown.
[0025] The neck 30 generally provides a transition region that connects the bar 2 and the hook 50 . The neck 30 comprises an upper and a lower strengthening member 34 and 36 , respectively, and an intermediate connecting portion 32 extending between the members 34 and 36 .
[0026] The hook 50 generally comprises an arcuate member for engaging a conventional pintle eye component as known in the art. The arcuate member is generally C-shaped or in the shape of a semi-circle as shown in FIG. 1. The hook 50 includes an inner engagement surface 52 and a latch contact surface 54 .
[0027] Referring to FIG. 1, the pintle assembly 1 further comprises an upper hinged jaw or latch 40 pivotally attached to a portion of the hook 50 or the neck 30 . The latch 40 is preferably pivotally attached by use of a pivot member 60 which serves as an axis for pivoting of the latch 40 . An aperture (not shown) is preferably defined in the latch 40 that serves to receive the pivot member 60 . An aperture 62 is also preferably provided in a region of the hook 50 or neck 30 for receiving the pivot member 60 . That member 60 preferably extends through or at least into both the aperture 62 in the hook 50 or the neck 30 , and the aperture defined in the latch 40 . The latch 40 further defines an aperture 46 along its mid-section. The aperture 46 is used in conjunction with a pin (not shown) that is used to provide a jaw locking arrangement. This is described in greater detail below. The latch 40 also includes an inner engagement surface 42 opposite the inner engagement surface 52 of the hook 50 . Also defined along the outer end of the latch 40 is a hook contact surface 44 which opposes and contacts the latch contact surface 54 of the hook 50 . As will be understood, the latch 40 preferably pivots about the pivot member 60 from a closed position, in which the contact surfaces 44 and 54 contact, or at least substantially so, each other, to an open position in which the latch 40 is pivoted upward thereby providing an opening between the surfaces 44 and 54 , the opening being sufficient to receive a pintle eye component for subsequent engagement with the hook 50 . As will be understood, once the latch 40 is in its closed position, it may be locked in that position by use of the jaw locking arrangement comprising a pin that is inserted in the aperture 46 . Other locking arrangements may be utilized.
[0028] [0028]FIG. 2 is a top view of the first preferred embodiment pintle hitch assembly, illustrating in greater detail the preferred configuration of the narrowed regions 6 and 12 . FIG. 2 illustrates the hitch assembly 1 having the upper latch 40 removed. It can be seen that each of two sides of the bar 2 defines a narrowed region 6 and another narrowed region 12 . The regions 6 and 12 are separated by the aperture 4 . The narrowed regions 6 on opposite sides of the bar 2 are preferably co-extensive with each other as shown in FIG. 2. Similarly, the narrowed regions 12 on opposite sides of the bar 2 are also coextensive with each other.
[0029] Referring to FIGS. 2 and 4, as noted, each narrowed region 6 includes a recessed surface 10 and a transition surface 8 that bounds the perimeter of the recessed surface 10 and which generally extends between the recessed surface 10 and the outer surface 22 of the bar 2 . As will be understood, FIG. 4 is a cross-sectioned view of the bar 2 taken along line IV-IV in FIG. 3. Each of the recessed surfaces 10 are preferably parallel to each other and also parallel to the longitudinal axis of the bar 2 . The transition surface 8 preferably extends at an angle other than 90° to the recessed surface 10 and the outer surface 22 of the bar 2 . Most preferably, the angle between the recessed surface 10 and the transition surface 8 is from about 100° to about 135°. It is also preferred that the region of intersection between the recessed surface 10 and the transition surface 8 be rounded and smoothed to minimized the tendency for dirt and other debris to collect therein.
[0030] Referring further to FIGS. 2 and 4, as noted, each narrowed region 12 includes a recessed surface 16 and a transition surface 14 that bounds the perimeter of the recessed surface 16 and which generally extends between the recessed surface 16 and the outer surface 22 of the bar 2 . Each of the recessed surfaces 16 is preferably parallel to each other and also parallel to the longitudinal axis of the bar 2 . The transition surface 14 preferably extends at an angle other than 90° with respect to the recessed surface 16 and the outer surface 22 of the bar 2 . Most preferably, the angle between the recessed surface 16 and the transition surface 14 is from about 100° to about 135°. As previously explained, it is also preferred that the region of intersection between the recessed surface 16 and the transition surface 14 be rounded and smoothed.
[0031] [0031]FIG. 3 illustrates the preferred embodiment pintle hitch assembly 1 , partially disassembled, having the latch 40 and pivot member 60 removed. Aperture 62 is defined in an upper portion of the region extending between the hook 50 and the neck 30 . The aperture 62 is sized to receive the pivot member 60 for securing the latch 40 to the remainder of the assembly 1 and for enabling the latch 40 to be pivoted about the member 60 .
[0032] Referring to FIG. 5, a second preferred embodiment pintle hitch assembly 100 according to the present invention is illustrated. The pintle assembly 100 comprises a longitudinal bar 102 , a hook 150 , and a neck 130 extending between the hook 150 and the bar 102 . The bar defines an aperture 104 proximate or near a bar end 120 as shown. The bar 102 has a bar surface 122 as shown.
[0033] The neck 130 generally provides a transition for connecting the portion between the bar 102 and the hook 150 . The neck 130 comprises upper and lower strengthening members 134 and 136 , respectively, and an intermediate connecting portion 132 .
[0034] The hook 150 , generally comprises an arcuate member for engaging a conventional pintle eye component as known in the art The hook 150 includes an inner engagement surface 152 and a latch contact surface 154 .
[0035] The pintle assembly 100 further comprises a latch 140 pivotally attached to a portion of the hook 150 or the neck 130 as shown. The latch 140 is preferably pivotally attached by use of a pivot member 160 which serves as the axis for pivoting of the latch 140 . The latch 140 further defines an aperture 146 along its mid-section. As previously explained, the aperture 146 is used in conjunction with a pin (not shown) to lock or secure the latch in a closed position. The latch 140 also includes an inner engagement surface 142 opposite the inner engagement surface 152 of the hook 150 . Also defined along the outer end of the latch 140 is a hook contact surface 144 which opposes and contacts the latch contact surface 154 of the hook 150 .
[0036] It is to be understood that all of the preferred embodiment pintle hitch assemblies described herein may be formed in a variety of ways, including welding. If welding is employed, a pintle hook and latch sub-assembly may be welded to a bar along a ridge 170 as shown in FIG. 5. It is also to be understood that the present invention one-piece pintle hitch assemblies may, in some applications, not utilize one or more narrowed regions, such as the previously described narrowed regions 6 and 12 . The second preferred embodiment 100 is illustrated as being devoid of any narrowed regions along its bar 102 .
[0037] Referring to FIG. 6, a third preferred embodiment pintle hitch assembly 200 according to the present invention is illustrated. The pintle hitch assembly 200 comprises a longitudinal bar 202 , a hook 250 and a neck 230 extending between the hook 250 and the bar 202 . The bar defines an aperture 204 proximate or near a bar end 220 as shown. The bar 202 has a bar surface 222 and a bar end 220 as shown.
[0038] The neck 230 generally provides a transition for connecting the portion between the bar 202 and the hook 250 . The neck 230 comprises upper and lower strengthening members 234 and 236 , respectively, and an intermediate connecting portion 232 .
[0039] This preferred embodiment 200 utilizes a combination ball lower jaw. Specifically, the hook 250 generally comprises a base 282 disposed at a distal end of the hook 250 . Projecting upward from the base 282 is a ball 280 . The ball 280 is preferably sized to be engageably received in a conventional socket housing. The hook 250 further includes an inner engagement surface 252 .
[0040] The pintle hook assembly 200 further comprises a latch 240 pivotally attached to the portion of hook 250 or neck 230 . The latch 240 is preferably pivotally attached by use of a pivot member 260 which serves as the axis for pivoting of the latch 240 . The latch 240 further defines an aperture 246 along its mid-section. The latch 240 also includes an inner engagement surface 242 opposite the inner engagement surface 252 of the hook 250 . Also defined along the outer end of the latch 240 is an inner contact surface 244 which opposes and contacts, or at least substantially so, the ball 280 of the hook 250 .
[0041] Referring to FIGS. 7 and 8, a fourth preferred embodiment pintle hitch assembly 300 according to the present invention is illustrated. The pintle hitch assembly 300 comprises a longitudinal bar 302 , a hook 350 , and a neck 330 extending between the hook 350 and the bar 302 . The bar defines an aperture 304 proximate or near a bar end 320 as shown. The bar 302 further defines a first and second medial narrowed region 306 and 306 a extending between the aperture 304 and the neck 330 . Preferably, the narrowed regions 306 and 306 a are defined on two oppositely directed faces of the bar 302 . Each narrowed region 306 and 306 a is defined by a recessed surface 310 or 310 a and a transition surface 308 or 308 a extending around the recessed surface 310 or 310 a . The bar 302 further defines a distal narrowed regioned 312 generally located between the aperture 304 and the bar end 320 . The distal narrowed regioned 312 defines a transition surface 314 that extends around a recessed surface 316 . The bar 302 has a bar surface 322 as shown.
[0042] The neck 330 generally provides a transition region for connecting the portion between the bar 302 and the hook 350 . The neck 330 comprises an upper and a lower strengthening member 334 and 336 , respectively, and an intermediate connecting portion 332 .
[0043] The hook 350 generally comprises an arcuate member for engaging a conventional pintle eye component as known in the art. The hook 350 includes an inner engagement surface 352 and a latch contact surface 354 .
[0044] The pintle assembly 300 further comprises a latch (not shown) pivotally attached to the region of hook 350 or neck 330 . Although the latch is not shown in FIGS. 7 and 8, it will be understood that the latch resembles and generally corresponds to any of the previously described latches 40 , 140 , and 240 . The latch is preferably pivotally attached by use of a pivot member (not shown) which serves as the axis for pivoting of the latch. An aperture 362 is defined in an upper portion of the region between the hook 350 and the neck 330 . The aperture 362 is sized to receive the pivot member.
[0045] The distal narrowed region 312 generally corresponds to the previously described distal narrowed region 12 in the preferred embodiment pintle hitch assembly 1 . Each of the medial narrowed regions 306 and 306 a generally correspond to the previously described medial narrowed region 6 in the preferred embodiment pintle hitch assembly 1 .
[0046] Referring to FIG. 9, a fifth preferred embodiment pintle hitch assembly 400 according to the present invention is illustrated. This embodiment finds particular use in applications in which the tow vehicle is at a lower elevation than the trailer or pintle eye. The pintle hitch assembly 400 comprises a longitudinal bar 402 , a hook 450 , a neck 430 , and an upward extension portion 470 extending between the hook 450 and neck 430 , and the bar 402 . The bar defines an aperture 404 proximate or near a bar end 420 as shown. The bar 402 further defines a medial narrowed region 406 extending between the aperture 404 and the extension portion 470 . The narrowed region 406 is defined by a recessed surface 410 and a transition surface 408 extending around the recessed surface 410 . The bar 402 further defines a distal narrowed region 412 generally located between the aperture 404 and the bar end 420 . The distal narrowed region 412 defines a transition surface 414 that extends around a recessed surface 416 . The bar 402 has a bar outer surface 422 as shown.
[0047] The neck 430 generally provides a transition for connecting the portion between the bar 402 and the hook 450 . The neck 430 comprises upper and lower strengthening members 434 and 436 , respectively, and an intermediate connecting portion 432 extending therebetween.
[0048] The hook 450 generally comprises an arcuate member for engaging a conventional pintle eye component as known in the art. The hook 450 includes an inner engagement surface 452 and a latch contact surface 454 .
[0049] The pintle assembly 400 further comprises a latch (not shown) pivotally attached to a portion of hook 450 or neck 430 . Although the latch is not shown in FIG. 9, it will be understood that the latch resembles and generally corresponds to any of the previously described latches 40 , 140 , and 240 . The latch is preferably pivotally attached by use of a pivot member (not shown) that extends through an aperture 462 which serves as the axis of pivoting of the latch.
[0050] Referring to FIG. 10, a sixth preferred embodiment pintle hitch assembly 500 according to the present invention is illustrated. This embodiment finds particular use in applications in which the tow vehicle is at a higher elevation than the trailer or pintle eye. The pintle hitch assembly 500 comprises a longitudinal bar 502 , a hook 550 , a neck 530 , and a downward extension portion 570 extending between the hook 550 and the bar 502 . The bar defines an aperture 504 proximate or near a bar end 520 as shown. The bar 502 further defines a medial narrowed region 506 extending between the aperture 504 and the portion 570 . The narrowed region 506 is defined by a recessed surface 510 and a transition surface 508 extending around the recessed surface 510 . The bar 502 further defines a distal narrowed regioned 512 generally located between the aperture 504 and the bar end 520 . The distal narrowed region 512 defines a transition surface 514 that extends around a recessed surface 516 . The bar 502 has a bar outer surface 522 as shown.
[0051] The neck 530 generally provides a transition for connecting the portion between the downward extension portion 570 and the hook 550 . The neck 530 comprises an upper and a lower strengthening member 534 and 536 , respectively, and an intermediate connecting portion 532 .
[0052] The hook 550 , generally comprises an arcuate member for engaging a conventional pintle eye component as known in the art. The hook 550 includes an inner engagement surface 552 and a latch contact surface 554 .
[0053] The pintle assembly 500 further comprises a latch (not shown) pivotally attached to the portion of hook 550 or neck 530 . The latch is preferably pivotally attached by use of a pivot member (not shown) that extends through an aperture 562 which serves as the axis of pivoting of the latch. Although the latch is not shown in FIG. 10, it will be understood that the latch resembles and generally corresponds to any of the previously described latches 40 , 140 , and 240 .
[0054] It is also to be understood that one or more features of each of the previously described preferred embodiments 1, 100, 200, 300, 400, and 500, may be combined with one or more other features of the noted preferred embodiments.
[0055] The various preferred embodiment pintle hitch assemblies replace conventional two-piece pintle hook or combination hook, and pintle mount adapters. These preferred embodiments offer savings in weight, installation, time and cost.
[0056] Specifically, the unique configuration of the narrowed regions described herein, when provided in the bar portion of the present invention hitch assembly, significantly reduces the weight of the final assembly without sacrificing strength, safety, or reliability. The preferred embodiment hitch assemblies described herein are about 35% lighter in weight as compared to competing two-piece hitch assemblies that do not utilize narrowed portions, and that employ mounting plates. As previously noted, the narrowed regions result in significant savings in material and time and labor otherwise necessary to carry out the requisite machining and forming. Another important feature of the present invention one-piece hitch assembly is that it is more compact and easier to stow than a corresponding hitch assembly utilizing mounting plates and threaded fasteners.
[0057] The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon a reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.
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A one-piece pintle hitch is disclosed. The one-piece hitch utilizes an integral drawbar that may be engaged with a conventional receiver assembly such as installed along the underside of a vehicle. The one-piece pintle hitch avoids the use of prior art mounting plates that bolt to one another. Accordingly, the problems associated with threaded fasteners such as loosening, fracturing, and corrosion, are eliminated. In addition, the one-piece pintle hitch utilizes a unique configuration along its bar portion that results in a significant reduction in weight and materials.
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BACKGROUND OF THE INVENTION
Progressing cavity pumps are in increasingly common use in the oil field for production of formation fluids to the surface. The pumps comprise a fixed outer body usually referred to as a stator which connects to the production tubing in the well. Within the stator is a rotating inner component called a rotor which in cooperation with the stator pumps the formation fluids.
The rotor is rotated by a string of drive rods that transmit torque from a prime mover at the well head. The prime mover is normally an electric motor that produces up to 100 horsepower and also generates very substantial torque. The drive rods extend from a drive head at the top of the well head down through the production tubing to the rotor.
The inside of the stator is rubber and friction is generated as the rotor spins. If the stator is not properly anchored, it will rotate in the clockwise direction (to the “right” when viewed from above) and if not checked, the tubing joints will eventually loosen and part, allowing the tool to fall to the bottom of the well. Production must then be halted until the pump is fished out. To prevent this, pump anchors are used which, when engaged against the well casing, restrict right-handed rotation of the pump.
The problem however is that the drive rods themselves store a considerable amount of energy in the form of twist. In fact, after the motor is turned on the rods might twist as many as 50 times before the stator begins to turn.
When the motor is stopped, the rods untwist to release their stored torque, and the release can be violent, made worse by the weight of the oil in the tubing from the pump to the surface, resulting in speeds approaching 20,000 rpm. Because the pump anchor has become unset in response to the counterclockwise (to the “left”) unwinding of the rods, the pump is unrestrained and whips around inside the well casing causing major damage to the pump and everything in its vicinity. The torque can also wildly spin the sheaves and pulleys that deliver torque from the motor to the drive rods which can cause additional failures and endanger anyone close by.
There are some anchors that are intended to restrain both left and right handed torque but these are typically “one set” or limited set devices and are usually referred to as “tension set anchors”. They must be recovered to the surface then refaced or redressed after each use, which limits their utility.
SUMMARY OF THE INVENTION
It is therefore a feature of the present invention to provide a torque anchor which obviates and mitigates from the disadvantages of the prior art.
It is a further feature of the present invention to provide an anchor that restrains torque in both the left and right handed directions.
It is yet another feature of the present invention to provide an anchor that can be used repeatedly between rebuilds.
According to one exemplary embodiment of the present invention, there is provided an anchor to inhibit rotation of a device relative to an oil well casing, comprising a tubular mandrel adapted for direct or indirect connection to the device; a cylindrical housing to receive at least a portion of said mandrel concentrically therethrough, said housing being rotatable relative to said mandrel and having a plurality of circumferentially spaced apart apertures formed in an outer surface thereof; a plurality of spaced apart anchoring slips disposed between said housing and said mandrel in registry with respective ones of said apertures in said housing's outer surface; first biassing means associated with said mandrel for rotation therewith in the clockwise or counterclockwise directions to engage and then move respective ones of said anchoring slips radially towards and then into temporarily anchoring contact with the casing to prevent further rotation of said mandrel and the device connected thereto in either of said clockwise or counterclockwise directions; and one or more drag block means disposed in said housing in registry with respective ones of said apertures in said housing's outer surface to extend radially outwardly therefrom, each of said drag block means being normally biassed into frictional contact with said casing to inhibit rotation of said housing relative to the casing.
According to another aspect of the present invention, there is provided a torque anchor for use in an oil well to temporarily prevent rotation of a device connected to the anchor in the clockwise or counterclockwise directions, or both, comprising a tubular mandrel operatively connected to the device to be anchored; a plurality of casing gripping anchor members disposed in spaced apart relationship about the circumference of said mandrel; a housing mounted concentrically around at least a portion of said mandrel to be rotatable thereon and to at least partially contain said anchor members therein, said anchor members being mounted in said housing for rotation therewith around the mandrel and for radial movement towards and away from said mandrel; cam means on said mandrel for operatively engaging respective ones of said anchor members to bias them towards and into gripping contact with said casing upon rotation of said mandrel in one direction, and to operatively engage another of said anchor members upon rotation of said mandrel in the opposition direction, whereby gripping of the casing by said anchor members effectively stops the rotation of said mandrel; and a plurality of friction members supported by said housing normally biassed into contact with the casing to stop rotation of said housing relative to the casing.
According to a further aspect of the present invention, there is provided a method for anchoring a device against rotation in a well bore, comprising the steps of non-rotatably connecting the device to a mandrel disposed either above or below the device; surrounding at least a portion of the mandrel with a cylindrical housing that is rotatable relative to said mandrel, said housing having associated therewith a first set of anchor members normally biassed into frictional contact with the well bore to hold the housing stationary relative thereto, and a second set of anchor members actuatable in response to rotation of said mandrel for movement between a first retracted position and a second well bore gripping position, wherein gripping of the well by said second set of anchor members prevents further rotation of said mandrel.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention will now be described in greater detail and will be better understood when read in conjunction with the following drawings in which:
FIG. 1 is a perspective view of the torque anchor of the present invention;
FIG. 2 is a side elevational cross-sectional view of the anchor of FIG. 1 ;
FIG. 3 is a cross-sectional view of the tool of FIG. 2 along the line 3 — 3 ;
FIG. 4 is a cross-sectional view of the tool of FIG. 2 along the line 4 — 4 ;
FIG. 5 is a perspective view of one end of a slip housing forming part of the tool of FIG. 1 ;
FIG. 6 is an end view of the other end of the slip housing shown in FIG. 5 with a drag block therein; and
FIG. 7 is a perspective view of a center mandrel forming part of the tool of FIG. 1 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring initially to FIG. 1 , the principal components of the present torque anchor 1 include a longitudinally extending tubular mandrel 10 , one or more cylindrical rotatable anchoring slip assemblies 20 that can be biassed against the well casing by the mandrel to prevent rotation of the anchor, frictional drag blocks 45 that are continuously biassed against the casing and a rotatable slip housing 75 that retains the slip assemblies and drag blocks in their operational positions.
With reference to FIGS. 2 and 7 , mandrel 10 is a hollow tubular member threaded at its opposite ends 5 and 6 for respective connection at one end to the stator of the progressing cavity pump (not shown), and at the other end to any tubing below the anchor (again not shown). At a point intermediate along its length the mandrel includes a section 9 serrated with longitudinally extending teeth 11 the configuration of which will be seen most clearly in FIG. 3 . The cross-sectional shape of toothed section 9 is generally trochoidal including three longitudinally symmetrical lobes 12 spaced apart by webs 13 . As will be seen most clearly in FIG. 3 , the teeth on lobes 12 extend radially above the outer surface 8 of mandrel 10 , whereas the teeth on webs 13 peak below surface 8 except where they transition into the lobes. As will be described in greater detail below, lobes 12 convert the rotating movement of mandrel 10 into linear movement of anchor slips 25 forming part of assemblies 20 to bias them against the well casing to set the anchor against rotation. The action of the lobes is therefore cam-like.
Ideally, the lobes and teeth of section 9 are machined into the mandrel's parent metal but the section can be formed as a discrete component and welded into place between sections of mandrel.
With reference to FIGS. 2 , 3 and 5 , anchor slip assemblies 20 include anchor slips 25 which are generally cylindrical in shape formed with longitudinally extending teeth 26 that extend around their entire circumference. Each slip is formed with an axially extending bore 27 therethrough to receive a spindle 28 about which the slip can rotate freely. The diameter of the bore preferably exceeds the diameter of the spindle so that there is some radial “play” between the two. This allows the slips to self-adjust a bit for small irregularities in the casing or small misalignments between the mandrel and the casing, and it also ensures that the slips can continue to rotate even if some sand or dirt works its way into bore 27 . The slips can also move a bit in the axial direction of the spindles if desired.
The slip's teeth 26 are shaped to engage teeth 11 on mandrel 10 . In a typical anchor, there will be as many slips 25 as there are lobes 12 on the mandrel. Although the present anchor could function with only a single slip assembly, as a practical matter there should be two or three slip assemblies and the use of more than three is also possible.
With reference to FIGS. 2 , 4 and 6 , the present anchor also includes at least one and more typically a plurality of drag blocks 45 . Each drag block is generally rectangular in shape with champhers 46 at their opposite ends to facilitate movement of the anchor up and down through the well bore. Each drag block may be a single metal block drilled on the underside to retain springs 52 used to continuously bias the drag blocks outwardly into contact with the well casing as will be described below. Each drag block is additionally formed with longitudinally extending flanges 44 that will bear against the edges of apertures 87 in slip housing 75 to prevent the drag blocks from being completely extruded by springs 52 . The embodiment shown includes three drag blocks but fewer or more can be used.
Slip assemblies 20 and drag blocks 45 are retained in place relative to mandrel 10 by slip housing assembly 75 . As will be seen most clearly in FIGS. 2 and 5 , slip housing 75 is cylindrical in shape for a concentric fit around mandrel 10 . The end of the housing that encloses slips 25 is internally hollowed out to provide a cavity 77 for the slips, lobes 12 and spring clips 30 that can optionally be used to normally bias the slips against mandrel teeth 11 .
The inner end of cavity 77 is machined out to accommodate a guide ring 80 . Ring 80 is itself formed with a plurality of grooves 81 to capture the axially extending ends of spindles 28 so that they can rotate freely as well as move up and down in the grooves. A plurality of bolts 83 extending through the outer surface of housing 75 connect the ring to the housing and prevent its rotation relative to the housing. The outer end of cavity 77 is formed with axially aligned grooves 86 similar in size and shape to the grooves in ring 80 and which similarly function to capture the other ends of spindles 28 for rotation and for up and down movement.
With reference to FIGS. 2 and 6 , the end of the slip housing that retains the drag blocks 45 is generally solid with the exception of rectangular notches 90 which house the drag blocks and springs 52 . The width of notches 90 is substantially equal to the width of flanges 44 on the drag blocks for a reasonably close fit allowing the drag blocks to move up and down in the notches. The drag blocks will extend outwardly through apertures 87 with which they are in registry in the slip housing's outer surface. As will be seen most clearly in FIG. 6 , the width of the apertures is less than the width of flanges 44 so that springs 52 don't completely extrude the drag blocks.
The outer surface of housing 75 is formed with additional apertures 88 , one in registry for each of slips 25 .
End caps 95 are connected to slip housing 75 such as by means of bolts 98 to close the ends of the housing and to hold the drag blocks and slips in place. When assembled, slip housing 75 and end caps 95 are free to rotate about mandrel 10 . Axial movement of the slip housing relative to the mandrel is prevented by means of the major diameter of lobes 12 being greater than the inner diameter of guide ring 80 and the end 74 of housing 75 .
In operation, the assembled torque anchor is connected below or occasionally above the pump and the combination is connected to the end of the production tubing and lowered into the well. When the pump is properly positioned in the well, the motor is turned on to transmit torque to the rotor via the drive rods extending down the interior of the production tubing. As the rotor begins to turn to the right, the stator also begins to turn to the right due to the friction of the rotor against the stator's internal rubber lining.
As the stator begins to turn, so too does mandrel 10 . Housing 75 however remains relatively stationary due to the frictional contact between drag blocks 45 and the well casing which also assists to center the anchor in the well bore. As the mandrel rotates, lobes 12 engage the teeth on slips 25 to cam or force the slips radially outwardly until the teeth on the slips extend above the surface of the slip housing to contact and engage the inner surface of the casing by biting into the casing's metal. This stops any further rotation of the mandrel and the pump stator connected thereto. The more torque transmitted to the mandrel, the tighter the anchoring contact engagement of the slips against the casing.
If the motor stops turning the pump for any reason, the tendency will be for the unwinding rods to torque the stator to the left. When that happens, the mandrel will also turn to the left but the drag blocks will continue to hold the slip housing relatively stationary. Lobes 12 will rotate to the left but will then quickly, within a fraction of a rotation, engage slips 25 to again force them outwardly against the casing, thereby preventing any destructive counter-rotation of the pump until the stored torque in the rods is dissipated. The trochoidal cross-sectional shape of toothed section 9 assures that slips 25 will have adequate space to retract inwardly towards mandrel 10 to completely disengage the well casing. As will be appreciated, the trochoidal cross-sectional shape of section 9 and the presence of teeth or webs 13 are preferred aspects. Other shapes are possible and the teeth on the webs can be reduced or even eliminated with the key aspect being that there is sufficient space between the mandrel and housing 75 to allow the slips to back off from anchoring contact with the well casing.
If any of the teeth on the slips are worn down, the slips can be rotated at surface, until fresh teeth are exposed to the lobes and to the casing. In this way, the present anchor enjoys an extended operational life compared to conventional anchors before major redressing or replacement of parts is required. Again, because of the trochoidal shape of toothed section 9 , the slips can be pulled away from mandrel 10 enough to clear the teeth on webs 13 which allows the slips to be rotated to expose fresh teeth without having to disassemble housing 75 .
Although the present anchor has been described for use to prevent rotation of a progressing cavity pump, it will be appreciated that it can be used with any downhole tool, device or installation that needs to be anchored against rotation in either the clockwise or counterclockwise directions, or both.
The above-described embodiments of the present invention are meant to be illustrative of preferred embodiments and are not intended to limit the scope of the present invention. Various modifications, which would be readily apparent to one skilled in the art, are intended to be within the scope of the present invention. The only limitations to the scope of the present invention are set forth in the following claims appended hereto.
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An anchor to inhibit rotation of a device relative to an oil well casing, comprising a tubular mandrel adapted for direct or indirect connection to the device; a rotatable cylindrical housing with a plurality of apertures and able to receive at least a portion of the mandrel concentrically therethrough; a plurality of spaced apart anchoring slips disposed between the housing and the mandrel in registry with respective ones of the apertures in the housing's outer surface; a rotation mechanism associated with the mandrel to engage and then move respective ones of the anchoring slips radially towards and then into temporarily anchoring contact with the casing; and one or more drag blocks disposed in the housing in registry with respective ones of the apertures in the housing's outer surface to extend radially outwardly therefrom, each of the drag blocks being normally biased into frictional contact with the casing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a multichannel optical measuring system, more particularly to a multichannel optical measuring system for measuring the optical response of a sample illuminated by light.
2. Description of the Prior Art
In recent years fluorochromes that have been developed are being used for quantitative measurement of calcium ions, magnesium ions and the like in various types of blood cells. However, systems now in use for measuring fluorescent and transmitted light are single channel systems for making measurements relating to just one sample or for measuring the optical response obtained with an incident light beam of just one wavelength.
However, such single channel systems cannot be used when a large number of samples have to be measured in a short space of time, such as for measurements relating to floating cells in the blood such as platelets, leukocytes and lymphocytes, with the aim of measuring changes in the calcium ion or magnesium ion content of blood platelets, for example, while at the same time measuring changes in the aggregation of such cells.
To provide a conventionally configured system with multichannel fluorometry capabilities would involve the addition of as many light sources as there are sample (measurement) cuvettes to be measured, and the corresponding optical systems for condensing the light from these sources and selecting wavelengths. The only way to do this would be to use an array of conventional single channel systems, which would result in an impractically large and costly arrangement.
Then there is the fact that fluorometry involves the use of costly high-voltage mercury or xenon lamps, and each optical system needs to have a switchover unit to switch among diffraction gratings or interference filters for measuring fluorescent intensities obtained at multiple wavelengths. The ability to measure changes in a cell's fluorescent intensity while at the same time measuring the intensity of the light transmitted by the cell enables the chemical composition of the cell to be determined from the spectral absorption characteristics and the shape of the cell to be determined from the scattered light. When studying cell physiology and pharmacological effects, such data is useful by enabling the relationships among the various parameters to be ascertained.
However, measurement systems based on conventional technology make simultaneous use of two photosensors, one being a photomultiplier that is used as the fluorescent photosensor and the other being a photodiode that is used as the transmitted light photosensor. Moreover, the beam of illumination used for measurement of fluorescence and the beam of illumination used for measurement of transmitted light are both projected along the same optical path to the measurement cuvette, a configuration that is not suitable for multichannel measurements. In addition, to implement the conventional system arrangement, in which a photomultiplier is used as a photosensor to facilitate measurement of the weak fluorescence, requires a large light-receiving section disposed near the measurement cuvette. In the case of a multichannel system having multiple measurement cuvettes, such an arrangement using photomultipliers as the photosensors would again be too bulky and costly.
SUMMARY OF THE INVENTION
An object of the present invention is therefore to provide a light, compact, simple and low-cost multichannel optical measuring system that is capable of simultaneously measuring the intensity of fluorescence and transmitted light of a plurality of samples.
In accordance with the present invention, the above object is achieved by a basic system arrangement whereby light from a single light source is directed through a condenser lens, and then through a multiple interference filter arrangement in which filters can be selected to select light of a prescribed wavelength, and the light of the selected wavelength is then directed along multiple branches of a quartz optical fiber and is thereby projected at glass cuvettes that each contain biological cell samples.
The tip of each of these optical fiber branches is arranged in the vicinity of a glass cuvette. Use of this multibranch optical fiber arrangement makes it possible to irradiate multiple glass cuvettes by means of a first single light source and its appurtenant optical system, thereby achieving a measurement system that is smaller and more resource-efficient. As the optical fibers are flexible and the tip of each is no more than 5 mm across, it is possible to arrange multiple measurement cuvettes close together, which also helps to reduce the size of the system.
To ensure that all of the measurement cuvettes receive the same uniform level of a first illumination light from the light source, the multibranch optical fiber arrangement is comprised of a randomly-divided bundle of several hundred optical fibers. For measurement purposes, the level of background light is reduced using a bundle filler that blocks fluorescent light.
A round glass sample cuvette is used for measurements. To minimize loss of the light passing through the glass, the light from the optical fibers is collimated and passed through an iris. This decreases background light during measurements and thereby improves measurement accuracy. Round glass cuvettes are much cheaper than square quartz cuvettes, making them suitable for use as the measurement cuvettes of a multichannel measurement system.
The intensity of transmitted light is measured using a light-emitting diode as a second light source arranged at right-angles to the optical axis of the first illumination light used for measuring fluorescence. A photodiode photosensor is disposed on the optical axis of light emitted by the light-emitting diode and at right-angles to the optical axis of the light brought by the optical fiber, with a single photodiode photosensor being used to measure the fluorescence intensity and transmitted light intensity. A photodiode photosensor provides adequate measurement capability for measuring the fluorescence of a multiplicity of cells in a measurement cuvette. The optical fibers positioned in the vicinity of the measurement cuvettes to be illuminated by light projected by the optical fibers, and the light-emitting diodes and photodiode photosensors, are all small, which enables multiple measurement cuvettes to be placed close together and thereby reduce the size of the system.
An appropriate selection of interference filter is made to cause the cells to be irradiated with excitation light of a prescribed wavelength, while at the same time the light-emitting diodes are energized so that they emit light at the same time the excitation light is being interrupted so as to effect simultaneous photodiodic measurement, in the form of a time-series, of the fluorescent and transmitted light intensities of multiple samples. Thus, it is possible to simultaneously measure the fluorescence, light absorption and scattered light of cells. In accordance with the above-described system configuration, therefore, it is possible to carry out simultaneous multichannel measurement of the intensity of fluorescent/transmitted light of multiple samples irradiated with light of different wavelengths.
BRIEF DESCRIPTION OF THE DRAWINGS
The purposes and features of the present invention will become more apparent from a consideration of the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a diagram for explaining the structure of the multichannel optical measuring system of the present invention;
FIG. 2 is a diagram for explaining the quartz optical fiber arrangement used in the system of FIG. 1;
FIG. 3 is a diagram for explaining the structure of the illumination system, light receiving section and measurement cuvette;
FIG. 4 is a circuit diagram of the amplifier of the light receiving section; and
FIGS. 5A and 5B are a set of graphs representing the results of measurements of cell aggregation and changes in cellular calcium ion concentrations in rabbit platelets carrying a calcium-ion-sensitive fluorochrome stimulated by collagen and thrombin.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described in detail on the basis of the preferred embodiment illustrated in the drawings.
FIG. 1 shows the structural arrangement of a system incorporating the present invention for the simultaneous four-channel measurement of fluorescent and transmitted light. A beam of light from a xenon lamp light source 1 is used to measure the intensity of fluorescent light. The beam of light from the xenon light source 1 is condensed by a set of quartz lenses 2, and is then passed through an interference filter 4 to obtain light of a prescribed wavelength which then impinges on a set of quartz optical fibers 5.
The interference filter 4 has a rotatable disk having a plurality of filter elements with different characteristics. A filter switching unit 3, under the control of a control unit 12, enables any particular interference filter element to be selected and the timing of the light incident on the optical fibers 5 to be controlled. The filter switching unit 3 consists of a DC motor and a photointerrupter or the like for detecting the position of the filter elements. The non-filter portions of the disk of the interference filter 4 are utilized to control the timing of the light impinging on the set of optical fibers 5.
With reference to FIG. 2, the set of quartz optical fibers 5 is constituted as bundle of some 300 quartz fibers 51, each of which has a core with a diameter of approximately 150 μm. Background light during measurements is reduced by using a filler 52 that does not transmit fluorescent light. The incident end portion I of each of the fibers of the bundle faces towards the xenon light source 1. Reference numerals 51a and 51b denote the cladding and core, respectively, of each quartz fiber 51.
To ensure that the light from the light source illuminates each measurement cuvette with the same intensity, at an intermediate point or at a point near the exit end portion O the quartz fibers 51 are randomly divided into four bundles of about 75 fibers each. The collective exit end portion O of each bundle is disposed facing one of four corresponding round sample measurement cuvettes 9 made of glass that are detachably inserted into the system apparatus (FIG. 1).
The optical fibers 5 are used to irradiate the sample measurement cuvettes 9 with ultraviolet (UV) excitation light. For simultaneously measuring the intensity of light transmitted by samples in the sample measurement cuvettes 9 , each of the cuvettes 9 is provided with a light-emitting diode (LED) 6, an interference filter 7 and a photodiode 8. The arrangement around each of the sample measurement cuvettes 9 is shown in detail in FIG. 3. UV excitation light from the optical fibers 5 is projected at the cuvette 9 after being collimated by a lens 10' and passing through an iris 11' to reduce stray light components being picked up through the glass of the cuvette 9.
The LED 6 used as the light source for measuring the intensity of transmitted light is arranged facing the measurement cuvette 9 at right-angles to the optical axis of the light from the optical fibers 5. Fluorescent and transmitted light is detected by the photodiode 8 which is arranged facing the cuvette 9 at right-angles to the optical axis of the light from the optical fibers. The interference filter 7 is provided at the front of the light-receiving face of the photodiode 8, as required, to select a particular fluorescent light wavelength.
A driver 61 and the control unit 12 are used to synchronize the switching on of the LED 6 with the selection of the interference filter 4 by the filter switching unit 3 or with the interruption of the light beam to the optical fibers. The amount (intensity) of light received by each of the photodiodes 8 is converted into a corresponding electrical signal that is input to a personal computer 11 via a SCSI, GPIB or other suitable interface after being amplified by an amplifier 81 and subjected to analog/digital (A/D) conversion by an A/D converter 10. The measurement cuvettes 9 are also connected to the personal computer 11 by a suitable interface means.
In most cases there are considerable differences in the intensity levels of fluorescent and transmitted light received by photodiodes, and in the intensity levels of the background light. To improve the signal/noise (S/N) ratio, as shown by FIG. 4 the amplifier 81 is constituted by three operational amplifier stages 811 to 813. The amplification factors of amplifiers 812 and 813 are arranged so that background light may be compensated for by the switching of offset voltages and amplifications based on control signals A, B, and C synchronized, respectively, with the switching of interference filter 4, interference filter 7, and pulses of light emitted by LED 6.
A Peltier element and thermistor arrangement (not shown) is used for temperature maintenance of the measurement cuvettes 9, and a magnetic stirrer is provided beneath the measurement cuvettes to stir the cells and solution in the measurement cuvettes.
The personal computer 11 is used to control interference filter 4 selection and, via control of the LED 6, UV excitation light and transmitted light, and is also used to measure the transmitted light and the fluorescent light produced by samples in the measurement cuvettes 9 based on the input from the A/D converter 10 of the amount of light received by the photodiode 8. The personal computer 11 contains software stored in memory and in secondary storage means for performing measurements and analyzing measured quantities. After measurement data is sampled and processed by the analysis software it is output to an output device such as a display monitor, printer or plotter.
The procedure used for simultaneously measuring the aggregation ability and calcium ion concentration of rabbit blood platelets will now be described.
In accordance with a standard procedure, blood containing citric acid is centrifuged to obtain washed blood platelets. These platelets are then incubated for 20 minutes in a nutrient solution that includes the fluorochrome fura-2 AM. This is followed by a centrifuging operation to enable the platelets to be washed in a nutrient solution that does not include fura-2 AM.
The suspension of platelets carrying fura-2 fluorochrome thus prepared is put in a measurement cuvette 9 which is then placed into position in the system apparatus, and stirring by magnetic stirrer is started. At the same time, 340 nm and 380 nm interference filters are switched while the LED is operated sequentially for periods of one second at a time, for example, to produce an input of fluorescent and transmitted light intensity signals obtained via the photodiode.
After the elapse of the prescribed measurement period, a measurement cuvette 9 containing platelets not carrying fura-2 is placed into the system apparatus, the 340 nm and 380 nm interference filters are switched and the same procedure is used to obtain an input of each background fluorescent light intensity. A measurement cuvette 9 containing only the nutrient solution is exposed to light from the LED to input the intensity of totally transmitted light.
The entire sequence of operations described above is controlled by the light measurement software of the personal computer 11 that has been specifically prepared for this system. The user performs the operations in accordance with directions displayed on a display monitor or the like.
Sampling data relating to the intensity levels of fluorescent and transmitted light obtained during the measurement periods via the A/D converter 10 is stored on magnetic storage media or the like by the personal computer 11. The analysis software uses this data to calculate the calcium ion concentration and aggregation performance of the target platelets, and displays or prints out the results. One possible output format is shown by FIG. 5 in which the calcium concentration and aggregation data during the prescribed measurement period are plotted against elapsed time.
The analysis software obtains the ratio of the intensities of the fluorescent light from platelets carrying fura-2 resulting from 340 nm and 380 nm excitation light after subtracting the background light. This can be treated as a value having a correlation to the calcium ion concentration of the cells. Agglutination performance of the platelets is indicated by changes in transmissivity.
The above measurement can be carried out with respect to all of the measurement cuvettes 9 of the apparatus. For example, it is possible to perform simultaneous measurements when the measurement cuvettes 9 each contain different samples, or to perform measurements relating to platelets with/without fura-2 and to simultaneously measure the intensity of totally transmitted light using just the nutrient solution.
FIG. 5 shows the results of measurement and analysis of calcium ions when thrombin and collagen were used to induce platelet aggregation. Specifically, using rabbit platelets carrying the calcium-ion-sensitive fluorochrome fura-2, FIG. 5 shows measured values of changes in calcium ion concentration and aggregation performance induced by thrombin (FIG. 5A) and collagen (FIG. 5B). F340 and F38 denote fluorescent intensity produced by excitation with 340 nm and 380 nm light, respectively, TR denotes transmitted light intensity, F340/F380 denotes the ratio of fluorescent light intensities related to cell calcium ion concentrations, and AG denotes the aggregation ratio obtained from the ratio of fluorescent light intensities.
FIG. 5A shows that the effect of thrombin was to produce large platelet aggregations, thereby reducing the numbers of cells impinged upon by the excitation light and therefore greatly reducing the intensity of the fluorescent light, making it impossible to measure the calcium ions. As seen from FIG. 5B, however, with the medium degree of aggregation produced using collagen, adequate measurement was possible.
This shows that in accordance with this embodiment changes in the intensity of fluorescent light from samples in a plurality of cuvettes can be measured using an arrangement comprising directing light from a single light source through condensing means and a wavelength-selection optical system and using multiple optical fibers to project this light at the target cells. As this objective of measuring fluorescent light intensities of a plurality of samples is achieved using a single optical system, the measurement apparatus is compact and resource-efficient.
The light from the optical fibers 5 is projected at the cuvette 9 after being collimated by a lens 10' and passed through an iris 11' to reduce autofluorescence and stray light from the round glass measurement cuvettes 9, enabling high-precision measurements to be carried out. Using round glass cuvettes 9 is simple and economical.
By enabling the measurement cuvettes to be placed in closer proximity, using photodiodes as the photosensors enables the size of the system apparatus to be decreased. Both fluorescent and transmitted light can be measured with a single photodiode by arranging the photodiode on the optical axis of the light emitted by the light-emitting diode at right-angles to the optical axis of the light from the optical fibers. Also, it is possible to measure the intensity of fluorescent light while at the same time measuring the intensity of transmitted light. The chemical composition of a sample can be determined on the basis of changes in the fluorescence and at the same time the shape of the cell can be determined on the basis of changes in the transmitted light, making this a valuable tool for physiological, medical and pharmacological research.
The apparatus according to this invention is particularly suited to measurements relating to floating cells in the blood such as platelets, leukocytes and lymphocytes. For example, it can be used to measure changes in calcium ion and magnesium ion levels in blood platelets while at the same time measuring changes in the aggregation performance of such cells, and to ascertain the relationship between the two.
The system apparatus of this invention is ideal for applications in which it is necessary to measure large numbers of such cell samples in a short space of time. The arrangement described above is used to measure fluorescent and transmitted light intensities of multiple samples. However, the same optical system may be used for simultaneous measurement of cell fluorescence and light absorption or light scattering.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention should not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A multichannel optical measuring system for measuring optical responses of samples illuminated by light of differing wavelengths has a plurality of measurement sample cuvettes each contain a sample to be measured. A first single light source provides a first illumination light. A plurality of sets of optical fibers direct the first illumination light from the first single light source to illuminate, along an optical axis, the samples contained in respective sample cuvettes. A second light source is provided for illuminating each respective sample cuvette with a second illumination light for measuring an intensity of transmitted light through the sample. The optical axis of the second illumination light is perpendicular to the optical axis of the first illumination light. A common photosensor disposed on the optical axis of the second light source measures the intensity of the first illumination light and the intensity of the transmitted light from each sample. Thus, the multichannel optical measuring system can simultaneously measure both the intensity of a first illumination light from a single light source, and the intensity of light transmitted through each sample, for a plurality of samples.
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BACKGROUND OF THE INVENTION
This invention relates to an improved resin coated sand for use in shell-molding foundry operations, to eliminate the problems of thermal shock caused when hot metal is cast into the mold. In conventional sand molding operations, a mixture of sand coated with resin binder is placed in a mold, and the heat of the processing steps causes reactions between the binder components to improve the pressed strength of the sand and retain the configuration of the part to be cast.
Upon introduction of the molten metal into the mold, the temperature difference between the molten metal and the mold is great, and the heat of molten metal is transferred to the mold creating thermal shock in the mold, which may create cracks and fissures in the sand mold. The abrupt expansion caused by the temperature differential, destroys the binding action of conventional phenolic binders and cracks and rupture of the mold occur.
The effect of the heat of the molten metal upon the binder is advantageous, since this heat destroys the binder holding the sand or aggregate, and allows, upon cooling, the easy removal of the sand from the cast molded part. The sand is removed by tapping or flogging the molten part to remove the particles. This is known as the shake out property of the mold.
Therefore a resin mixture must be selected that will provide adequate thermal shock protection as well as allow simple removal of the binder-aggregate from the cast item.
A known method to solve the drawback for preventing the molds from cracks has been adopted by means of incorporating cushioning substances into phenolic resins or coated sand obtained therefrom. This method can make the molds flexible as well as free from stress at heating thereof. Said conventional cushioning substances are Vinsol, bisphenol A, petroleum resins, rosin, etc. While these substances play a role of cushioning effect in the molds to a certain extent, they have drawbacks in that they emit a disagreeable odor at pouring, due to a thermal decomposition of evaporation thereof. Also, the molds containing such materials are poor in the shake-out property.
After much investigation to overcome said drawbacks, the inventors hereof have found that the presence of mono-styrenated o-cyclohexylphenols having the following generic formula in resin coated sand: ##STR2## prevents the molds from cracks at pouring, free from disagreeable odor, and do not impair the shake-out property.
SUMMARY OF THE INVENTION
This invention discloses method to improve the resistance to thermal shock of phenolic resins employed as binders in said molding operations. Incorporated into the resin or resin-sand mixture is a compound selected from the following generic formulae: ##STR3## The incorporation of such compounds provide improved shake-out properties for castings using this binder in said-molding operations. The phenolic resin may be of the novolac type, the resole type or a mixture of novolac and resole phenolic resins.
DESCRIPTION OF THE DRAWING
The FIGURE is a side view of the test device used to determine the shake-out property of the cured resin coated sand.
DETAILED DESCRIPTION OF THE INVENTION
Conventional shell molding operations employ coated foundry sand or aggregated prepared by mixing heated sand with a phenolic resin until an uniform dispersion is obtained. Catalysts and fillers can be added if desired. The phenolic resin can be selected from novolac resins, resole resins or mixtures thereof.
Novolac type phenolic resins are generally prepared by reacting 1 mole of phenols with 0.6 to 0.9 moles of aldehydes in the presence of acidic catalysts, as their molar proportion range. Resole type phenolic resins are generally prepared by reacting 1 mole of phenols with 1 to 3 moles of aldehydes in the presence of basic catalysts, as their molar proportion range.
The phenolic resins used in the present invention are any of the novolac, the resole type or a mixture thereof. Phenols for preparing said phenolic resins are phenol, cresol, xylenol, etc., however, they are usable in the presence of resorcin, cathecol, hydroquinone, aniline urea, melamine, cashew nut shell oil, etc. Formaldehyde for preparing said phenolic resins is selected from formalin, paraformaldehyde, trioxane, etc. Catalysts for the reaction of phenol and formaldehyde are one or more of acidic substances generally such as oxalic, hydrochloric and sulfuric acid, and organic metal salts for novolac type resin prepartion. Basic substances used as catalysts for resole type resin preparation are generally selected from primary amines such as ammonia and ethyl amine; secondary amines such as ethylene diamine and diethyldiamine; tertiary amines such as triethylamine; hydroxides of alkali metals such as sodium hydroxide and potassium hydroxide; and hydroxide of alkali earth metals such as calcium hydroxide and magnesium hydroxide.
The inventors hereof have found that the presence of substances selected from the following generic formula preventing the mold from cracking at pouring and do not impair the shake out properties of the mold: ##STR4##
The most preferable incorporating proportion range of said mono-styrenated o-cyclohexylphenols is 0.5 to 40 parts by weight into 100 parts by weight of phenolic resins. When it is less than 0.5 parts by weight, it is insufficient to prevent the mold cracks. When it is more that 40 parts by weight, it impairs the initial strength of the molds.
The proper time for incorporating said mono-styrenated o-cyclohexylphenols during the process of preparing phenolic resin is optional: at the beginning, during or after reacting phenols with formaldehyde. Alternatively, after preparing said solid phenolic resin, said mono-styrenated o-cyclohexylphenols are incorporated thereinto by mix-grinding or melt-mixing with a kneading machine such as an extruder. It is also possible to incorporate the mono-styrenated o-cyclohexylphenols during the resin coated sand production steps; the proper time for incorporating the mono-styrenated substances thereinto is optional: prior to, during or after adding the phenolic resin thereinto. The mono-styrenated o-cyclohexylphenols are incorporated either as they are, or as dispersed in a medium. Any incorporating method reduces the abrupt thermal expansion of shell-molds obtained from resin coated sand.
Lubricant are usable according to the present invention, which are ordinary ones, however, preferable are ethylene bis-stearic amide, methylene bis-stearic amide, oxy-stearic amide, stearic amide, and methylol stearic amide. Lubricant-containing phenolic resins can be obtained by adding said lubricant to phenolic resins at any stage of their preparation; prior to, during or after the reaction.
Methods for producing resin coated sand in the present invention may be any of the commercial hot-coating, semi-hot-coating, cold-coating and powder-solvent coating, however, hot-coating is preferably recommended for the present invention.
The inventors hereof will explain the present invention by the following nonlimitative Examples and Comparative Examples, wherein "parts" and "percent" indicate "parts by weight" and "percent by weight", respectively.
PREPARATION EXAMPLES 1 AND 2
To a reaction kettle with a reflux cooler and a stirrer, 1000 parts of phenol, 650 parts of 37% formalin, and 10 parts of oxalic acid were charged. The temperature of the mixture was gradually elevated, and when it reached 96° C., it was refluxed for 120 minutes. 10 parts of methylene bis-stearic amide and 100 parts of the following mono-styrenated o-cyclohexylphenol (I) were added thereto. After the mixture was mixed well, it was dehydrated under vacuum and successively discharged from the kettle. Thus, a lubricant-containing novolac type phenolic resin was obtained as Preparation Example 1.
Except for changing mono-styrenated o-cyclohexylphenols from the following (I) to (II), the same operations were run, and a novolac type phenolic resin was obtained as Preparation Example 2. ##STR5##
PREPARATION EXAMPLE 3
To a reaction kettle with a reflux cooler and a stirrer, 1000 parts of phenol, 1795 parts of 37% formalin, 160 parts of 28% aqueous ammonia, and 60 parts of 50% sodium hydroxide solution were charged. The temperature of the mixture was gradually elevated, and when it reached 90° C., it was refluxed for 30 minutes, 40 parts of ethylene bis-stearic amide and 165 parts of said mono-styrenated substance (II) were added. After the mixture was mixed well, it was dehydrated under vacuum, discharged from the kettle and chilled quickly. Thus, a lubricant-containing solid resole type phenolic resin was obtained.
PREPARATION EXAMPLE 4
To a reaction kettle with a reflux cooler and a stirrer, 1000 parts of phenol, 650 parts of 37% formalin, and 10 parts of oxalic acid were charged. The temperature of the mixture was gradually elevated, and when it reached 96° C., it was refluxed for 30 minutes. 10 parts of methylene bis-stearic amide were added thereto. After the mixture was mixed well, it was dehydrated under vacuum, and discharged from the kettle. Thus, 970 parts of a novolac type phenolic resin was obtained.
PREPARATION EXAMPLE 5
To a reaction kettle with a reflux cooler and a stirrer, 1000 parts of phenol, 1795 parts of 37% formalin, 160 parts of 28% aqueous ammonia, and 60 parts of 50% sodium hydroxide solution were charged. The temperature of the mixture was gradually elevated, and when it reached 96° C., it was refluxed for 30 minutes. 40 parts of methylene bis-stearic amide were added thereto. After the mixture was mixed well, it was dehydrated under vacuum discharged from the kettle, and chilled quickly. Thus, 1100 parts of a solid resole type phenolic resin was obtained.
EXAMPLE 1
Preheated at 130° to 140° C., 7000 parts of Sanei No. 6 silica sand were charged into a whirl-mixer. After 140 parts of novolac type phenolic resin obtained according to Preparation Example 1 were added thereto, they were mixed for 40 seconds, and 21 parts of hexamethylene tetramine dissolved in 105 parts of water were added thereto. The mixture was further mixed well until it crumbled. 7 parts of calcium stearate were added thereto, and after 30 seconds mixing, discharged and aerated. A resin coated sand was obtained.
EXAMPLE 2
Except for using novolac type phenolic resin obtained according to Preparation Example 2, resin coated sand was obtained by the same conditions as Example 1.
EXAMPLE 3
Preheated at 130° to 140° C., 7000 parts of Sanei No. 6 silica sand were charged into a whirl-mixer. After 140 parts of resole type phenolic resin obtained according to Preparation Example 3 were added thereto, they were mixed for 40 seconds, and 105 parts of cooling water were added thereto. The mixture was further mixed well until it crumbled. 7 parts of calcium stearate were added thereto, mixed for 30 seconds, discharged and aerated. A resin coated sand was obtained.
EXAMPLE 4
Preheated at 130° to 140° C., 7000 parts of Sanei No. 6 silica sand were charged into a whirl-mixer and successively 130 parts of novolac type phenolic resin obtained according to Preparation Example 4 were added thereto. Followed by 20 seconds mixing, 13 parts of said mono-styrenated substance (II) were added thereto. After mixing for 20 seconds, 21 parts of hexamethylene tetramine dissolved in 105 parts of water were added thereto. The mixture was further mixed until it crumbled. 7 parts of calcium stearate was added thereto, followed by 30 seconds mixing, the mixture was discharged and aerated. A resin coated sand was obtained.
EXAMPLE 5
Preheated at 130° to 140° C., 7000 parts of Sanei No. 6 silica sand were charged into whirl-mixer. After 13 parts of said mono-styrenated substance (I) were added thereto, they were mixed for 20 seconds. 78 parts of lubricant-containing novolac type phenolic resin according to Preparation Example 4 and 52 parts of lubricant-containing resole type phenolic resin according to Preparation Example 5 were added thereto, and mixed for 20 seconds. Then, 13 parts of calcium stearate were added thereto, mixed for 30 seconds, discharged and aerated. A resin coated sand was obtained.
COMPARATIVE EXAMPLE 1
Preheated at 130° to 140° C., 7000 parts of Sanei No. 6 silica sand were charged into a whirl-mixer. After 140 parts of novolac type phenolic resin obtained according to Preparation Example 4 were added thereto, they were mixed for 40 seconds, and 21 parts of hexamethylene tetramine dissolved in 105 parts of water were added thereto. The mixture was mixed until it crumbled. 7 parts of calcium stearate were added thereto, mixed for 30 seconds, discharged and aerated. A resin coated sand was obtained.
COMPARATIVE EXAMPLE 2
Preheated at 130° to 140° C., 7000 parts of Sanei No. 6 silica sand were charged into a whirl-mixer. After 140 parts of resole type phenolic resin obtained according to Preparation Example 5 were added, they were mixed for 40 seconds, and 105 parts of cooling water were added thereto. The mixture was mixed until it crumbled. 7 parts of calicium stearate were added thereto, mixed for 30 seconds, discharged and aerated. A resin coated sand was obtained.
Table 1 indicates the characteristics of various kinds of resin coated sand obtained according to Examples 1, 2, 3, 4, and 5, and Comparative Examples 1 and 2, as well as the abrupt thermal expansion rate and the shake-out property of shell-molds obtained therefrom.
TABLE I__________________________________________________________________________ Comparative Example Example 1 2 3 4 5 1 2__________________________________________________________________________No. of Preparation Examples 1 2 3 4 4 + 5 4 5(phenolic resin used)Kind of substances used I II II II I -- --Incorporating proportion of substances 10 10 15 10 10 0 0into 100 parts of phenolic resinResin coated sand Stick point (°C.) 95 97 90 98 92 102 98 Bending strength 31.5 31.7 29.1 31.5 29.5 30.1 28.9 (Kg/cm.sup.2)Shell mold Tensile 30 sec. 2.0 2.2 1.5 2.1 1.9 2.5 1.9 strength under heat (Kg/cm.sup.2) 45 sec. 4.5 4.7 2.6 4.6 4.0 5.0 3.1 at 250° C. 60 sec. 7.8 7.9 5.8 8.0 7.0 8.2 6.6 Abrupt thermal 1.15 0.92 0.85 1.08 1.22 1.50 1.63 expansion rate (%) Shake-out 30 31 30 31 30 32 29 property (times)__________________________________________________________________________
Procedures used for testing of samples in Table 1.
Bending strength:
according to JACT Method SM-1
Stick point:
according to JACT Method C-1
Tensile strength under elevated temperature:
according to JACT Method SM-10
Abrupt thermal expansion rate:
according to JACT Method SM-7 at 1000° C.
Shake-out property:
Preparation of specimen:
Coated sand is fed into an iron pipe of 29 mm in diameter and 150 mm length. After 30 minutes' baking, it is covered with aluminum foil and further heated for 3 hours at 370° C. After cooling, the sand molded pipe is removed.
Test method:
The specimen if flogged by the impact arm of the apparatus illustrated in FIG. 1. Crumbled sand is removed from the pipe after each flogging. Weighing the residual molded sand of the specimen until it becomes zero, and the shake-out property is defined by the number of floggings required.
Test apparatus:
In FIG. 1, A is a molded sand specimen and B is the arm which revolves around pivot C set at 30 cm high, said arm is at first set horizontally, and then allowed to drop so as to flog the specimen.
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An improved resin coated sand for use in foundry shell-molding applications is disclosed which has increased resistance to thermal shock at the time of pouring. The improved product uses a phenolic resin as binder with aromatic compounds selected from the following generic formulae: ##STR1## The foundry aggregates are mixed with the phenolic resin and organic compounds under conventional mixing conditions to form a sand-resin mixture that can be formed into shell-molds. Upon casting the molten metal into these molds, the abrupt thermal expansion of the coated sand is controlled to eliminate the cracking that occurs when conventional phenolic-sand mixtures are employed.
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BACKGROUND OF THE INVENTION
This invention relates to coating thickness measurement devices utilizing the radiation backscatter technique, and more particularly to a shielding arrangement for use with such devices to shield an operator from stray radiation which will emanate from such devices during the course of their use.
Various types of coatings are commonly applied to small electronic parts such as connectors, contacts for connectors, and the like. Because of the critical nature of the coating thickness in such applications, it is necessary that the thickness be determined with a high degree of precision. The use of beta radiation backscatter has been found to provide the necessary degree of precision required for the accurate measurement of such thicknesses. As a consequence, several devices have been developed to apply the beta radiation backscatter technique to the measurement of coating thicknesses on various types of electronic parts, such as, for example, on printed circuit boards, and also in other applications. For example, U.S. Pat. No. 3,529,158 shows one type of portable probe in which a base member receives a guide for aligning the member with the area to be measured, the guide then being removed from the member and replaced by a measuring head. U.S. Pat. No. 3,720,833 shows another type of portable probe in which a spring biased locator carried by the probe housing is retracted within the housing by a cam arrangement in response to the lowering of the measuring probe unit into engagement with the workpiece.
Although the radiation utilized in such beta radiation backscatter measurement techniques is of a relatively low level, and even though the penetration power of beta radiation is substantially less than that of gamma radiation, there are times when it may be necessary or desirable to provide some degree of shielding in connection with such a device in order to minimize the exposure of an operator of such devices to beta radiation.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a shielding arrangement for use with measurement devices utilizing the beta radiation backscatter technique.
It is another object of the present invention to provide a shielding arrangement for such devices whereby the shield may be conveniently positioned with respect to an aperture through which the radiation passes.
It is a further object of the present invention to provide a radiation shield arrangement for such devices wherein such shielding is sufficient to attenuate such radiation to a predetermined exposure level.
It is still a further object of the present invention to provide a shielding arrangement for such devices wherein a plurality of shields is provided to minimize the stray radiation during the various phases of the measurement operation.
Briefly stated, in accordance with one aspect of the present invention, a shielding arrangement is provided in a device for measuring coating thickness by the beta radiation backscatter technique, the device including a movable housing which contains a radiation source and an aperture through which the radiation can pass, the shielding arrangement including a first shield adapted for placement over the aperture and in engagement with the housing, the shield being of a suitable material and thickness sufficient to preclude the passage of beta radiation therethrough. The first shield is removable in order to permit the radiation to pass through the aperture and against the surface of the part carrying the coating, the thickness of which is to be measured. A second shield is provided which is adapted to be brought into covering relationship with respect to the aperture when a measurement is not being made, and which is movable out of covering relationship with the aperture when it is intended to make a thickness measurement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a coating thickness measuring device utilizing the beta radiation backscatter technique and showing a shielding arrangement in accordance with the present invention.
FIG. 2 is a plan view of the device shown in FIG. 1.
FIG. 3 is a transverse cross-sectional view, partially broken away, taken through the mechanism enclosure of the device shown in FIGS. 1 and 2 to illustrate the internal arrangement of the drive means for moving the isotope-containing housing and for moving a swingable shield into and out of operating position.
FIG. 4 is a fragmentary view, partially in section, showing means for holding in position under the radiation aperture either a closure shield or, alternatively, a calibration standard.
FIG. 5 is a cross-sectional view taken along the line 5--5 of FIG. 2.
FIG. 6 is a cross-sectional view taken generally along the line 6--6 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and particularly to FIG. 1 thereof, there is shown a coating thickness measuring device very similar to that shown and described in a copending application entitled, "COATING THICKNESS MEASURING DEVICE," Ser. No. 257,975, filed Apr. 24, 1981, the disclosure of which is hereby incorporated herein by reference, and which application is commonly owned by the assignee of the present invention.
As shown in FIG. 1, the device includes a base 10 upon which is positioned a mechanism enclosure 11 and a part positioning system 12. The part positioning system shown is a fixture 13 which is positioned on an X-Y slide 14 secured to base 10. The X-Y slide can be of a readily commercially available type, if desired, and is adapted to move fixture 13 in directions at right angles to each other in order to permit proper placement of the part for subsequent measurement. Alternatively, a rotary slide, a magnetic fixture holder such as is disclosed in the copending application referred to hereinabove, or any other type of positioning device could also be used.
An operating handle 15a is secured to control shaft 15, the purpose of which is to raise and lower an isotope housing 16, which is supported in a housing mount 17 carried by a shaft 18 which extends into and is carried by mechanism enclosure 11 for vertical sliding movement. The interrelationship between operating handle 15a and shaft 18 will be hereinafter described in more detail. As shown, housing mount 17 includes a cam-type rotary lock 19 which is adapted to hold isotope housing 16 firmly in position with respect to mount 17.
Positioned within isotope housing 16 is an isotope (not shown) providing a source of beta radiation. The radiation source is positioned in the lower portion of housing 16 adjacent an aperture (not shown), and above the radiation source there is provided a radiation detection means (not shown) which can be, for example, a standard Geiger-Muller tube for detecting radiation backscatter. The output of the Geiger-Muller tube can be connected to a suitable display device (not shown), which can be a standard meter of known type, or, if desired, it can be a direct digital readout, as will be readily appreciated by those skilled in the art.
A stop mechanism is mounted on the enclosure 11 and comprises an adjusting screw 20 and an adjusting collar 21 which can be raised or lowered along the axis of adjusting screw 20 to provide a vertical stop for housing mount 17. Although not normally utilized when the device is in its measuring mode, the adjusting collar can be utilized for the proper orientation of a positioning microscope (not shown) which can be positioned in mount 17 in place of housing 16 to facilitate positioning of the parts to be measured directly beneath the central axis of isotope housing 16. The use of such a positioning microscope is described in the co-pending application referred to hereinabove.
Swingably connected to mechanism enclosure 11 is a supporting arm 22 which is adapted to be brought into and out of underlying relationship with isotope housing 16. As shown in FIG. 1 supporting arm 22 is in position beneath isotope housing 16 and carries a closure shield 23, which can be formed of plastic materials. The closure shield is adapted to slidably fit over the end of isotope housing 16 in which the aperture is formed, and which includes a base portion which overlies the end of isotope housing 16 so as to cover the aperture. Preferably as shown in FIG. 5, the portion of closure shield 23 overlying the aperture in isotope housing 16 includes a radiation shield in the form of a disc 40, which can be of metallic construction, or any other suitable material which provides sufficient attenuation for the radiation which would otherwise emanate from the aperture in isotope housing 16. Supporting arm 22 includes a slidable yoke 24 which is so configured as to overlie an outwardly extending flange of closure shield 23 to retain it in position with respect to supporting arm 22. Slidable yoke 24 is also slidable rearwardly to permit the removal of housing 16 with closure shield 23 in covering relationship to the aperture, if desired. Additionally, supporting arm 22 also can carry a calibration standard (not shown) having a known thickness of the coating to be measured, which can be in the form of a coated disc carried by supporting arm 22 and which can be positioned in underlying relationship to isotope housing 16 to permit calibration of the readout device. The actuation of supporting arm 22 into and out of its position in underlying relationship with isotope housing 16 can be accomplished by control knob 25, which is interconnected therewith in a manner to be hereinafter described, or it can be accomplished by other means.
Also shown in FIG. 1 is another shielding means comprising a partial enclosure 26, which is positioned between isotope housing 16 and the operator for additional attenuation of stray radiation, in order to provide a shield for the operator at those times when isotope housing 16 is not in contact with shield arm 30, and shield 23 is not in place, at which times stray radiation can pass from the measuring zone. Enclosure 26 can be provided with an opening 30a in a side thereof to permit arm 30 carried by enclosure 11 to swing therethrough, and can be formed of a number of materials, so long as the materials are sufficient to stop stray radiation. Although the precise materials will be dependent upon the type of isotope utilized, which will influence the strength of the radiation to be encountered, it has been found that metals or plastics are sufficient to provide the desired radiation shielding. Although it is not essential that enclosure 26 be transparent, since measurement can be made without the operator viewing the part as the coating thickness is being determined, it is desirable to provide transparency so that observation of the part during the measuring process can be maintained. Depending upon the strength of the radiation source, transparent plastics such as Plexiglass, Lexan, and the like would be suitable, as would ordinary window glass, although the latter is considerably heavier than the former.
Enclosure 26 extends across the front of the device and along two of the sides and carries a shaft 27 which is supported in a bearing block 28 which, in turn, is secured to mechanism enclosure 11. Shaft 27 permits enclosure 26 to be pivoted into and out of position with respect to the measuring zone to permit the removal or insertion of parts to be measured. A stop shaft 29 can be provided to limit the rearward travel of enclosure 26.
A further radiation shield can be provided for interposition between the aperture in isotope housing 16 and fixture 13 during those times when a measurement is not in progress. Such an additional shield can be provided by a shield arm 30 which is pivotally secured to mechanism enclosure 11 by means of shaft 31 as shown in FIG. 2. As in the case of supporting arm 22, shield arm 30 is positioned to be swung into and out of covering relationship with the aperture in isotope housing 16. Thus shield arm 30 is adapted to be swung from the dot dash position shown in FIG. 2 through opening 30a in enclosure 26, to an outlying position as shown in solid lines in FIG. 2 as the isotope housing 16 is moved from a raised inoperative position to a lowered operative or measuring position, and is also adapted to be swung to the underlying position relative to the aperture in housing 16 as illustrated in dot dash lines in FIG. 2 when isotope housing 16 has been retracted to its upper position after a measurement has been made. As shown more clearly in FIG. 5, shield arm 30 is positioned in a plane which is spaced upwardly from the plane in which supporting arm 22 is positioned. Additionally, shield arm 30, which can be made of any convenient material, such as, for example, aluminum, is provided with a shield element, which can be a steel disc, which is positioned in shield arm 30 so as to be in covering relationship with the aperture in housing 16 to effectively block radiation therefrom during those times when isotope housing 16 is spaced from fixture 13.
The drive means for swinging shield arm 30 into and out of its position with respect to isotope housing 16 is shown in FIGS. 3 and 6. As shown, shaft 31 on which shield arm 30 is positioned passes into and within mechanism enclosure 11 and terminates in a bevel gear 32, which is in driving engagement with a cooperating bevel gear 33 carried by a shaft 34 which is positioned at right angles to shaft 31. Shaft 34 is rotatably carried in a boss 35 and at its opposite end carries another bevel gear 36, which, in turn is in driving engagement with bevel gear 37 carried by shaft 15a. Thus, as operating handle 15 is moved in a counterclockwise direction as viewed in FIG. 1, shaft 31 turns in a clockwise direction as viewed in FIG. 3, thereby moving shield arm 30 out of position and away from isotope housing 16. Although shown and described in terms of of a gear train, other drive means can be provided to actuate swing arm 30 into and out of position, such as belts, links, servomotors, and the like.
The internal arrangement for moving housing mount 17 into and out of position with respect to fixture 13 is shown in FIG. 5. Connected to the shaft 15 on which operating handle 15a is positioned is a cam roller 37, which is cooperatively engaged with a cam follower 38 which is secured to shaft 18. Thus, when control shaft 15 is rotated in a counterclockwise direction as viewed in FIG. 5, cam roller 37 initially urges cam follower 38 upwardly until cam roller 37 rotates sufficiently far to the left, whereupon the weight of shaft 18 and housing mount 17 and housing 16 will cause the assembly to descend vertically downwardly. The rate of descent of housing mount 17 is controlled by means of a dashpot 39 (see FIG. 3), which is essentially a pneumatically operated piston-cylinder arrangement having a needle valve to control the escape of air from the cylinder, and thereby control the rate of descent of housing mount 17 to provide a gentle contact between isotope housing 16 and the part having the coating, the thickness of which is to be measured. Again, although disclosed in terms of a cam roller and cam follower arrangement, it will be apparent to those skilled in the art that other means to move housing mount 17 can be employed, if desired.
As shown in FIG. 5, means are provided to hold supporting arm 22 in position so that it underlies isotope housing 16. Thus, a limit arm 41 is secured to the shaft 42 to which supporting arm 22 is secured, the limit arm being adapted to contact a stop member 43 which is provided with a magnet 44 to securely hold limit arm 41 in the position shown in full lines in FIG. 2.
The drive arrangement between control knob 25 and supporting arm 22 can be as shown in FIG. 6, wherein control knob 25 is secured to shaft 45, which carries a bevel gear 46 in meshing engagement with a cooperating bevel gear 47, which, in turn, is carried by upwardly extending shaft 42 to which supporting arm 22 is secured.
In the embodiment shown in the drawings, an X-Y slide 14 is provided, which includes a pair of micrometer adjustments, the micrometer barrels having a length which extend beyond and through enclosure 26. In order to provide an additional barrier to radiation, an optional inner shield 48 can be provided adjacent the micrometer barrels to cover the necessary notches 49, 50 which are provided in enclosure 26 to permit it to be pivoted rearwardly. If a relatively low energy isotope is employed, shield 48 can be omitted, if desired.
In operation, part fixture 13 can be properly positioned with respect to the axis of isotope housing 16 by means of the microscope arrangement disclosed in the co-pending application referred to hereinabove. After the fixture and its associated part are properly positioned, the microscope is removed from housing mount 17 and adjusting collar 21 is rotated to cause it to move downwardly along adjusting screw 20 until it is in a position in which it does not impede contact by isotope housing 16 with the part to be measured. Shield 26 is moved into position between the measuring zone and the operator. Isotope housing 16, which includes a suitable source of radiation and which carries a closure shield 23, can be positioned in housing mount 17 and restrained from upward movement relative to mount 17 by means of lock 19. At this point operating handle 15a is moved to its rearmost position to elevate mount 17. Supporting arm 22 is positioned beneath isotope housing 16 by means of control knob 25 and yoke 24, if not in its rearmost position, is moved rearwardly, away from the axis of isotope housing 16.
After supporting arm 22 is in position beneath housing 16, operating handle 15a is brought forward to cause housing 16 to descend until closure shield 23 is in contact with supporting arm 22. Slidable yoke 24 is moved forwardly to position it in engagement with closure shield 23 so that it overlies the rim thereof. Operating handle 15a is then moved rearwardly to elevate housing mount 17 once again, whereupon closure shield 23 is separated from isotope housing 16 and is retained by supporting arm 22. At that point supporting arm 22 can be swung out of the way by means of turning control knob 25 to position arm 22 adjacent mechanism enclosure 11.
When housing mount 17 has been elevated to its uppermost position, shield arm 30 is in underlying position with respect to the aperture in isotope housing 16. When it is desired to take a thickness measurement, operating handle 15a is rotated so that the arm thereof moves in a direction toward the operator, whereupon cam roller 37 urges cam follower 38 in an upward direction. After cam follower 38 has been so elevated with the consequent effect that housing mount 17, and, in turn, isotope housing 16 have been similarly elevated, further movement of control shaft 15 causes shield arm 30 to move outwardly from beneath isotope housing 16, and further movement of shaft 15 will move cam roller 37 so that it is substantially displaced from cam follower 38, the vertical movement of which is slowed by means of dashpot 39. The descent of isotope housing 16 is relatively gradual in order to minimize the impact force between it and the part having the coating, the thickness of which is to be measured. When housing mount 17 has descended to its lowermost position, wherein the aperture in isotope housing 16 is in contact with the coated part, the sensing tube senses the radiation backscatter and provides a suitable signal to an indicating device (not shown) to permit the operator to determine the coating thickness on the part.
Once the thickness determination has been made, the operating handle is moved in a direction away from the operator to cause cam roller 37 to bear against cam follower 38 and thereby lift the same as shaft 15 rotates. As cam follower 38 is elevated, shaft 18 and housing mount 17 are elevated at the same time, and because of the gearing arrangement between shield arm 30 and control shaft 15, shield arm 30 begins to move inwardly toward the axis of the isotope housing and when isotope housing 16 has reached its maximum upward position, shield arm 30 is directly beneath it. Further movement of operating handle 15a rearwardly to its extreme position causes cam roller 37 to engage the dispersion in cam follower 38, which, in turn, causes isotope housing 16 to descend slightly so that the aperture thereof is covered by shield arm 30, thereby providing shielding against stray radiation during the time when no coating thickness determination is being made.
During all the times the foregoing operations are taking place, enclosure 26 provides an additional shield between the measurement zone and the operator, thereby further minimizing the radiation to which the operator might otherwise be subjected. It is thus apparent that the present invention provides a shielding arrangement whereby three separate shielding means can be provided and utilized during the various phases of the operation of the device. The first shielding means is closure shield 23, which can be in position over the aperture of isotope housing 16 both before and after its insertion into housing mount 17. Upon removal of closure shield 23, shield arm 30 functions to prevent stray radiation when a measurement is not in progress. Additionally, enclosure 26 and optional inner shield 48 additionally provide shielding effective to attenuate radiation during those short periods of time between the disengagement of shield arm 30 from isotope housing 16. Thus, at each stage of operation of the device there is at least one radiation shield in position between the operator and the source of radiation.
While particular embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various modifications can be made without departing from the spirit and scope of the present invention, and it is intended to cover in the appended claims all such changes and modifications that fall within the scope of the present invention.
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A shielding arrangement for a coating thickness device utilizing the radiation backscatter technique. An isotope housing is provided having an aperture through which radiation can pass. A removable cover shield is attached to the housing to cover the aperture when the device is not in use. Means are provided to remotely remove the cover shield from the housing and expose the aperture. A secondary shield carried by the device is provided to swing into and out of covering relationship to the aperture to block radiation passage through the aperture between measurements. The secondary shield is operatively connected with the operating handle of the device to coordinate movement of the secondary shield with the position of the isotope housing. A tertiary shield, which can be of transparent plastic material, is provided between the measuring zone of the device and the operator to provide additional shielding during the times the secondary shield is not in covering relationship with the aperture.
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FIELD OF THE INVENTION
The present invention relates generally to knitting machines and more particularly to knitting instrumentalities for such knitting machines, in particular circular knitting machines and method of forming such knitting instrumentalities.
BACKGROUND OF THE INVENTION
Knitting machines, and in particular circular knitting machines, employ knitting instrumentalities to produce the knitted fabric. In a circular knitting machine, a rotating needle cylinder has a multiplicity of vertical grooves in the outer periphery formed by insert pieces which are stationary or fixed. These vertical grooves receive latch needles, intermediate jacks, patterning jacks and possibly other movable knitting instrumentalities for high speed reciprocation. A lubricating oil is sprayed in mist form onto these knitting instrumentalities to ensure smooth and uninterrupted reciprocation.
However, as knitting speed increases, these knitting instrumentalities tend to adhere to the insert pieces causing the lubricating oil to be expelled from the grooves and the movable knitting instrumentalities to move sluggishly. An abnormal load is applied to the knitting instrumentalities, particularly the butts of the latch needles and, if the condition persists, such abnormal loads frequently result in breakage of the knitting instrumentalities. Such breakage may cause a chain reaction of breakage of other knitting instrumentalities or peripheral parts of the knitting machine.
Attempts have been made to solve this problem with some success, but at substantially increased manufacturing costs because of the complicated processes required to produce the knitting instrumentalities. One example of such movable knitting instrumentalities is disclosed in Japanese Utility Model Laid-Open No.560-127387 (1985). Such knitting instrumentalities are provided with cutouts on opposite side faces with the cutouts on one face being positioned alternately with the cutouts on the other face. Another example is found in Japanese Utility Model Publication H-43419 (1989) in which the movable knitting instrumentalities are provided with projections on their side faces and bottoms.
SUMMARY OF THE INVENTION
With the foregoing in mind, it is an object of the present invention to provide knitting instrumentalities which are easy and less expensive to manufacture in large quantities while maintaining stable quality and which obviate the deficiencies and disadvantages of prior knitting instrumentalities.
This object of the present invention is accomplished by providing knitting instrumentalities that may be manufactured by stamping such instrumentalities from sheet metal in which a fine concave-and convex pattern has been formed to reduce the frictional forces on such knitting instrumentalities and substantially eliminate the tendency thereof to adhere to the insert pieces. In accordance with the present invention, such knitting instrumentalities include both movable and fixed elements capable of being formed by a metal stamping operation and which have surfaces rubbing against other surfaces. Examples of such movable elements are latch needles, intermediate jacks, patterning jacks, etc. and of such fixed elements are insert pieces, etc. Further, examples of such fine concave-and-convex patterns include multiple spaced-apart indentations on at least one surface of the knitting instrumentalities; several continuously formed indentations in at least one surface thereof; an undulating or sinuous shape for at least a portion of the length of the instrumentality; and a cross-sectional shape having thick and thin portions.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds when considered in conjunction with the accompanying drawings, in which:
FIG. 1 is a side elevational view of a knitting instrumentality, i.e. a patterning jack, formed in accordance with the present invention;
FIG. 2 is an enlarged sectional view taken substantially along line 2 — 2 in FIG. 1;
FIG. 3 is a side elevational view similar to FIG. 1 of another embodiment of a knitting instrumentality of the present invention;
FIG. 4 is an enlarged sectional view taken substantially along line 4 — 4 in FIG. 3;
FIG. 5 is a side elevational view similar to FIGS. 1 and 3 of a further embodiment of a knitting instrumentality of the present invention;
FIG. 6 is an elevational view of the knitting instrumentality of FIG. 6 looking in the direction of the arrows 6 — 6 in FIG. 6; and
FIG. 7 is a perspective view of a friction resistance apparatus used for testing and evaluating the knitting instrumentalities of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
Referring now more specifically to the drawings and particularly to FIG. 1, there is illustrated a knitting instrumentality, generally indicated at 10 , in the form of a patterning jack. The knitting instrumentality 10 is formed of sheet metal 11 and is preferably formed by a stamping process by which large quantities can be produced easily and relatively inexpensively while maintaining stable quality.
As illustrated in FIGS. 1 and 2, the knitting instrumentality 10 is provided with a fine pattern of concave-and-convex areas in the form of indentations 12 . Indentations 12 are spaced apart with certain intervals therebetween, such as 0.5 mm for example. Indentations 12 are preferably concave polygons, such as triangles, squares, rectangles, etc. or of any other desired shape, such as dimples on a golf ball.
Indentations 12 may be formed on only one side of the knitting instrumentality 10 but are preferably formed on both sides thereof. Indentations 12 may be formed in the sheet metal 11 from which knitting instrumentality 10 is stamped, by passing the same through the nip of a pair of rolls having projections on the surface thereof corresponding to the desired pattern of indentations 12 .
The pattern of concave-and-convex areas result in thick and thin portions in the knitting instrumentality 10 . In the knitting instrumentality 10 , the indentations 12 define the thin portions 13 and the intervals between the indentations 12 define the thick portions 14 . The difference between the thick portion 14 and the thin portion 13 is preferably between about 0.01 mm and about 0.05 mm and most preferably about 0.02 mm.
Referring now to FIGS. 3 and 4, in which like reference characters with the prefix “1” added are used to refer to like elements, there is illustrated a knitting instrumentality, generally indicated at 110 , in the form of a patterning jack. Knitting instrumentality 110 is likewise formed of sheet metal 111 and is produced by a metal stamping operation. In cross-section, knitting instrumentality 110 has a thick center portion 114 and relatively thin outer or end portions 113 . The difference in thickness between portions 113 and 114 is preferably approximately 0.02 mm. The cross-sectional shape of knitting instrumentality 110 is preferably formed by passing the sheet metal 111 through the nip of a pair of rolls (not shown), the surfaces of which have profiles corresponding to the desired cross-sectional shape.
Referring now to FIGS. 5 and 6, in which like reference characters with the prefix “2” added are used to refer to like elements, there is illustrated a knitting instrumentality 210 , in the form of a patterning jack. Knitting instrumentality 210 is also formed of sheet metal 211 and has a medial or trunk portion 215 thereof formed in an undulating or sinuous shape longitudinally thereof. As illustrated, there are five (5) undulations 216 which are formed by pressing the stamped knitting instrumentality between upper and lower dies (not shown). In use, only the apogees of the undulation will contact the inserts and therefore the area of contact is substantially reduced. The reduced contact area permits lubricating oil to be supplied into the grooves between the inserts and other knitting instrumentalities 10 , 110 or 210 so that the movable knitting instrumentalities can move smoothly. Heat generation is also reduced, as is abrasion on the butts of the knitting instrumentalities, thereby prolonging the useful life of the knitting instrumentalities.
The knitting instrumentalities 10 , 110 or 210 of the present invention may be evaluated by a resistance tester 20 (FIG. 7) which measures the static frictional forces on the knitting instrumentalities 10 , 110 , or 210 and, for comparison purposes, conventional knitting instrumentalities. The tester 20 includes a table, generally indicated at 21 , having a top 22 and legs 23 and 24 . Leg 23 has a horizontal guide 25 mounted thereon, which in turn mounts a spring scale 26 for sliding movement therealong. A weight 27 is connected to spring scale 26 by a line 28 trained about a pulley 29 to bias or move the spring scale 26 to the left as seen in FIG. 7 along an X axis.
A wand 30 extends upwardly from the top of the spring scale 26 and engages a knitting instrumentality 10 , 110 , or 210 or a conventional knitting instrumentality (not shown). A reinforcing plate 31 is mounted on table top 22 in position to engage the opposite end portion of the knitting instrumentality 10 , 110 and 210 . Plate 31 serves as a fulcrum about which the instrumentality pivots when the weight 27 is released and moves the spring scale 26 to the left for a predetermined distance and as a stop to stop pivoting movement of the knitting instrumentality at the predetermined distance from the starting position.
In conducting this evaluation, ten knitting instrumentalities 10 , 110 and 210 of the present invention and ten conventional knitting instrumentalities of the same shape were selected. The table top 22 was first sprayed with lubricating oil and then a knitting instrumentality was placed thereon in the starting position along a Y axis (shown in FIG. 7) and the knitting instrumentality is then moved in a reciprocating sliding manner twenty (20) times along the Y axis while the knitting instrumentality is pressed downwardly at points A and B by the person conducting the test. The spring scale 26 is then moved to the right until the wand 30 engaged the right side edge of the knitting instrumentality and the weight 27 is released and permitted to fall freely until the knitting instrumentality is stopped by plate 31 . The scale 26 is then read and the amount shown thereon is recorded. Table 1 below lists the results recorded in tests on the ten conventional knitting instrumentalities and the ten knitting instrumentalities 10 (Example 1 in Table 1), the ten knitting instrumentalities 110 (Example 2 in Table 1) and the ten knitting instrumentalities 210 (Example 3 in Table 1).
TABLE 1
Unit: g
1
2
3
4
5
6
7
8
9
10
Average
Conventional
55
85
85
60
77
93
64
64
52
70
70.5
Product
Example 1
20
8
16
5
11
35
28
11
16
13
16.3
Example 2
40
20
20
29
12
5
17
16
26
11
19.6
Example 3
21
20
17
3
15
14
15
14
10
7
13.9
As is readily apparent, the knitting instrumentalities 10 , 110 and 210 of the present invention are subject to significantly reduced static frictional forces compared to the conventional knitting instrumentalities.
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A knitting instrumentality for use in a knitting machine and method of forming the same is provided and includes an elongate body member ( 10, 110, 210 ) stamped from sheet metal ( 11, 111, 211 ) in a predetermined shape and having a fine concave-and-convex pattern ( 12, 113, 114, 215 ) formed in the side faces thereof to reduce the contact area of such knitting instrumentality when placed in the knitting machine to reduce the static frictional forces thereon.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Application No. 60/523,236 filed Nov. 19, 2003.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates generally to a tree stand and, more particularly, to an apparatus and method for hunting in trees.
[0006] 2. Related Art
[0007] Tree stands are load supporting platforms used primarily by hunters. The stands are used to support a hunter at an elevated position on the trunk of a tree. Most conventional tree stands have a foot platform and a seat. Examples of such tree stands are disclosed by U.S. Pat. Nos. 2,855,980, issued to Konieczka on Oct. 14, 1958; 4,120,379, issued to Carter on Oct. 17, 1978; 4,819,763, issued to Grote on Apr. 11, 1989; 5,363,941, issued to Richard on Nov. 15, 1994; and 5,848,666, issued to Woodall et al. on Dec. 15, 1998.
[0008] As most hunters know, tree selection for tree stand placement is critical. This is especially true for bow hunters because of the limited effective range of the bow. Finding a perfectly straight tree in a perfect hunting spot, however, rarely can be accomplished. More often than not, trees at ideal locations have a “lean” or angle making them difficult for installation and use of the tree stand.
[0009] Installing a standard tree stand in a tree that leans presents one of two major problems for the hunter. Either the tree stand is declined such that the hunter feels that he or she could easily fall out of the tree stand or the tree stand is inclined such that the hunter is at a disadvantageous angle for viewing the ground and/or prey. Either case is unwanted by the hunter and, hence, installing a standard tree stand in a leaning tree is undesirable even if it is in an ideal location.
[0010] There remains a need in the art for an apparatus and method for hunting in trees.
SUMMARY OF THE INVENTION
[0011] It is in view of the above problems that the present invention was developed. The invention is an apparatus and method for hunting in trees. The apparatus includes an adjustable tree stand for use in leaning and non-leaning trees. The tree stand includes means for adjusting the angle of the tree stand relative to the tree. The adjustable tree stand has top and/or bottom adjustment. Adjustment is provided through the use of an adjustment device attached to a support or a cross-member.
[0012] In another aspect of the invention, there is provided a universal adjustment device. The universal adjustment device can be installed on existing tree stands. The universal adjustment device increases the flexibility and functionality of an existing tree stand.
[0013] The apparatus also includes a measuring device for use in measuring tree “lean.” The measuring device connects to the bottom of the tree stand. The measuring device includes a handle, a level and a sliding member having units of measurement.
[0014] The invention also includes a method of gross adjustment of the tree stand upon measurement of tree lean. The measuring device is used by placing the handle against a tree, verifying that the sliding member is level, and measuring the distance to the tree using the sliding member. The user then makes a gross adjustment of the tree stand based upon the distance measurement. In some embodiments, fine adjustment is made after the stand is mounted in the tree
[0015] Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and together with the description, serve to explain the principles of the invention. In the drawings:
[0017] FIG. 1 is a perspective view of a tree stand in a first embodiment;
[0018] FIG. 2 is a detailed perspective view of the tree stand in a second embodiment;
[0019] FIG. 3 a is a detailed perspective view of the tree stand in a third embodiment;
[0020] FIG. 3 b is a detailed perspective view of the tree stand in a third embodiment;
[0021] FIG. 3 c is a detailed perspective view of the tree stand in a third embodiment;
[0022] FIG. 3 d is a detailed perspective view of the tree stand in a third embodiment;
[0023] FIG. 3 e is a detailed perspective view of the tree stand in a third embodiment;
[0024] FIG. 4 is a detailed perspective view of a universal adjustment device for use with a tree stand;
[0025] FIG. 5 is a side view of the tree stand in a third embodiment in use;
[0026] FIG. 6 a is a bottom perspective view of the tree stand and a measuring device;
[0027] FIG. 6 b is a side view of the measuring device; and
[0028] FIG. 6 c is a side view of the measuring device in use;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] Referring to the accompanying drawings in which like reference numbers indicate like elements, FIG. 1 illustrates a tree stand assembly 11 comprised of a tree stand 10 and an adjustment device 12 . The tree stand 10 includes a platform 14 , a seat 16 , a first support member 18 , and a second support member 20 . In the depicted embodiment, the platform 14 and the seat 16 are parallel to one another. The support members 18 , 20 are connected by a first cross-member 22 and a second cross-member 24 .
[0030] In a first embodiment depicted in FIG. 1 , the adjusting device 12 is operatively connected to the first cross-member 22 . While in the depicted embodiment the adjusting device 12 is shown connected to the first cross-member 22 , those skilled in the art will understand that the adjusting device could also be attached to the second cross-member 24 or both of the cross-members 22 , 24 . The adjusting device 12 includes a V-shaped member 26 and adjustment fingers 28 . The V-shaped member has a top 26 a, sides 26 b, and a bottom (not shown). In the depicted embodiment, the adjustment fingers 28 are operatively connected to the top 26 a of the V-shaped member 26 ; however, the adjustment fingers 28 could also be attached to the sides 26 a or the bottom. The adjustment fingers 28 are extendable in length and are independently adjustable relative to one another. In the depicted embodiment, each of the adjustment fingers 28 includes a screw 28 a and a nut 28 b.
[0031] FIG. 2 illustrates a variation of the adjustment device 12 shown in the first embodiment. In the depicted embodiment of FIG. 2 , the first cross-member 22 includes first holes 30 . While in the depicted embodiment the holes 30 are shown connected to the first cross-member 22 , those skilled in the art will understand that the second cross-member 24 or both of the cross-members 22 , 24 could include holes. The adjustment fingers 28 are operatively connected to the first holes 30 . In the depicted embodiment, the adjustment fingers 28 and the first holes 30 are threaded and operatively engage one another. In an optional embodiment, each of the adjustment fingers 28 includes a handle 32 .
[0032] FIG. 3 a illustrates a third embodiment of the adjusting device 12 . In this third embodiment, the adjusting device 12 is operatively connected to the first support 18 and/or second support 20 rather than the cross-members 22 , 24 . The first support 18 includes an outer side 18 a (not shown) and an inner side 18 b opposite the outer side 18 a. The second support 20 includes an outer side 20 a and an inner side 20 b (not shown) opposite the outer side 20 a. The adjusting device 12 includes a first adjustment finger 34 operatively connected to the first support member 18 and a second adjustment finger 36 operatively connected to the second support member 20 . The first and second adjustment screws 34 , 36 are operatively connected to the inner sides 18 b, 20 b of the first and second supports 18 , 20 in the depicted embodiment of FIG. 3 a. In the depicted embodiment each of the first and second adjustment screws engage a nut 38 .
[0033] FIG. 3 b illustrates a variation of the third embodiment. FIG. 3 b depicts the first adjustment finger 34 and the second adjustment finger 36 . The first and second adjustment fingers 34 , 36 are operatively connected to the outer sides 18 a, 20 a of the first and second supports 18 , 20 in the embodiment depicted in FIG. 3 b. In the depicted embodiment each of the first and second adjustment fingers includes a tube 42 and a pin 44 . The tube 42 includes second holes 46 , and the pin 44 includes third holes 48 . A keeper 50 , such as a cotter pin, can be placed through the holes 46 , 48 when in alignment to fix the overall length of the first and second adjustment fingers 34 , 36 .
[0034] FIG. 3 c illustrates a variation of the embodiment shown in FIG. 3 b. In FIG. 3 c, the first and second adjustment fingers 34 , 36 have both a gross and a fine adjustment. As is the case of the embodiment shown in FIG. 3 b, the embodiment shown in FIG. 3 c includes the tube 42 and the pin 44 . The tube 42 and the pin 44 can be displaced relative to each other for gross adjustment of the first and second adjustment fingers 34 , 36 . The embodiment shown in FIG. 3 c further includes a fine adjustment device 52 . In the depicted embodiment of FIG. 3 c, the fine adjustment device 52 includes a threaded rod 54 , an adjustment nut 56 , and a jam nut 58 . The fine adjustment device 52 operatively connects to the pin 44 . In the depicted embodiment of FIG. 3 c, the pin 44 includes a fourth hole 60 which the threaded rod 54 engages.
[0035] FIG. 3 d illustrates a variation of the embodiment shown in FIG. 3 c. In FIG. 3 d, the first and second adjustment fingers 34 , 36 have both a gross and a fine adjustment. The first and second adjustment fingers 34 , 36 each include a sleeve 62 , depicted as a square tube, and an extensible member 63 . The extensible member 63 slides within the sleeve 62 . A locking mechanism 64 locks in place the extensible member 63 to hold it in a selectable position. In the embodiment depicted in FIG. 3 d, the locking mechanism 64 is a screw-type locking mechanism. The depicted embodiment includes a nut 64 a, a screw 64 b, and a handle 64 c. To use the locking mechanism 64 , a user turns the handle 64 c which turns the screw 64 b. The screw 64 b engages the extensible member 63 . Friction between the screw 64 b and the extensible member 63 prevents the extensible member 63 from moving.
[0036] The embodiment shown in FIG. 3 d further includes a fine adjustment device 65 . In the depicted embodiment of FIG. 3 d, the fine adjustment device 65 includes an adjustment screw 65 a and a jam nut 65 b. The fine adjustment device 65 operatively connects to the extensible member 63 . In the depicted embodiment of FIG. 3 d, the extensible member 63 includes an opening 63 a which the adjustment screw 65 a engages.
[0037] FIG. 3 e illustrates a variation of the embodiment shown in FIG. 3 d. In the embodiment depicted in FIG. 3 e the locking mechanism 64 is in the form of a toggle cam lock. The depicted locking mechanism includes a toggle cam mounting 64 d, a cam 64 e, and a toggle handle 64 f. The cam 64 e may be comprised of metal, plastic or resilient material. To use the locking mechanism 64 , a user rotates the toggle handle 64 f which rotates the cam 64 e. The cam 64 e frictionally engages the extensible member 63 through a slot (not shown) in the sleeve 62 thereby locking the extensible member 63 in place.
[0038] The locking mechanism 64 provides a device that quickly immobilizes or releases the extensible member 63 . While a screw-type lock and a cam lock have been shown, those skilled in the art will understand that numerous devices that can quickly immobilizes or releases the extensible member 63 .
[0039] FIG. 4 illustrates a perspective view of a universal adjustment device 200 . The universal adjustment device 200 is adapted to operatively connect to an existing tree stand (shown in phantom). In the embodiment depicted in FIG. 4 , the universal adjustment device 200 bolts onto the existing tree stand. The universal adjustment device 200 includes a first adjustment mechanism 210 and a second adjustment mechanism 212 . Each adjustment mechanism includes a sleeve 214 , an extensible member 216 , and a locking mechanism 218 . The extensible member 216 slides within the sleeve 214 and the locking mechanism 218 locks the extensible member 216 in place. In an optional embodiment, each adjustment mechanism also includes a fine adjustment device 220 . A connector 222 operatively connects the first and second adjustment mechanisms 210 , 212 . In the depicted embodiment, the connector 222 is in the shape of a flat plate, but other shapes, a beam for example, may be used. The connector 222 provides rigidity to the universal adjustment device 200 .
[0040] A mounting bracket 224 operatively connects the universal adjustment device 200 to the existing tree stand. In the depicted embodiment, the mounting bracket 224 has a U-shaped portion for receiving a cross-member of the existing tree stand. The U-shaped portion is formed by the combination of a top plate 226 , a spacer 228 , and a bottom plate 230 . The mounting bracket 224 is operatively connected to the sleeves 214 . In some embodiments, the mounting bracket 224 may also be operatively connected to the connector 222 .
[0041] The universal adjustment device 200 may be connected to the existing tree stand through the use of fasteners or by welding. In the depicted embodiment, the universal adjustment device 200 is bolted to the existing tree stand through the use of a screw 232 , lock washer 234 , and a nut 236 .
[0042] FIG. 5 illustrates a side view of the tree stand 10 in use. The user places the tree stand 10 against the tree 100 . The user loosens the locking mechanism 64 . In the embodiment depicted in FIG. 5 , the user loosens the locking mechanism 64 by turning the handle 64 a. The user then slides out the extensible member 63 and locks it in place with the locking mechanism 64 . In an optional step, the user may adjust the fine adjustment device 65 . The user adjusts the fine adjustment device 65 by loosening the jam nut 65 b and adjusting the adjustment screw 65 a until the adjustment screw 65 a touches the tree 100 . The user then tightens the jam nut 65 b to lock the adjustment screw 65 a in place.
[0043] FIG. 6 a illustrates a bottom 15 of the platform 14 . A measuring device 70 operatively connects to the bottom 15 . In the depicted embodiment, the measuring device is connected through the use of spring clamps 72 . The measuring device 70 is used to measure the “lean” of the tree so that a user (not shown) can adjust the tree stand before placement in the tree.
[0044] FIG. 6 b illustrates a detailed view of the measuring device 70 . The measuring device 70 includes a handle 74 , a support sleeve 76 , a level 78 , and a sliding member 80 . The sliding member 80 includes indicia 82 that indicate units of measurement. The support sleeve 76 is operatively connected to the handle 74 . The sliding member 80 slidably engages the support sleeve 76 . The level 78 is operatively connected to the support sleeve 76 .
[0045] A method of measuring tree “lean” for the purpose of adjusting the tree stand is shown in FIG. 6 c. In a first step, the user places the handle 74 against a tree 100 . The user adjusts the measuring device 70 until the level 78 indicates that the support sleeve 76 and the sliding member 80 are horizontal. The user extends the sliding member 80 until it touches the tree 100 . The user notes the indicia 82 and adjusts the adjustment device 12 . The adjustment device 12 is adjusted by either extending or retracting the adjustment fingers. In the embodiment depicted in FIG. 1 , the adjustment fingers are extended or retracted through rotation.
[0046] A method of assembling a tree stand is also provided. The method comprises the steps of: providing a platform; operatively connecting a first support member to said platform; operatively connecting a second support member to said platform and spaced apart from said first support member; interconnecting said first support member and said second support member with at least one cross-member; and connecting an adjustment device to said at least one cross-member, said adjustment device having at least two adjustment fingers for engagement with the tree, and said at least two adjustment fingers being adjustable relative to one another. Optionally, the method may include the step of connecting at least one fine adjustment device to at least one of said at least two adjustment fingers
[0047] In view of the foregoing, it will be seen that the several advantages of the invention are achieved and attained.
[0048] The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
[0049] As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, the adjustment device may be connected to the supports or to the cross-members. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.
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An apparatus and method for hunting in leaning and non-leaning trees is disclosed. The apparatus includes an adjustable tree stand having top and/or bottom adjustment. Adjustment is provided through the use of an adjustment device attached to a support or a cross-member. The apparatus also includes a measuring device for use in measuring tree “lean.” The measuring device connects to the bottom of the tree stand. The method includes making a gross adjustment of the tree stand based upon measurement of tree lean using the measuring device.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a sealed contact device, and more particularly to an electromagnetic relay for power loads which can promptly extinguish an arc which occurs.
2. Related Art
In the related art, as an arc extinguisher used in a sealed contact device, for example, Japanese Unexamined Patent Publication No. 2005-285547 discloses a device which extinguishes an arc occurring between a movable contact piece and a fixed contact piece when a contact of the fixed contact piece is separated from a contact of the movable contact piece by narrowing the arc between right and left sidewalls of an arc barrier.
However, the above-mentioned arc extinguisher, as illustrated in FIG. 1 of the prior art, has had a problem that an arc can be extinguished when the arc between contacts reaches an arc barrier 5 , but the arc cannot be promptly and certainly extinguished when the arc does not reach the arc barrier.
The present invention has been made in view of the above-mentioned problem of the related art, and an object of the present invention is to provide a sealed contact device which can attract an arc if and when it occurs to extinguish the arc promptly and certainly.
SUMMARY
In order to solve the above-mentioned problem, in accordance with one aspect of the invention, there is provided a sealed contact device including
a housing, a fixed contact and a movable contact disposed in the housing in such a manner as to face each other, and permanent magnets which are disposed with the fixed contact and the movable contact interposed therebetween and which attracts an arc between the fixed contact and the movable contact using a magnetic force, wherein
an arc shielding member is disposed at a position to which the arc is attracted by current flowing between the fixed contact and the movable contact and by the magnetic force of the permanent magnets, in the housing.
According to the present invention, even though the arc occurs in an arbitrary direction, the arc is attracted in a desired direction by the current and the magnetic force so that the arc may reach the arc shielding member, resulting in the arc being extinguished.
As an embodiment of the present invention, the arc shielding member may have at least one arc receiving piece. This configuration allows an increase in surface area of the arc shielding member. This also allows the arc to easily hit the arc shielding member, thereby increasing the performance of the mechanism utilized to extinguish the arc.
As another embodiment of the present invention, the arc shielding member may be disposed at both sides of the contacts and formed along opposed surfaces of the permanent magnets. The opposed surfaces are arranged so that the magnetic field flows from one magnet to another. This configuration enables the arc to hit the arc shielding member disposed on either one of the contacts so that the arc may be extinguished even though a direction of the arc changes.
As a further embodiment of the present invention, the arc shielding member may be formed to have an approximately cross-sectional U shape and may be disposed in the housing. By forming the arc shielding member to have the sectional U shape, the arc shielding member can be relatively easily gripped and the mounting workability of mounting the arc shielding member to a sealed space improves as compared with a plate-like arc shielding member.
A cross-sectional U-shaped base portion of the arc shielding member may be placed on the bottom in the housing. This configuration can secure a mountability of the arc shielding member to the housing, without interfering with movements of the fixed contact and the movable contact.
As a yet further embodiment of the present invention, the arc shielding member may be made of a metal. This configuration allows the arc which has hit the arc shielding member to be cooled, so that an ability of extinguishing the arc can be enhanced.
As a yet further embodiments of the present invention, the arc shielding member may include a plate-like connector and arms which are formed to perpendicularly bend from both ends of the connector, respectively, in which the at least any one of the connector and the arms may be provided with at least one arc receiving piece.
As a yet further embodiment of the present invention, the arc shielding member may have at least one arc receiving piece obtained by bending an edge portion of the connector.
As a yet further embodiment of the present invention, the at least one arc receiving piece may be provided by bending an edge portion of the arm, and an inside surface of the arm may be provided with a protrusion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a whole perspective view illustrating an embodiment of a sealed contact device according to the present invention;
FIG. 2 is an exploded perspective view of the sealed contact device illustrated in FIG. 1 ;
FIGS. 3A and 3B are a side sectional view and a front sectional view before the sealed contact device illustrated in FIG. 1 operates;
FIGS. 4A and 4B are a perspective view and a sectional view of an arc shielding member of a first embodiment according to the present invention;
FIGS. 5A and 5B are a perspective view and a side elevation view of an arc shielding member of a second embodiment according to the present invention;
FIGS. 6A and 6B are a perspective view and a side elevation view of an arc shielding member of a third embodiment according to the present invention;
FIGS. 7A and 7B are a perspective view and a side elevation view of an arc shielding member of a fourth embodiment according to the present invention;
FIGS. 8A and 8B are a perspective view and a side elevation view of an arc shielding member of a fifth embodiment according to the present invention;
FIGS. 9A and 9B are a perspective view and a side elevation view of an arc shielding member of a sixth embodiment according to the present invention;
FIGS. 10A and 10B are a perspective view and a side elevation view of an arc shielding member of a seventh embodiment according to the present invention;
FIGS. 11A and 11B are a perspective view and a side elevation view of an arc shielding member of an eighth embodiment according to the present invention;
FIG. 12 is a graph which illustrates resistance of a sealed contact device according to the number of interceptions between contacts in a case where there is an arc shielding member and a case where there is no arc shielding member.
DETAILED DESCRIPTION
An embodiment in which a sealed contact device according to the present embodiment is applied to a sealed electromagnetic relay is described with reference to FIGS. 1 through 12 of the accompanying drawings.
As illustrated in FIG. 2 , the sealed electromagnetic relay according to the present embodiment is configured by disposing a contact mechanism part 30 and an electromagnet part 50 which drives the contact mechanism part 30 from the outside of a sealed space 43 shown in FIG. 3A in a housing which is formed by attaching a cover 20 to a case 10 . The contact mechanism part 30 is incorporated in the sealed space 43 formed by a ceramic plate 31 , a metallic cylindrical flange 32 , a plate-like first yoke 37 and, and a closed end barrel 41 .
The case 10 is an approximately box-shaped resin-molding article, and has a mounting hole 11 provided in a hornlike portion disposed in a lower corner of an outer surface. The case 10 further has a bulging portion 12 in the corner of a side surface for pulling out a lead (not shown in the drawing) and latching holes 13 in opposed side surfaces and at an edge portion of an opening.
The cover 20 has a plane shape which can cover an opening of the case 10 , and is provided with terminal holes 22 and 22 at both sides of a partition wall 21 formed to protrude in the center of the upper surface thereof. The cover 20 is provided with a projection 23 , on one side surface of one side thereof, which can prevent so-called flapping of the lead (not shown) by being inserted in the bulging portion 12 of the case 10 . The cover 20 is provided with latching claws 24 at an edge portion of the opening and in the opposite side surface, and the latching claws 24 can be latched in the latching holes 13 of the case 10 .
The contact mechanism part 30 is disposed in the sealed space 43 (refer to FIG. 3A ) formed by the ceramic plate 31 , the metallic cylindrical flange 32 , the plate-like first yoke 37 , and the closed end barrel 41 as described above. The contact mechanism part 30 includes a magnet holder 35 , a fixed iron core 38 , a movable iron core 42 , a movable shaft 45 , and a movable contact piece 48 .
The ceramic plate 31 has a plane shape so that the ceramic plate 31 may be brazed to an edge portion of an upper opening of the metallic cylindrical flange 32 described below, is provided with a pair of terminal holes 31 a , and is used in combination with an auxiliary plate 31 c . The ceramic plate 31 has a metal layer (not shown) at each of an outer periphery portion of the upper surface thereof and opening edge portions of the terminal holes 31 a . As illustrated in FIG. 3B , fixed contact terminals 33 which have fixed contacts 33 a firmly attached to the bottoms, respectively are brazed to the edges of the terminal holes 31 a of the ceramic plate 31 .
The metallic cylindrical flange 32 brazed to the outer periphery portion of the upper surface of the ceramic plate 31 has an approximately cylindrical shape as illustrated in FIG. 2 and is formed by press-processing a metallic plate. An outer periphery portion of a lower portion of the metallic cylindrical flange 32 is integrally combined with the plate-like first yoke 37 by welding.
The magnet holder 35 accommodated in the metallic cylindrical flange 32 is formed of a heat-resistant insulating member having a box shape, and is provided with pocket grooves 35 a which can retain the permanent magnets 36 therein, respectively and which are in both external side surfaces opposite to each other. The magnet holder 35 is provided with an annular cradle 35 c (refer to FIG. 3B ) in a lower deck in the center of the bottom surface, and a cylindrical insulating portion 35 b which protrudes downward from the lower surface of the center of the annular cradle 35 c . Even though an arc occurs and a voltage in a path between the metallic cylindrical flange 32 , and the plate-like first yoke 37 and the fixed iron core 38 is increased to a high voltage, because the cylindrical insulating portion 35 b electrically insulates the cylindrical fixed iron core 38 and the movable shaft 45 from each other, both of them can be prevented from being integrally welded. Positioning plates 26 disposed in such a manner as to face each other in the magnet holder 35 are disposed so as to be brought into contact with the movable contact piece 48 , and positions the movable contact piece 48 by preventing rotation of the movable contact piece 48 . A rubber plate 27 is disposed between the magnet holder 35 and the first yoke 37 to buffer the shock which arises between the magnet holder 35 and an annular jaw 45 a when the fixed contact 33 a and the movable contact 48 a are separated from each other.
In addition, an arc shielding member 61 according to a first embodiment of the present invention is arranged inside of the magnet holder 35 . The arc shielding member 61 is made of, for example, a metal such as Stainless steel, and has an approximately sectional U shape as illustrated in FIGS. 4A and 4B .
That is, the arc shielding member 61 includes a plate-like connector 62 and arms 63 formed by bending upward both ends of the connector 62 . Opposed edge portions of the connector 62 are provided with tongue-shaped pieces (arc receiving pieces) 64 , respectively which are bent upward to stand upright. Each of the arms 63 includes an upper rib (arc receiving piece) 65 which bends inward from an upper end, a pair of side edge ribs (arc receiving pieces) 66 which bends inward from opposed side edges, and draining board-like protrusions (arc receiving pieces) 67 which protrude inward from the inside surface.
In addition, in the arc shielding member 61 , the connector 62 is placed on a bottom wall of the magnet holder 35 , and the arms 63 are fixed to opposed side walls of the magnet holder 35 .
As illustrated in FIG. 2 , the plate-like first yoke 37 has a plane shape which may be fitted into the edge portion of the opening of the case 10 , an elastic plate 37 a fixed to an upper surface thereof, and a caulking hole 37 b in the center thereof. An upper end of the cylindrical fixed iron core 38 is fixed to the caulking hole 37 b of the plate-like first yoke 37 in a caulking manner, and the plate-like first yoke 37 is fitted into the lower opening of the metallic cylindrical flange 32 and is integrally combined with the metallic cylindrical flange 32 by welding performed from the outside.
The movable shaft 45 with an annular flange 45 a is slidably inserted in a through-hole of the cylindrical fixed iron core 38 via the cylindrical insulating portion 35 b of the magnet holder 35 . The movable shaft 45 is fixed by inserting a release spring 39 and welding the movable iron core 42 to the bottom of the release spring 39 .
As for the closed end barrel 41 in which the movable iron core 42 is accommodated, the edge portion of the opening is hermetically joined with a lower edge portion of the caulking hole 37 b provided in the plate-like first yoke 37 . Next, inside air is suctioned from a degassing pipe 34 so that the inside space is sealed to form a sealed space 43 .
As illustrated in FIG. 3B , a dish-like receiving tool 46 is latched by the annular flange 45 a provided in the middle portion of the movable shaft 45 so that the inserted contact spring 47 and the movable contact piece 48 may be prevented from falling apart, and a stopper ring 49 is fixed to an upper end portion of the movable shaft 45 . The movable contacts 48 a provided at both ends of the upper surface of the movable contact piece 48 are disposed to face with each other and to be able to move to and from the fixed contacts 33 a of the contact terminal 33 disposed in the metallic cylindrical flange 32 .
As illustrated in FIG. 2 , in the electromagnet part 50 , coil terminals 53 and 54 are press-fitted and fixed to a flange 52 a of a spool 52 around which a coil 51 is wound, and the coil 51 and the lead (not shown) are connected to each other via the coil terminals 53 and 54 . The closed end barrel 41 is inserted in the through-hole 52 b of the spool 52 and is fitted into a fitting hole 56 a of a second yoke 56 . Subsequently, upper ends of both side portions 57 and 57 of the second yoke 56 engage with both end portions of the plate-like first yoke 37 , respectively and then fixed to each other by a method such as caulking, press-fitting, and welding, so that the electromagnet part 50 and contact mechanism part 30 are integrally combined.
Next, operation of the sealed magnetic relay having the above-described structure will be described.
First, as illustrated in FIGS. 3A and 3B , when a voltage is not applied to the coil 51 , the movable iron core 42 is biased to a lower side by the spring force of the release spring 39 , the movable shaft 45 is pushed down, and the movable contact piece 48 is pulled down. At this time, although the annular flange 45 a of the movable shaft 45 engages with the annular cradle 35 c of the magnet holder 35 and the movable contact 48 a is separated from the fixed contact 33 a , the movable iron core 42 is not in contact with the bottom surface of the closed end barrel 41 .
Subsequently, when a voltage is applied to the coil 51 so that the coil 51 is magnetized, the movable iron core 42 is attracted by the fixed iron core 38 and the movable shaft 45 will slide up against the spring force of the release spring 39 . Even after the movable contact 48 a is brought into contact with the fixed contact 33 a , the movable shaft 45 is pushed up against the spring force of the release spring 39 and the contact spring 47 , the upper end of the movable shaft 45 projects from a shaft hole 48 b of the movable touch piece 48 , and the movable iron core 42 is attracted and attached to the fixed iron core 38 .
Next, when the application of the voltage to the coil 51 is stopped and the magnetization is resolved, the movable iron core 42 will separate from the fixed iron core 38 due to the spring force of the contact spring 47 and the release spring 39 . For this reason, after the movable shaft 45 slides down to the lower side and the movable contact 48 a separates from the fixed contact 33 a , the annular flange 45 a of the movable shaft 45 engages with the annular cradle 35 c of the magnet holder 35 , and thus returns to the original state.
At this time, an arc may occur between the fixed contact 33 a of a high voltage and the movable contact 48 a . In FIG. 3B , the arc is attracted and induced in a direction orthogonal to the orientation of arms 63 of arc shield member 61 by the current which flows between the fixed contact 33 a and the movable contact 48 a , and the magnetic force which is horizontally generated between the opposed permanent magnets 36 . The arms 63 of the arc shielding member 61 are installed in the direction in which the arc is attracted. For this reason, even though the arc is generated in an arbitrary direction, the arc is first induced in a desired direction by the current which flows between the fixed contact 33 a and the movable contact 48 a and the magnetic force which is generated horizontally between the opposed permanent magnets 36 , and is allowed to hit the arc shielding member 61 , so that the arc is extinguished.
Especially, because the arc shielding member 61 has a plurality of protrusions 67 , the surface area of the inside surface of the arc shielding member 61 is increased. Because of this, the arc can be promptly cooled, and thus the arc can be efficiently extinguished.
In addition, the arc shielding member 61 is formed to have an approximately sectional U shape, and the connector (base portion) 62 in the sealed space 43 (magnet holder 35 ) is placed on the bottom surface in the magnet holder 35 . For this reason, compared with the case of using a simple plate-like arc shielding member, the arc shielding member 61 can be gripped easily so that a mounting workability to the sealed space 43 (magnet holder 35 ) may improve. In addition, the mountability of the arc shielding member 61 into the sealed space 43 can be secured without interfering with movements of the fixed contact 33 a and the movable contact 48 a.
The arms 63 of the arc shielding member 61 are disposed at both sides of the fixed contact 33 a and the movable contact 48 a and disposed along the opposed surfaces of the permanent magnets 36 . For this reason, even though the directions of the current and/or the magnetic flux change and thus the direction in which an arc occurs changes, the arc can hit either one of the arms 63 and be extinguished.
In addition, because the arc shielding member 61 is made of a metal, the arc which hits the arc shielding member 61 can be efficiently cooled, and the capability of extinguishing the arc can be enhanced.
Other embodiments of the arc shielding member which can be used with the sealed contact device described herein are described below with reference to FIGS. 5A-B to 11 A-B.
Second Embodiment
An arc shielding member 71 according to a second embodiment of the present invention is illustrated in FIGS. 5A and 5B .
Although the arms 63 of the arc shielding member 61 according to the first embodiment are provided with the protrusions 67 , the configuration is not limited thereto. Arms 72 of a simple plate shape may be adopted like the arc shielding member 71 according to the second embodiment. With this configuration, it is possible to certainly prevent the arc from passing by the arms 72 . Because other portion are the same as those of the first embodiment, like portions are denoted by like reference signs and detailed description thereof is not given.
Third Embodiment
An arc shielding member 73 according to a third embodiment of the present invention is illustrated in FIGS. 6A and 6B .
Although the arms 63 of the arc shielding member 61 according to the first embodiment are provided with the protrusions 67 , the configuration is not limited thereto. For example, like arms 74 of the arc shielding member 73 according to the third embodiment, protruding pieces (arc receiving pieces) 77 protruding inward from an upper edge and a lower edge of an opening 76 which are provided side by side in a folded plate 75 may be formed by cutting out. Thereby, the arc shielding member 73 with a high yield of material is obtained. Because other portion are the same as those of the first embodiment, like portions are denoted by like reference signs and detailed description thereof is not given.
Fourth Embodiment
An arc shielding member 80 according to a fourth embodiment of the present invention is illustrated in FIGS. 7A and 7B .
Although the arms 63 of the arc shielding member 61 according to the first embodiment are provided with the side edge ribs 66 , the configuration is not limited thereto. For example, like arms 81 of the arc shielding member 80 according to the fourth embodiment, there may be provided a plurality of flexing portions (arc receiving portions) 83 each of which is bent inward from both opposed side edges of a folded plate 82 , and each of which extends along the inside surface of the folded plate 82 . This configuration allows an increase in surface area of the arms 81 so that the arms can be easily hit by the arc, and certainly prevents the arc from passing to the back side. Because other portion are the same as those of the first embodiment, like portions are denoted by like reference signs and detailed description thereof is not given.
Fifth Embodiment
An arc shielding member 85 according to a fifth embodiment of the present invention is illustrated in FIGS. 8A and 8B .
Arms 86 of the arc shielding member 85 according to the fifth embodiment further include linear reinforcement pieces 87 , which connect flexing portions 83 and 83 to each other, at end portions of the flexing portions 83 and 83 of the fourth embodiment, respectively. This configuration increases the strength of the flexing portions 83 and improves the bending accuracy. Because other portion are the same as those of the first embodiment, like portions are denoted by like reference signs and detailed description thereof is not given.
Sixth Embodiment
An arc shielding member 90 according to a sixth embodiment of the present invention is illustrated in FIGS. 9A and 9B .
Each arm 91 of an arc shielding member 90 according to the sixth embodiment is provided with a rectangular extension plate (arc receiving piece) 93 and a covering plate (arc receiving piece) 94 . The extension plate 93 extends to broaden outward from one side edge of a folded plate 92 . The covering plate 94 broadens outward from the other side edge of the folded plate 92 , extends toward the extension plate 93 , and extends along the folded plate 92 . This configuration allows an increase in the width of the arms 91 so that the arc can be more certainly extinguished. The covering plate 94 is provided with a plurality of openings 95 so that the surface area may be increased. Because other portion are the same as those of the first embodiment, like portions are denoted by like reference signs and detailed description thereof is not given.
Seventh Embodiment
An arc shielding member 97 according to a seventh embodiment of the present invention is illustrated in FIGS. 10A and 10B .
Each arm 98 of the arc shielding member 97 according to the seventh embodiment is provided with an extension portion (arc receiving piece) 103 including a first narrow rib 100 which extends to broaden outward from one side edge of a folded plate 99 , a second rib 101 which extends and bends outward from an end of the first rib 100 , and a third rib 102 which bends to the back side from an end of the second rib 101 and extends toward the folded plate 99 . Because the extension portion 103 is brought close to the fixed contact 33 a and the movable contact 48 a , an arc which spreads sideways can be easily trapped. Because other portion are the same as those of the first embodiment, like portions are denoted by like reference signs and detailed description thereof is not given.
Eighth Embodiment
An arc shielding member 105 according to an eighth embodiment of the present invention is illustrated in FIGS. 11A and 11B .
As for an each arm 106 of the arc shielding member 105 according to the eighth embodiment, a plate-like covering plate 108 which extends from an upper end of a folded plate 107 is bent inward, and then bent downward to extend along the folded plate 107 , and both side edge portions of a distal end thereof are latched to a lower end of a side edge rib 66 . For this reason, an arc can be prevented from passing to the back side of the arm 106 . In addition, the covering plate 108 is provided with a plurality of openings 109 so that the surface area may be increased. Because other portion are the same as those of the first embodiment, like portions are denoted by like reference signs and detailed description thereof is not given.
Example
Inventors of the present application conducted experiments on durability of a sealed contact device which uses the arc shielding member 61 of the present invention. Specifically, an experiment was repeatedly performed which cancels (interrupts) the application of the voltage to the coil 51 in a state in which the current of 500 A is supplied between the fixed contacts 33 a and 33 a and the movable contacts 48 a and 48 a at a direct current voltage of 400V so that the fixed contacts 33 a and 33 a and the movable contacts 48 a and 48 a may separate from each other. At this time, as illustrated in FIG. 12 , in the sealed contact device with the arc shielding member 61 , as illustrated by a solid line, even though the experiment was repeated 20 times, it turned out that degradation of the fixed contact 33 a and the movable contact 48 a attributable to an arc was inhibited, and an abrupt decrease in an insulation resistance value of the sealed contact device was prevented. On the other hand, in the sealed contact device without the arc shielding member 61 , as illustrated by a dotted line, when the experiment was repeated 5 times, it turned out that the fixed contact 33 a and the movable contact 48 a were degraded due to an arc which occurred, and the insulation resistance value of the sealed contact device abruptly decreased.
The inventors of the present application measured duration of the arc which occurred when the fixed contact 33 a and the movable contact 48 a are separated. As compared with the sealed contact device without the arc shielding member 61 , the duration of the arc is shortened by 12.5% in the sealed contact device with the arc shielding member 61 .
As for the sealed contact device according the present invention, it is needless to say that it may apply not only to the above-mentioned sealed electromagnetic relay but to other electromagnetic switches.
There has thus been shown and described a sealed contact device which fulfills all the objects and advantages sought therefore. 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.
Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.
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The invention provides a sealed contact device capable of extinguishing an arc which extends in an arbitrary direction. The sealed contact device includes a housing; a fixed contact and a movable contact disposed in the housing in such a manner as to face each other; and permanent magnets which are disposed with the fixed contact and the movable contact interposed therebetween and which attracts an arc between the fixed contact and the movable contact using a magnetic force. An arc shielding member is disposed at a position to which the arc is attracted by current flowing between the fixed contact and the movable contact and by the magnetic force between the permanent magnets, in the housing.
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TECHNICAL FIELD
[0001] The present invention relates to a helical broach.
BACKGROUND ART
[0002] As a working method of cutting an internal gear which is a typo of gear, there is broaching in which a broach is used as a cutting tool in which blades are arranged in a saw shape (for example, PTL 1). This is internal work performed on a workpiece by installing, in a broaching machine as a working machine dedicated to broaching, a broach and the workplace as a piece to be cut, and pulling the broach with respect to the workpiece or pulling the workplace with respect to the fixed broach.
[0003] A broach is a bar-shaped bladed material in which a large number of cutting blades are arranged to be formed in a saw shape, and the cutting blades of the broach are arranged in dimensional order such that the height and the blade width of the blades gradually increase from one end side (the leading end of the cutting direction) toward the other end side (the trailing end of the cutting direction). One of the features of the broach is that various working processes can be combined, in a single cutting tool. For example, in a case where a broach having a roughing section for roughing of the workplace and a finishing section for finishing of the workpiece is used, in the broaching machine, roughing and finishing are completed only by pulling the broach with respect to the workpiece once such that the workpiece can be forced to an internal gear.
[0004] Since broaching is performed by only pulling the workpiece or the broach once, working speed from roughing to finishing of the workpiece is faster than that of other internal work. In addition, the finished dimensions of the workpiece by broaching become substantially the same as those of the final blades (finishing blades at the rearmost end of the cutting direction) of the broach used for working, and thus cutting work can be performed with high accuracy and the repetition accuracy of the cutting work is high.
[0005] As a type of broach, there is a helical broach. This is for cutting a workplace to a helical internal gear in which the tooth lead of the internal gear is inclined with respect to the axis of the gear. The helical broach and the workplace are installed on a broaching machine and the helical broach is pulled with respect to the workplace while being rotated, thereby forming the workplace to the helical internal gear.
[0006] An example of an existing helical broach is illustrated in FIG. 4 , and a method of finishing a workplace in the existing helical broach is illustrated in FIG. 5 .
[0007] As illustrated in FIG. 4 , a helical broach 101 includes a roughing section 103 and a finishing section 104 , and roughing blades (not illustrated) in the roughing section 103 and finishing blades 150 ( FIG. 5 ) in the finishing section 104 are arranged to be inclined with respect to the axial direction of the helical broach 101 .
[0008] In the roughing blades (not illustrated) in the roughing section 103 and the finishing blades 150 in the finishing section 104 , a gear tooth helix angle α is set along the tooth lead direction of the helical internal gear to be formed. In order to enhance the working accuracy and the like, in the finishing blades 150 in the finishing section 104 , a blade groove helix angle β may further be set.
[0009] In addition, the blade groove helix angle β is set to a direction that is not perpendicular to the direction of the gear tooth helix angle α in order to enhance the working accuracy and the like. Therefore, as illustrated in FIG. 5 , one end portion 151 (upper left portion in FIG. 5 ) in the finishing blade 150 has an acute angle, and the other end portion 152 (lower left portion in FIG. 5 ) has an obtuse angle.
[0010] In addition, in order to enhance the working accuracy and the like, in the finishing section 104 of che helical broach 101 , a single finishing blade 150 is set to abut and cut only one of tooth surfaces including a left tooth surface 170 in a work-piece W (one tooth surface along the tooth lead of the workpiece W) and a right tooth surface 180 (the other tooth surface along che cooth lead of the workpiece W). That is, the finishing blades 150 in the finishing section 104 of the helical broach 101 are formed to be divided into left tooth surface finishing blades 150 a which cut only the left tooth surfaces 170 in the workplace W and right tooth surface finishing blades 150 b which cut only the right tooth surfaces 180 in the workpiece W.
[0011] Therefore, the left tooth surface finishing blade 150 a performs cutting by allowing an acute angle portion 151 to abut the left tooth surface 170 in the workpiece W, and the right tooth surface finishing blade 150 b performs cutting by allowing an obtuse angle portion 152 to abut the right tooth surface 180 in the workpiece W.
CITATION LIST
Patent Literature
[0012] [PTL 1] Japanese Patent Application Publication No. 2009-220261
SUMMARY OF INVENTION
Technical Problem
[0013] However, in a case where the tooth surface (the right tooth surface 180 in FIG. 5 ) of the workpiece W is cut by the obtuse angle portion 152 , the surface roughness of the cut surface is increased compared to a case where the tooth surface (the left tooth surface 170 in FIG. 5 ) of the workpiece W is cut by the acute angle portion 151 . Therefore, a cutting amount d 2 (the amount of the tooth surface of the workpiece W being cut by each blade) with which the obtuse angle portion 152 performs cutting has to be set to be smaller than a cutting amount d 1 with which the acute angle 151 perforins cutting. Accordingly, in order to cut equal amounts of the left tooth surface 170 and the right tooth surface 180 of the workpiece W, the number of blades of the obtuse angle portion 152 needs to be greater than the number of blades of the acute angle portion 151 . This results in an increase in the axial length of the finishing section 104 , that is, a shell 120 , and thus causes an increase in the size of the tool and the working machine and an increase in the manufacturing cost.
[0014] The present invention has been made by taking the foregoing problems into consideration, and an object thereof is to reduce the axial length of a finishing section by allowing no difference in the cutting accuracy between a right tooth surface and a left tooth surface of a workpiece which is a piece to be cut, during broaching by a helical broach.
Solution to Problem
[0015] A helical broach according to a first invention to solve the problems is a helical broach including: a cylindrical shell in which finishing blades having a predetermined gear tooth helix angle are formed on an outer peripheral side, in which the shell includes a first shell and a second shell which are divided in an axial direction, a first finishing blade having the gear tooth helix angle and a first blade groove helix angle is formed in the first shell, and a second finishing blade having the gear tooth helix angle and a second blade groove helix angle which is different from the first blade groove helix angle is formed in the second shell.
[0016] A helical broach according to a second invention to solve the problems is the helical broach according to the first invention, in which the first finishing blade cuts one tooth surface along a tooth lead in a piece to be cut, and the second finishing blade cuts the other tooth surface along the tooth lead in the piece to be cut.
[0017] A helical broach according to a third invention to solve the problems is the helical broach according to the first or second invention, in which both of a rake angle of the first finishing blade and a rake angle of the second finishing blade are an acute angle.
Advantageous Effects of Invention
[0018] According to the helical broach according to the first invention, since the shell has the structure divided into the first shell and the second shell, the finishing blades having different gear tooth helix angles can be formed in the single helical broach. For example, the first finishing blade in the first shell has an appropriate shape to cut one surface in the piece to be cut, and the second finishing blade in the second shell has an appropriate shape to cut the other surface in the piece to be cut stxch that the finishing blades that match the surfaces of the piece to be cut can be formed.
[0019] According to the helical broach according to the second invention, since the first finishing blade in the first shell cuts one surface in the piece to be cut and the second finishing blade in the second shell cuts the other surface in the piece to foe cut, the finishing blades that toatch the surfaces of the piece to be cut can be formed. For example, the finishing blades having an appropriate acute angle for the cutting perform cutting while abutting a right tooth surface and a left tooth surface of the piece to be cut, and thus the working accuracy and the surface roughness of the cut surface of the piece to be cut can be enhanced.
[0020] According to the helical broach according to the third invention, since the right tooth surface and the left tooth surface of the piece to be cut are cut by the finishing blades having an appropriate acute angle for the cutting, the working accuracy and the surface roughness of the cut surface of the piece to be cut can be enhanced. In addition, the tooth surfaces of the piece to be cut are not cut by finishing blades having an obtuse angle which is not appropriate for the cutting. Accordingly, there is no need to reduce cutting amounts unlike the related art and the cutting amounts of the finishing blades can be set to be sufficiently large. Therefore, the axial lengths of the shell in which the first shell and the second shell are assembled, and the finishing section can be reduced, and thus the tool and the working machine can also be reduced in size, thereby reducing the manufacturing cost.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a side view illustrating a helical broach according to Embodiment 1.
[0022] FIG. 2 is a side view and a longitudinal sectional view illustrating shells of the helical broach of Embodiment 1.
[0023] FIG. 3 is an explanatory view illustrating finishing by the helical broach according to Embodiment 1.
[0024] FIG. 4 is a side view illustrating an example of an existing helical broach.
[0025] FIG. 5 is an explanatory view illustrating an example of finishing by the existing helical broach.
DESCRIPTION OF EMBODIMENTS
[0026] Hereinafter, an embodiment of a helical broach according to the present invention will be described in detail with reference to the accompanying drawings. As a matter of course, the present invention is not limited to the following embodiment, and it is natural that various modifications can be made without departing from the spirit of the present invention.
Embodiment 1
[0027] First, the structure of the helical broach according to Embodiment 1 of the present invention will be described with reference to FIGS. 1 to 3 .
[0028] A helical broach 1 according to this embodiment is a cutting tool for forming a substantially cylindrical workpiece W which is a piece to be cut, to a helical internal gear having a gear tooth helix angle α. As illustrated in FIG. 1 , the helical broach 1 includes a shank section 2 to be installed in a broaching machine (not illustrated), a roughing section 3 for roughing of the workpiece W, and a finishing section 4 for finishing of the rough-worked workpiece W and is formed by assembling a first shell 20 and a second shell 30 included in the finishing section 4 to a broach body 10 having the shank section 2 and the roughing section 3 .
[0029] The roughing section 3 is formed integrally with the broach body 10 such that roughing blades having a gear tooth helix angle α protrude toward the outer peripheral side of the helical broach 1 in a radial direction. In addition, in order to form teeth having predetermined dimensions in the workplace W, the roughing blades are arranged such that the height of the blades gradually increases from the leading end of the cutting direction toward the trailing end of the cutting direction.
[0030] Each of the first shell 20 and the second shell 30 in the finishing section 4 forms a substantially cylindrical shape. As illustrated in FIG. 2 , the first shell 20 and the second shell 30 are arranged in an axial direction of the helical broach 1 , are engaged with a shell engagement portion 11 of the broach body in, and are assembled such that the first shell 20 abuts a shell abutsing surface 12 of the broach body 10 and the second shell 30 is pressed toward the leading end (the left side in FIG. 2 ) of the cutting direction by a fastener 40 together with the first shell 20 . In addition, the fastener 40 is fixed to the broach body 10 by a bolt (not illustrated) or the like.
[0031] In order to relatively align the phases in a peripheral direction (around the axis of the helical broach 1 ) of the broach body 10 and the first and second shells 20 and 30 in the helical broach 1 , a positioning protrusion 13 is provided in the shell abutting surface 12 , a positioning groove 21 is provided in one end (the left end in FIG. 2 ) of the first shell 20 , a positioning protrusion 22 is provided in the other end (the right end in FIG. 2 ) of the first shell 20 , and a positioning groove 31 is provided in one end (the left end in FIG. 2 ) of the second shell 30 .
[0032] The first shell 20 and the second shell 30 are assembled to the broach body 10 in a state in which positioning protrusion 13 of the shell abutting surface 12 and the positioning groove 21 of the first shell 20 are fitted to each other and the positioning protrusion 22 of the first shell 20 and the positioning groove 31 of the second shell 30 are fitted to each other, that is, in a state in which the phases are relatively aligned with each other.
[0033] In this embodiment, since the finishing section 4 has a structure divided into the first shell 20 and the second shell 30 , the first shell 20 and the second shell 30 included in the finishing section 4 may be formed with different finishing blades 50 and 60 ( FIG. 3 ).
[0034] As illustrated in FIG. 3 , in this embodiment, in the finishing blades 50 of the first shell 20 , a cutting amount d 1 is set to cut only the left tooth surface 70 (one tooth surface along the tooth lead of the workpiece W) in the workpiece W, and a blade groove helix angle β 1 is set with respect to a direction perpendicular to the axis of the first shell 20 so as to allow a rake angle θ 1 with which the left tooth surface 70 in the workpiece W is cut to be an acute angle. In the finishing blades 60 of the second shell 30 , a cutting amount d 2 is set to cut only a right tooth surface 80 (the other tooth surface along the tooth lead of the workpiece W) in the workpiece W, and a blade groove helix angle β 2 is set with respect to a direction perpendicular to the axis of the second shell 30 so as to allow a rake angle θ 2 with which the right tooth surface 80 in the workpiece W is cut, to be an acute angle.
[0035] That is, in this embodiment, the first shell 20 is a shell for the left tooth surface, in which the finishing blades 50 that cut only the left tooth surface 70 in the workpiece W at the rake angle θ 1 which is an acute angle are provided, and the second shell 30 is a shell for the tight tooth surface, in which the finishing blades 60 that cut only the right tooth surface 80 in the workpiece W at the rake angle θ 2 which is an acute angle are provided.
[0036] In order to form each of the left tooth surface 70 and the right tooth surface 80 in the workpiece W to predetermined dimensions, the finishing blades 50 in the first shell 20 and the finishing blades 60 in the second shell 30 are formed to be arranged such that the width of the blades gradually increases from the leading end of the cutting direction toward the trailing end of the cutting direction.
[0037] In general, in the working blades of a cutting tool, a cutting portion having an acute angle has a higher cutting ability than that of those having an obtuse angle and enables cutting with good surface roughness for cut surfaces.
[0038] Therefore, in this embodiment, the blade groove helix angle β 1 is set to allow the rake angle θ 1 with which the finishing blades 50 in the first shell 20 cut the left tooth surface 70 in the workplace W to be an acute angle, and the blade groove helix angle β 2 is set to allow the rake angle θ 2 with which the finishing blades 60 in the second shell 30 cut the right tooth surface 80 in the workplace W to be an acute angle.
[0039] The finishing blades 50 in the first shell 20 abut the left tooth surface 70 in the workpiece W with the cutting amount d 1 and have guide surfaces 51 that abut the right tooth surface 80 in the workplace W. Since the guide surfaces 51 are provided in the finishing blades 50 , the finishing blades 50 are prevented from wobbling toward the right tooth surface 80 in the workpiece W due to the cutting reaction force when cutting the left tooth surface 70 in the workpiece w and thus can accurately cut the left tooth surface 70 in the workpiece W only with the cutting amount d 1 .
[0040] The finishing blades 60 in the second shell 30 abut the right tooth surface 80 in the workpiece W with the cutting amount d 2 and have guide surfaces 61 that abut the left tooth surface 70 in the workpiece W. Since the guide surfaces 61 are provided in the finishing blades 60 , the finishing blades 60 are prevented from wobbling toward the left tooth surface 70 in the workpiece W due to the cutting reaction force when cutting the right tooth surface 80 in the workpiece W and thus can accurately cut the right tooth surface 80 in the workpiece W only with the cutting amount d 2 .
[0041] In addition, the finishing blades 50 and 60 are subjected to work such as chamfering (not illustrated) so as not to allow the guide surfaces 51 and 61 to cut the right tooth surface 80 and the left tooth surface 70 in the workpiece W.
[0042] Next, finishing by the helical broach according to Embodiment 1 of the present invention will be described with reference to FIGS. 1 to 3 .
[0043] The helical, broach 1 according to Embodiment 1 of the present invention and the workpiece W are installed in the broaching machine (not illustrated), and when the helical broach 1 is moved in the axial direction while being pulled with respect to the workpiece W, the workpiece W can be formed to a helical internal gear as described below.
[0044] First, the roughing blades (not illustrated) in the roughing section 3 of the helical broach 1 come into contact with the inner peripheral surface of the substantially cylindrical workpiece W. By the roughing blades arranged such that the height of the blades gradually increases from the leading end of the cutting direction toward the trailing end of the cutting direction, teeth having predetermined dimensions are formed in the workpiece W.
[0045] Subsequently, the finishing blades 50 in the first shell 20 positioned at the leading end of the cutting direction in the finishing section 4 of the helical broach 1 come into contact with the left tooth surface 70 and the right tooth surface 80 in the workpiece W subjected to roughing. The finishing blades 50 abut the left tooth surface 70 in the workpiece W with the cutting amount d 1 , and the guide surfaces 51 of the finishing blades 50 abut the right tooth surface 80 in the workpiece W.
[0046] Since the guide surfaces 51 of the finishing blades 50 abut the right tooth surface 80 in the workpiece W, the finishing blades 50 are prevented from wobbling toward the right tooth surface 80 in the workpiece W due to the cutting reaction force when cutting the left tooth surface 70 in the workpiece W and thus can accurately cut the left tooth surface 70 in the workpiece W only with the cutting amount d 1 . By the finishing blades 50 that are arranged such that the width of the blades gradually increases from the leading and of the cutting direction toward the trailing end of the cutting direction, the left tooth surface 70 in the workpiece W are cut to predetermined finished dimensions.
[0047] Subsequently, the finishing blades 60 in the second shell 30 positioned at the trailing end of the cutting direction in the finishing section 4 of the helical broach 1 come into contact with the left tooth surface 70 subjected to finishing and the right tooth surface 80 subjected to roughing in the workpiece W. The finishing blades 60 abut the right tooth surface 80 in the workpiece W with the cutting amount d 2 , and the guide surfaces 61 of she finishing blades 60 abut she left tooth surface 70 in the workpiece W.
[0048] Since the guide surfaces 61 of the finishing blades 60 abut the left tooth surface 70 in the workpiece W, the finishing blades 60 are prevented from wobbling toward the left tooth surface 70 in the workpiece W due to the cutting reaction force when cutting the right tooth surface 80 in the workpiece W and thus can accurately cut the right tooth surface 80 in the workpiece W only with the cutting amount d 2 . By the finishing blades 60 that are arranged such that the width of the blades gradually increases from the leading end of the cutting direction toward the trailing end of the cutting direction, the right tooth surface 80 in the workpiece W are cut to predetermined finished dimensions.
[0049] As described above, by broaching using the helical broach 1 according to Embodiment 1 of the present invention, the left tooth surface 70 and the right tooth surface 80 in the workpiece W are accurately cut to predetermined finished dimensions, thereby forming a helical internal gear having high accuracy.
[0050] Since the finishing blades 50 having the blade groove helix angle β 1 with respect to the gear tooth helix angle α are formed in the first shell 20 , the rake angle θ 1 of the finishing blades 50 is an acute angle. Accordingly, the cutting ability of the finishing blades 50 in the first shell 20 is high, and the surface roughness of the surface cut by the finishing blades 50 is enhanced. Therefore, the cutting amount d 1 of the left tooth surface 70 in the workpiece W by the finishing blades 50 in the first shells 20 can be set to be sufficiently large.
[0051] Since the finishing blades 60 having the blade groove helix angle β 2 with respect to the gear tooth helix angle α are formed in the second shell 30 , the rake angle θ 2 of the finishing blades 60 is an acute angle. Accordingly, the cutting ability of the finishing blades 60 in the second shell 30 is high, and the surface roughness of the surface cut by the finishing blades 60 is enhanced. Therefore, the cutting amount d 2 of the right tooth surface 80 in the workpiece W by the finishing blades 60 in the second shells 30 can be set to be sufficiently large as in the first shell 20 .
[0052] In the related art, as illustrated in FIG. 5 , one tooth surface (the left sooth surface 170 in FIG. 5 ) of the left tooth surface 170 and the right tooth surface 180 in the workpiece W is cut by the acute angle portion 151 (a portion having an acute rake angle) of the finishing blade 150 in the shell 120 , and the other tooth surface (the right tooth surface 180 in FIG. 5 ) is cut by the obtuse angle portion 152 (a portion having an obtuse rake angle) of the finishing blade 150 in the shell 120 . Therefore, the surface roughness of the surface cut by the obtuse angle portion 152 is coarse, and thus the cutting amount d cannot be set to be sufficiently large. Accordingly, the number of blades of the obtuse angle portion 152 is set to be larger than the number of blades of the acute angle portion 151 . That is, the number of blades of the obtuse angle portion 152 is larger than the number of blades of the acute angle portion 151 , and thus the finishing section 104 , that is, the shell 120 is elongated in the axial direction.
[0053] In the helical broach 1 according to this embodiment, as illustrated, in FIG. 3 , the left tooth surface 70 and the right tooth surface 80 in the workpiece W are cut by the finishing blades 50 in which the rake angle θ 1 is an acute angle in the first shell 20 and by the finishing blades 60 in which the rake angle θ 2 is an acute angle in the second shell 30 . Therefore, the surface roughness of the surface cut by the finishing blades 50 and 60 is good and the cutting amounts d 1 and d 2 can be set to be sufficiently large. Accordingly, the axial length of the finishing section 4 , that is, the first shell 20 and the second shell 30 can be smaller than the axial length of the existing shell 120 .
REFERENCE SIGNS LIST
[0054] 1 Helical Broach
[0055] 2 Shank Section
[0056] 3 Roughing Section
[0057] 4 Finishing Section
[0058] 10 Broach Body
[0059] 11 Shell Engagement Portion of Broach Body
[0060] 12 Shell Abutting Surface of Broach Body
[0061] 13 Positioning Protrusion of Broach Body
[0062] 20 First Shell
[0063] 21 Positioning Groove of First Shell
[0064] 22 Positioning Protrusion of First Shell
[0065] 30 Second Shell
[0066] 31 Positioning Groove of Second Shell
[0067] 40 Fastener
[0068] 50 Finishing Blade in First Shell
[0069] 51 Guide Surface
[0070] 60 Finishing Blade in Second Shell
[0071] 61 Guide Surface
[0072] 70 Left Tooth Surface in Workpiece
[0073] 30 Right Tooth Surface in Workpiece
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The finishing part ( 4 ) of this helical broach ( 1 ) is formed by a first shell ( 20 ) and a second shell ( 30 ) which are divided in the axial direction, and is obtained by forming a first finishing blade ( 50 ), which comprises a prescribed gear tooth helix angle (α) end a first blade groove helix angle (β 1 ), on the aforementioned first shell ( 20 ) and forming a second finishing blade ( 60 ), which comprises the aforementioned prescribed gear tooth helix angle (α) and a second blade groove helix angle (β 2 ) which differs from the aforementioned first blade groove helix angle (β 1 ) on the aforementioned second shell ( 30 ).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a restraining device for use in performing a spinal tap or lumbar puncture procedure and in particular to a garment-like restraint for engaging predetermined portions of a subject's body and securely immobilizing the subjects body in a forwardly arched position, the back of the subject being exposed.
2. Description of the Prior Art
The lumbar puncture procedure, more commonly refered to as a "spinal tap" and in which a small sample of spinal fluid is taken from the patient is a valuable diagnostic test procedure. This procedure is, however, painful. Simultaneously, during the performance of this procedure it is essential that the patient remain quite still. This is to avoid injury to the patient by reason of a bent or broken needle caused in turn by movement of a patient during the procedure, and to obviate a traumatic tap and the drawing of a bloody test sample which can render the test of little or no value.
Since a local anesthetic is rarely used, the difficulties in performing this procedure are further compounded when the procedure is performed on pediatric patients. It is therefore, necessary to have a nurse or other trained personnel present during the performance of the procedure to physically maintain the patient in a proper and essentially immobile position. Such a method is not entirely effective do to the quickness, strength, and unexpected movements of the pediatric patient. Correspondingly, use of trained personnel to physically restrain pediatric patients requires not only the presence of an additional person, it is also less than totally effective.
It has been proposed to provide a padiatric restraining device for securely holding the pediatric patient immobile during the spinal tap procedure. Such a device, for example, is manufactured by Olympic Medical Corp. 4400 7th South, Seattle Washington and is called an L P seat. This device includes a seat, rigid frames, and a mechanical harness. The device further holds the pediatric patient in an upright position during the procedure, this position not being desirable during the performance of this procedure, (a horizontal position being preferred).
There is, therefore, a need for a simple yet effective restraining device which may manufactured of a flexible material such as fabric, reinforced paper or plastic.
SUMMARY OF THE INVENTION
Broadly, the invention is a garment-like restraint for restraining a patient from movement during the spinal tap procedure.
The restraint includes an elongated panel provided with a plurality of openings for the head, shoulders, and legs of a patient and a plurality of straps which cooperate to securely yet comfortably engage selected portions of the patients body and to hold the patient immobile.
More specifically, the invention comprises an elongated and flexible panel having front and back surfaces and including upper tension, torso, thigh and lower tension portions, shoulder openings, upper thigh openings and a lower thigh opening formed in the panel between the upper tension and torso portions, between the torso and thigh portions, respectively. Laterally extending shoulder straps are fixedly secured to the panel adjacent the shoulder openings; buttocks and shin straps are fixedly secured to the panel in lateral extending spaced-apart relationships adjacent the upper thigh opening. The restraint is placed on the subject with the back surface of the torso portion against the front of the subjects torso, the subjects thighs passing through the upper thigh opening from the back surface to the front surface thereof. The subject's shoulders extend through the shoulder openings in a direction from the rear of the panel to the front thereof, and the buttocks and the shoulder straps are adjustably secured around and behind the subjects buttocks and shoulders, respectively. The upper and lower portions are drawn together forwardly of the torso portion to draw the subject into a forwardly arched position. The tension portions are adjustably secured together to hold the subject in this position.
Lastly, shin straps are secured around the front of the subjects lower legs or shins.
In one embodiment of the invention, the patients head may be restrained in a forwardly and downwardly extended position by the upper tension panel or in the alternative, may be extended in an unrestrained position through the forward tension panel via the head and neck openings provided therein.
In another specific embodiment of the invention, pockets are formed in the forward surface of the torso portion of the panel for recieving the patients hands. Wrist engaging straps are secured to the torso panel adjacent the pockets. The wrist straps are secured to hold the patients hands within the pockets to prevent the patient from using their hands to remove the restraint or otherwise move their arms and hands to produce undesired movement during the procedure.
It is therefore an object of the invention to provide a restraint for use in immobilizing a pediatric patient during the performance of the lumbar puncture procedure.
Another object of the invention is to provide such a restraint of a garment-like character which is easily fitted to a patient.
Still another object of the invention is to provide such a restraint which does not require the use of an additional trained person to physically restrain the patient to prevent undesired movement of the patient during the spinal tap procedure.
Another object of the invention is to provide such a restraint which includes means for immobilizing the movement of the hands and the arms of the patient.
Another object of the invention is to provide such a restraint which selectively permits restraining movement of the head of the patient.
Still another object of the invention is to provide such a restraint made from a fabric-like material.
Yet another object of the invention is to provide such a restraint which is readily adjustable to patients of different sizes.
Another object of the invention is to provide such a restraint in which adjustment of size is an integral part of placing the restraint on the patient.
Another object of the invention is to provide such a restraint which can be fabricated of a disposable fabric-like material.
Another object of the invention is to provide such a restraint which securely immobilizes the pediatric patient in a forwardly arched position with the back portion of the patient exposed.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features and objects of this invention and the manner of attaining them will become more apparent and the invention itself will be best understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a perspective view showing the restraint of the present invention placed on a pediatric patient;
FIG. 2 is a perspective view of the restraint of the present invention which has been laid flat for identification of the panel portions;
FIG. 3 is a perspective drawing illustrating the first step in the sequence of steps in placing the restraint on the patient;
FIG. 4 is a perspective illustration of the second step in placing the restraint on the patient,
FIG. 5 is a perspective view showing placement of the patients hands to prevent movement;
FIG. 6 is a front perspective view in illustrating the final step of placing the garment on the pediatric patient when the head of the patient is to be permitted to move;
FIG. 7 is a perspective view showing the next sequential step in placing the restraint on the patient when it is desired to restrain the patients head movements;
FIG. 8 further illustrates placing the garment on a pediatric patient when the head restraining feature is utilized;
FIG. 9 is a rear perspective view showing the patient with the restraint fully placed thereon.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is shown a restraint in accordance with the present invention indicated generally at 10. The restraint 10 comprises an elongated, rectangular panel 12 which is fabricated from a strong stretch resistant and flexible material such as cotton denim. The panel 12, has a front surface 14 and a back surface 16. As viewed in FIG. 2, the left end portion of the panel 12 is identified as the upper tension portion 18, this portion extending from the end 20 of panel 12 to the dashed junction line 22. The portions of panel 12 between dashed junction lines 22 and 24 is identified as the torso portion 25, the portion between lines 24 and 26 as the thigh portion 27, and the portion between lines 26 and 28 as the lower tension portion 29.
A neck opening 30 is formed in the panel 12 at the juncture of upper tension panel 18 and torso portion 25, opening 30 being dimensioned to comfortably receive the neck of a child therethrough but smaller than a childs head.
An elongated slit 32 extends through opening 30 in a direction towards ends 20, slit 32 being provided with a conventional zipper 34 which, as will be explained below, permits the opening 30 to be enlarged to permit the passage of a patients head therethrough and then closed to prevent the patient from removing their head from the opening.
Shoulder openings 36, 38 are formed in the torso portion 25 adjacent junction line 22, openings 38 being disposed in laterally spaced-apart relationship and being dimensioned to receive the childs shoulders therethrough. A pair of pockets 40, 42 are stiched to the front surface 14, of panel 12 near the center of torso portion 25. Pockets 40, 42 are stiched along the side and outside ends, the inwardly disposed end 44 of pockets 40, 42 being open to permit the patients hands to be comfortably received therein.
An elongated strap 46 is fixedly secured to the front surface 14 of torso portion 25 adjacent the center of open end 44 of pocket 42 by means such as stitching. The opposite ends, 48, 50 of strap 46 are fitted with complementary Velcro material such that the straps can be secured around the wrist of the patient when the patients hand is in pocket 42. Similarly, a strap 52 is secured adjacent the center of open end of pocket 40.
An upper thigh opening 56, is formed adjacent the juncture line 24 of torso portion 25 and the thigh portion 27, opening 56 being dimensioned to comfortably recieve the childs thighs therethrough.
The upper tension portion 18 and lower tension portion 29 are provided with elongated strips of Velcro material as at 60, 62 respectively. The strips 60 on the upper tension panel are secured to the back surface 16 of the panel 12 while the strips 62 are secured to the front surface 14 thereof, strips 60 and 62 being of complementary Velcro material such that, and will again be explained in more detail below, the upper and lower tension panels can be adjustably secured together and overlying relationship.
The elongated shoulder straps 64, 66 extend laterally outwardly from the left (as viewed in FIG. 2) end of torso portion 25, straps 64, 66 being laterally in alignment with the shoulder strap openings 38.
Buttocks straps 68, 70 and shin straps 72, and 74 similarly extend laterally outwardly from panel 12 adjacent junction line 24. It will be observed that each pair of straps 64, 66, 68, 70, and 72, 74 is provided with a Velcro material fastening strip on its upper (as viewed in FIG. 2) surface, the opposite ones of each of these pairs of straps being provided with a complementary strip of Velcro fastening material on the under-surface as indicated by dashed lines at 76, 78 and 80 such that the strips can be adjustably secured together in overlying relationship.
Preferably, a padded welting as at 82 is stitched to the peripheries of the neck, shoulder, and lower thigh openings 30, 38, 56, and 58.
Referring next to FIG. 3, there is illustrated the first step in placing the restraint 10 on the patient. The patients legs 86 are passed sequentially through the upper and then the lower thigh openings 56, 58 with the legs entering the upper thigh opening 56 from the rear surface 16 of panel 12, passing over the upper surface 88 of thigh portion 27 and entering the lower thigh opening 58 from the front surface 14 of panel 12. Thus positioned, the torso portion 25 passes vertically upwardly in front of the patients torso overlying the abdomen and chest with the pockets 40, 42 being disposed on the front surface 14 of panel 12 away from the patients body. The lower tension panel 29 extends upwardly and forwardly (with respect to the patients body) of the torso portion 25.
Referring next to FIG. 4, placement of the restraint 10 on a patient continues by placing the patients shoulders 90 through the shoulder openings 98 and securing the shoulder straps 64, 66 together snugly across the patients back 92. It will be apparent that the elongated Velcro strips 76 enable adjustment of the straps to any patient with a minimum of effort. In a similar manner, the buttocks straps 68, 70 are secured and snugged behind the buttocks adjacent the lower back.
Referring now to FIG. 5, the next step in placing the restraint 10 on the patient is to place the patients hands into pockets 40, 42. The patient's hands are retained in the pockets by securing the Velcro straps 48, 50 and 52 about the patient's wrists. This prevents the patient from moving his or her hands from the pockets 40, 42.
The upper and lower tension portions 18, 29 are now drawn together in overlapping relationship. Sufficient force is applied to urge the patient into a forwardly arched position and the two tension panels 18 and 29 are secured by means of the Velcro strips 60, 62.
If it is desired to leave the patient's head free, the final step in placing the restraint 10 on the patient includes the steps of placing the patient on his or her side, securing the lower portion of the patients legs 96 by securing the shin straps 72, 74 forwardly and around the lower legs or shins.
The patient is now positively and safely immobilized in a proper horizontal and forwardly arched position for performance of the spinal tap procedure.
In some instances, and in particular when the restraint is used on small children, it may also be desired to restrain movement of the head. To effect this, and as can best be seen in FIG. 7 and 8, the zipper 34 closing the slit 32 is opened and the upper restraining portion 18 is drawn over the patients head and neck with the head passing through opening 30. The zipper 34 is now closed thereby fitting the neck opening 30 snuggly about the patient's neck 98. The upper tension panel 18 can now be drawn up and over the patient's head as can best be seen in FIG. 8. The upper and lower tension panels are again drawn together in overlying relationship with enough force to draw the patient into a forwardly arched position. In this instance, it will be seen that the patient's head 100 is gently forced downwardly with the chin adjacent the chest and is prevented from movement by upper tension panel 18. Again, the child or patient is in a horizontal position with the entire back portion 102 and spinal column being fully exposed for performance of the spinal tap procedure.
It will be further observed that since the restraint is fabricated entirely of a flexible fabric material, no discomfort is caused by cold metal or plastic surfaces. Bruising or other irritation of the body is obviated. The restrained position of the patient is not unduly uncomfortable and the patient, both with the head exposed and restrained as shown in FIGS. 9 and 6, respectively, is able to see. It will be observed that with the child thus restrained, a doctor can perform a lumbar puncture or a spinal tap with substantially increased ease and safely. The child is more effectively restrained from movement than can be effected by manually holding the child by a nurse or other trained personnel.
It is anticipated that the restraint can be fabricated in a minimum number of sizes in view of the adjustment available from the use of elongated Velcro strips for securing the garment. It is however, also contemplated that the entire restraint can be fabricated from a fiber reinforced paper-like material having sufficient strength. The Velcro strips can be replaced with suitable adhesive strips protected from sticking prior to use by conventional removeable plastic or waxed paper elements. Using such materials, the restraint can be made disposable for purposed of sterility and cleanliness without loss of its effectiveness and without imposing undue expense. It will further be observed that while a particular geometric configuration of the elongated panel has been illustrated, the fundamental physical and functional characteristics of the restraint can be effected using varied geometry. In the broad aspects of the invention, is is necessary only that flexible shoulder and thigh engaging means be provided, these being adjustably coupled together forwardly of the patient's body to securely hold the patient in an immobile and forwardly arched position.
While there have been described above the principles of this invention in connection with specific apparatus, it is to be clearly understood that this description is made only by way of example and not as a limitation to the scope of the invention.
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A restraint for use in performing a Lumbar Puncture procedure on a pediatric patient, the restraint including a flexible panel having a plurality of portions, openings and straps for securing predetermined parts of a patient's body and securely holding same immobilized in a forwardly arched position with the subject's back fully exposed.
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FIELD OF THE INVENTION
The present invention relates to the field of fluorinated hydrocarbons and has more particularly as subject-matter novel compositions which can be used for cleaning or drying solid surfaces.
BACKGROUND OF THE INVENTION
1,1,2-Trichloro-1,2,2-trifluoroethane (known in the trade under the name F113) has been widely used in industry for cleaning and degreasing highly-varied solid surfaces (metal components, glasses, plastics, composites) for which the absence or at least the lowest possible residual content of impurities, in particular of organic nature, is required. F113 was particularly well suited to this use because of its nonaggressive nature with regard to the materials used. This product was used in particular in the field of the manufacture of printed circuits, for removing the residues of the substances used to improve the quality of the soldered joints (denoted by the term solder flux). This removal operation is denoted in the trade by the term “defluxing”.
Mention may also be made of the applications of F113 in the degreasing of heavy metal components and in the cleaning of mechanical components of high quality and of great accuracy, such as, for example, gyroscopes and military, aerospace or medical equipment. In its various applications, F113 is generally used in combination with other organic solvents (for example methanol), in order to improve its cleaning power. It is then preferable to use azeotropic or near-azeotropic mixtures. The term “near-azeotropic mixture” is understood to mean, within the sense of the present invention, a mixture of generally miscible chemical compounds which, under certain specific conditions of proportions, temperature and pressure, boils at a substantially constant temperature while retaining substantially the same composition. When it is heated to reflux, such a near-azeotropic mixture is in equilibrium with a vapour phase, the composition of which is substantially the same as that of the liquid phase. Such azeotropic or near-azeotropic behaviour is desirable in ensuring satisfactory operation of the devices in which the abovementioned cleaning operations are carried out and in particular in ensuring the recycling by distillation of the cleaning fluid.
F113 is also used in fields, in particular in optics, where it is required to have available surfaces which are devoid of water, that is to say surfaces where water is only present in the form of traces undetectable by the measurement method (Karl Fischer method). F113 is, for this purpose, employed in drying (or dewetting) operations on the said surfaces, in combination with hydrophobic surface-active agents.
However, the use of compositions based on F113 is now forbidden as F113 is one of the chlorofluorocarbons (CFCs) suspected of attacking or damaging the stratospheric ozone.
In these various applications, F113 can be replaced by 1,1-dichloro-1-fluoroethane (known under the name F141b), but the use of this substitute is already controlled because, although low, it still has a destructive effect with regard to ozone.
Application EP 0,512,885 discloses a composition, comprising from 93 to 99% by weight of 1,1,1,3,3-pentafluorobutane and from 1 to 7% of methanol, which can be used as substitute for F113. 1,1,1,3,3-pentafluorobutane, also known in the trade under the name F365mfc, has no destructive effect with regard to ozone.
Application EP 0,856,578 discloses a composition, comprising from 10 to 90% by weight of 1,1,1,2,3,4,4,5,5,5-decafluoropentane, from 10 to 90% of dichloromethane and from 0 to 10% of methanol, which can also be used as substitute for F113. 1,1,1,2,3,4,4,5,5,5-Decafluoropentane, known in the trade under the name 43-10mee, also has no destructive effect with regard to ozone.
DETAILED DESCRIPTION OF THE INVENTION
The aim of the invention is to provide other compositions capable of being used as substitute for F113 or F141b and which have no destructive effect with regard to ozone.
In order to contribute to the resolution of this problem, the subject-matter of the present invention is therefore azeotropic or near-azeotropic compositions comprising:
from 45 to 65% of 1,1,1,3,3-pentafluorobutane, preferably from 50 to 60%,
from 30 to 50% of dichloromethane, preferably from 35 to 45%,
from 1 to 10% of methanol, preferably from 2 to 5%, and from 0.1 to 2% of 1,1,1,2,3,4,4,5,5,5-decafluoropentane, preferably from 0.2% to 1%.
Except when otherwise indicated, the percentages used in the present text to indicate the content of the compositions according to the invention are percentages by weight.
In this range, there exists an azeotrope, the boiling temperature of which is 31.9° C. at standard atmospheric pressure (1.013 bar).
The compositions according to the invention make it possible to obtain very good results in the cleaning and degreasing of solid surfaces, as well as in drying and dewetting operations on surfaces. Furthermore, these compositions do not exhibit a flash point under the standard determination conditions (ASTM Standard D 3828) and therefore make it possible to operate in complete safety.
The compositions according to the invention can be easily prepared by simple mixing of the constituents. 43-10mee is commercially available; 365mfc can be prepared by at least one of the following methods:
Zh. Org. Khim., 1980, 1401-1408 and 1982, 946 and 1168, Zh. Org. Khim., 1988, 1558, J. Chem. Soc. Perk. I, 1980, 2258, J. Chem. Soc. Perk. Trans., 2, 1983, 1713, J. Chem. Soc. C Perk. Trans., 2, 198, 1713, J. Chem. Soc. C1969, 1739, Chem. Soc., 1949, 2860, Zh. Anal. Khim., 1981, 36(6Y, 1125, J. Fluorine Chem., 1979, 325, Lzv. Akad. Nauk. SSSR. Ser Khim., 1980, 2117 (in Russian), Rosz. Chem., 1979 (48), 1697 and J.A.C.S., 67, 1195 (1945), 72, 3577 (1950) and 76, 2343 (1954).
As in the known cleaning compositions based on F113 or F141b, the cleaning compositions based on 365mfc, on dichloromethane, on methanol and on 43-10mee according to the invention can, if desired, be protected against chemical attacks resulting from their contact with water (hydrolysis) or with light metals (constituting the solid surfaces to be cleaned) and/or against radical attacks capable of taking place in cleaning processes by adding a conventional stabilizer thereto, such as, for example, nitroalkanes (in particular nitromethane, nitroethane or nitropropane), acetals (dimethoxymethane) or ethers (1,4-dioxane or 1,3-dioxolane). The proportion of stabilizer can range from 0.01 to 5% with respect to the total weight of the composition. It is preferable to use dimethoxymethane as stabilizer, the boiling point of dimethoxymethane being close to that of the azeotropic compositions according to the invention; for this reason, this stabilizer conforms perfectly to the cycle of evaporation and condensation of the solvent, which is particularly advantageous in cleaning applications.
The compositions according to the invention can be mixed with other solvents, such as alcohols, ketones, ethers, acetals, esters, hydrocarbons, chlorinated, brominated or iodinated solvents, sulphones or water, in the presence of (anionic, nonionic or cationic) surfactants which comprise fluorine or silicone, or not, in order to obtain specific properties, in particular in dry-cleaning.
The compositions according to the invention can be used in the same applications and be employed according to the same methods as the prior compositions based on F113 or F141b. They are therefore particularly suitable for use in the cleaning and degreasing of solid surfaces, preferably in the defluxing of printed circuits, as well as in drying operations on surfaces.
As regards the latter use, it is preferable to add a soluble hydrophobic surfactant to the composition, in order to further improve the removal of water from the surfaces to be treated, until 100% removal is achieved.
Among hydrophobic surfactants, the diamides of formula:
R—CO—NR—(CH 2 ) n —NH—CO—R (I)
in which R is an alkyl radical comprising from 14 to 22 carbon atoms, preferably from 16 to 20 carbon atoms, and n is an integer between 1 and 5 inclusive, preferably equal to 3.
According to this preferred alternative form of the compositions according to the invention, the composition generally comprises from 92 to 99.5% of the quaternary azeotropic composition and from 0.05 to 8% of surfactant.
As regards the forms of use of the compositions according to the invention, mention may particularly be made of the use in devices suitable for the cleaning and/or drying of surfaces, as well as by aerosol.
As regards the aerosol use, the compositions according to the invention can be packaged with, as propellant, 134a (or 227e of formula CF 3 CHF—CF 3 ) and their mixture with 152a and/or DME (dimethyl ether), in order to offer additional cleaning possibilities, in particular at room temperature. The compositions according to the invention, thus packaged, do not exhibit a flame length according to Standard 609F of the Fédération Européenne des Aérosols [European Aerosol Federation] (Brussels, Belgium) (Determination of the ignition distance of a spray or of a stream emitted from an aerosol container).
These compositions can, in addition, be used as a blowing agent for polyurethane foams, as an agent for the dry-cleaning of textiles and as a refrigerating medium.
EXAMPLES
The following example illustrates the invention without limiting it.
Example 1
a) Demonstration of a 365mfc/dichloromethane/methanol/43-10mee Azeotrope:
50 g of 43-10mee and 100 g of 365mfc, 50 g of methanol and 100 g of dichloromethane are introduced into the boiler of a distillation column (30 plates). The mixture is subsequently heated at reflux for one hour in order to bring the system to equilibrium.
When the temperature is observed to be stationary, a fraction weighing approximately 20 g is collected. This fraction, as well as the bottom fraction remaining in the boiler, are analysed by gas chromatography.
Examination of the results recorded in the table below indicates the presence of an azeotropic composition.
Composition (weight %)
365mfc
CH 2 Cl 2
CH 3 OH
43-10mee
Starting mixture
33
33
17
17
Fraction collected
56.2
39.8
3.5
0.5
at 31.9° C.
b) Confirmation of the Azeotropic Composition:
200 g of a mixture comprising 56.2% of 365mfc, 39.8% of CH 2 Cl 2 , 3.5% of MeOH and 0.5% of 43-10mee are introduced into the boiler of a distillation column (30 plates). The mixture is subsequently heated at reflux for one hour in order to bring the system to equilibrium.
A fraction weighing approximately 20 g is withdrawn and is analysed by gas chromatography.
Examination of the results recorded in the following table indicates the presence of a 365mfc/CH 2 Cl 2 /CH 3 OH/43-10mee quaternary azeotrope, since the fraction collected has the same composition as the starting mixture. It is a positive azeotrope, since its boiling point is lower than that of each of the pure products, i.e. 40° C. for 365mfc, 40° C. for CH 2 Cl 2 , 65° C. for CH 3 OH and 55° C. for 43-10mee.
Composition (weight %)
365mfc
CH 2 Cl 2
CH 3 OH
43-10mee
Starting mixture
56.2
39.8
3.5
0.5
Fraction collected
56.2
39.8
3.5
0.5
at 31.9° C.
The above azeotropic composition can be stabilized with 0.5% of dimethoxymethane.
Example 2
Cleaning of Solder Flux
The following test is carried out on five test circuits in accordance with Standard IPC-B-25 described in the manual of the test methods of the IPC (Institute for Interconnecting and Packaging Electronic Circuits; Lincolnwood, Ill., USA). These circuits are coated with solder flux based on colophony (product sold by the Company Alphametal under the name flux R8F) and are reflowed in an oven at 220° C. for 30 seconds.
To remove the colophony thus reflowed, these circuits are cleaned using the azeotropic composition of Example 1 in a small ultrasonic device, for 3 minutes by immersion in the liquid phase and 3 minutes in the vapour phase.
The cleaning is evaluated according to the standardized procedure IPC 2.3.26 (also described in the abovementioned manual) using an accurate conductivity meter.
The value obtained, 1.9 μg/cm 2 eq. NaCl, is below the threshold for ionic impurities tolerated by the profession (2.5 μg/cm 2 eq. NaCl).
Example 3
Surface Drying
250 ml are prepared of a drying composition comprising 99.8% of the composition described in Example 1, to which is added 0.2% of dioleyl(oleyl-amido)propyleneamide (compound of formula (I) in which R is an alkyl radical comprising an average of 18 carbon atoms and n is equal to 3).
A stainless steel mesh with dimensions of 5×3 cm is dipped in water for a few seconds.
The water-retaining ability of this mesh is measured by dipping the mesh in absolute ethyl alcohol and then quantitatively determining by the Karl Fischer method employed with this alcoholic solution.
This mesh is subsequently immersed for 30 seconds in the drying composition thus prepared, with manual stirring. The mesh is removed from this composition and the residual water is quantitatively determined by means of the Karl Fischer method, as described above.
The amount of residual water after drying, divided by the water-retaining ability of the mesh (corrected for the water content of the absolute ethyl alcohol used), is known as the degree of removal (expressed as a percentage).
A degree of removal of the water of 100% is measured.
Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all of the alternatives and variations that fall within the spirit and scope of the appended claims. The above references are hereby incorporated by reference.
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In order to replace compositions based on CFC or on HCFC in cleaning or drying applications on solid surfaces (in particular defluxing), the invention provides azeotropic or near-azeotropic compositions based on 1,1,1,3,3-pentafluorobutane, on dichloromethane, on methanol and on 1,1,1,2,3,4,4,5,5,5-decafluoropentane.
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[0001] This application is a continuation of U.S. patent application Ser. No. 12/895,280 filed Sep. 30, 2010 which was a continuation-in-part of PCT/US 2009/038711 filed Mar. 29, 2009.
INTRODUCTION
[0002] Machines originally designed as front end loaders with tracks or wheels, whether having skid-steering wheels or turnable wheels, such as Bobcat brand machines, have been adapted to become general purpose tool carriers that can receive a variety of controllable tool attachments to be attached to the front or back of the machine and controlled by an operator sitting in the operator's seat. This tool attachment carrying system can be improved upon by (1) allowing linear acting tools to be attached on the side, (2) placing the operator's seat and controls on a controllable swivel 10 so that the operator can swivel to an optimum location for viewing the work, and (3) providing the operator with a controllable articulating arm 11 with a bucket, claw, rake or compactor or similar implement which the operator can operate to accomplish a task in a coordinated fashion with the linear acting tool which is attached below the swivel. The engine may also be above the swivel, in which case it drives a hydraulic pump that pumps fluid through the swivel to drive the linear acting tool attached below the swivel. So that the swivel can rotate without limitation, electrical control signals may pass through conductor rings in the swivel or via wireless radio signal to the linear acting tool, or additional hydraulic circuits may be added passing through the swivel. The linear acting tool may be hydraulically adjusted in response to operator controls or location of a string datum line or a curb or gutter or GPS coordinates. The adjustment may move the tool vertically without pivoting to stay plumb or it may pivot the tool about a pivot point.
SUMMARY OF THE INVENTION
[0003] In one aspect, the invention is a tool carrying and controlling system wherein an operator can control a swiveling tool and either a first linear acting controllable tool or a second linear acting controllable tool to operate in coordination with the first tool. The system comprises (a) a set of wheels or tracks on which the machine rides supporting a support structure; (b) coupled to and supported by the support structure, an operator's seat and operator's controls; (c) coupled to and supported by the support structure, a vertical swivel 10 such that components coupled to an upper side of the swivel can swivel about a vertical axis relative to the support structure; (d) an articulating arm 11 coupled to the upper side of the vertical swivel, controllable by the controls, with a first tool mounted on a distant end of the arm; (e) coupled to and supported by the support structure and fixed to a lower side of the swivel, a mounting support 66 for mounting to one side of the path of the tracks or wheels a linear acting tool; (f) a first linear acting tool mountable on the mounting base 66 , the first tool or mounting base including moving parts such that an operator can, using controls at the operator's seat, control the swiveling tool and, also using controls at the operator's seat, control the moving parts of the first tool or mounting base, which does not swivel with the swiveling tool, so that the two tools perform an operation in coordination with each other; and (g) a second linear acting tool mountable on the mounting base 66 , the second tool or mounting base including moving parts controllable by the controls such that an operator can remove the first tool and replace it with the second tool and then, using controls at the operator's seat, control the swiveling tool and, also using controls at the operator's seat, control the moving parts of the second tool or mounting base, which does not swivel with the first tool, so that the two tools perform an operation in coordination with each other.
[0004] The above elements (a) through (d) may be provided by an excavator, particularly a mini-excavator. So that the swivel 10 can fully swivel any number of rotations without limitation, the system may include an electrical circuit coupling the controls with the moving parts of the mounting support or first or second tool, the electrical circuit passing through the swivel via electrical conductor rings and brushes. Alternatively, the control signals may be communicated with a wireless link that carries radio communications from the controls to the mounting support or first of second tool. In this case, electrical power to operate a wireless communication component coupled to the mounting support or first of second tool may be provided by a hydraulic generator which receives power from flow of hydraulic fluid passing through the swivel from a hydraulic pump on the engine mounted above the swivel.
[0005] The swiveling tool may be an earth moving bucket 43 or a claw or a rake or vibratory compactor or any similar implement. The first and second linear acting tools may be any of: a curb and gutter grading blade; a curb and gutter extruder; a sidewalk and shoulder grading blade; an asphalt paver; a concrete paver; a fence installer; a trencher; a concrete/asphalt saw; a side roller/compactor; a vibratory roller; a snow plow; and other similar tools.
[0006] In another aspect, the invention is a side tool carrying and controlling machine in the form of a modified excavator, comprising a common excavator, which is: (a) a set of wheels or tracks on which the machine rides supporting a support structure; (b) coupled to and supported by the support structure, a vertical swivel 10 such that components coupled to an upper side of the swivel can swivel about a vertical axis relative to the support structure; (c) coupled to and supported by the upper side of the swivel, an operator's seat, operator's controls, and an articulating arm having a tool on a distant end. The modification consists of: (d) coupled to and supported by the support structure and fixed to a lower side of the swivel, a side tool mounting support 66 adapted for mounting a linear acting tool to one side of a path of the wheels or tracks; (e) a set of source side hydraulic couplers disposed proximate to the mounting support and available for use with mating hydraulic couplers of a hydraulically controlled side tool, each source side coupler coupled to a hydraulic pump disposed above the swivel via hydraulic lines having control valves that control flow through the lines in response to actuation at the operator's controls.
[0007] The side tool carrying and controlling machine may be designed to fully swivel any number of rotations without limitation by ensuring that any hydraulic or communication circuits pass through the swivel with slip fittings or use wireless radio.
[0008] The side tool carrying and controlling machine may further include a hydraulic actuator coupled to the mounting support and configured for adjusting the support or an attached linear acting tool in response to a control, which may be an operator control or an automated control that responds to location relative to a string datum line or that responds to a slope sensor or that responds to position with respect to global positioning system satellites.
[0009] In yet another aspect, the invention is a curb and gutter extruding machine made by modifying a common excavator, which is a set of wheels or tracks on which the excavator rides supporting a support structure; coupled to and supported by the support structure, a vertical swivel 10 such that components coupled to an upper side of the swivel can swivel about a vertical axis relative to the support structure; coupled to and supported by the upper side of the swivel, an operator's seat, operator's controls, and an articulating arm 11 having a tool on a distant end. The modification consists of: coupled to and supported by the support structure and fixed to a lower side of the swivel 10 , a curb and gutter extruder attachment comprising a hopper and a slip form mounted to extrude a curb or gutter to one side of a path of the wheels or tracks.
[0010] The curb and gutter extruder may further comprise a hydraulic actuator coupled to a hydraulic valve that is automatically controlled by a controller that adjusts height of the extruder relative to one of: location with respect to a datum line string, tilt with respect to gravity, or location with respect to global positioning system satellites.
[0011] The curb and gutter extruder may be mounted to an attachment base 66 on the excavator which may be a typical front blade of the excavator. It may be braced by a diagonal brace to a track roller chassis of the excavator.
[0012] In yet another aspect, the invention is a sidewalk paving machine made by modifying a common excavator, the modification comprising: coupled to and supported by the support structure and fixed to a lower side of the swivel, a sidewalk paving attachment comprising lateral material retaining fins, a spreading auger and a smoothing plate with a vibrator mounted to spread and smooth formable paving material to one side of a path of the wheels or tracks.
[0013] The sidewalk paving machine may include one or more heating elements on the smoothing plate to heat asphalt paving material. It may further include at least one curb follower attached to a side of a material retaining fin to maintain proper height relative to a curb. The paving attachment may be mounted to a blade of the excavator. It may include a diagonal brace to a track roller chassis of the excavator.
[0014] In yet another aspect, the invention is a sidewalk grading machine with vertical blade adjustment made by modifying a common excavator, the modification comprising: coupled to and supported by the support structure and fixed to a lower side of the swivel, a sidewalk grading blade attachment with a straight vertical adjusting component, the vertical adjusting component comprising: (1) an excavator side attachment fitting, coupled to (2) a set of vertical tracks, which are engaged by (3) a set of vertical sliders, which are attached to the grading blade, and (4) a hydraulic actuator that adjusts vertical sliding of the sliders on the tracks, thereby vertically adjusting the height of the grading blade.
[0015] The sidewalk grading machine may further comprise a sonar position detector that detects position of a datum line relative to the detector which detected information is used to adjust the vertical adjusting component. The datum line may be a string or a concrete curb or gutter or a laser line or plane, a road surface, or an established grade.
[0016] In yet another aspect, the invention is a sidewalk or shoulder rolling machine, comprising (a) a common excavator comprising a set of wheels or tracks on which the excavator rides supporting a support structure; coupled to and supported by the support structure, a vertical swivel such that components coupled to an upper side of the swivel can swivel about a vertical axis relative to the support structure; coupled to and supported by the upper side of the swivel, an operator's seat, operator's controls, and an articulating arm having a tool on a distant end; and (b) coupled to and supported by the support structure and fixed to a lower side of the swivel, a side roller attachment comprising a frame, which supports at least one axis which holds at least one weighted cylindrical roller located to roll an approximately horizontal surface to one side of a path of the wheels or tracks. The rolling machine may include a vibrator on the frame located to vibrate the at least one roller.
[0017] In yet another aspect, the invention is a silt fence installing machine, comprising: (a) a common excavator comprising a set of wheels or tracks on which the excavator rides supporting a support structure; coupled to and supported by the support structure, a vertical swivel such that components coupled to an upper side of the swivel can swivel about a vertical axis relative to the support structure; coupled to and supported by the upper side of the swivel, an operator's seat, operator's controls, and an articulating arm having a tool on a distant end; and (b) coupled to and supported by the support structure and fixed to a lower side of the swivel, a silt fence installing attachment comprising a frame, which supports a fence roll support bar for holding a roll of fencing, a plowing edge, and following the plowing edge, a diagonal direction changing edge which redirects the fabric from vertical movement to horizontal movement. The silt fence installing machine may include at least one height adjustable wheel or skid that contacts an earth surface and limits a depth of plowing of the plowing edge.
[0018] In yet another aspect, the invention is a machine for installing rolled-up fencing with attached posts, comprising: (a) an attachment mount adapted to attach to an attachment base on a mobile machine; (b) coupled to the attachment mount, a fence dispenser adapted to hold vertically a roll of fence material with attached fence posts and allow the fence material with posts to feed off the roll; (c) coupled to the attachment mount, a plowing edge adapted to plow a trench as the mobile machine moves forward; (d) a fence material guide adapted to guide fence material with posts coming off the roll into installation position as the mobile machine moves forward; and (e) a fence post pusher adapted to push each fence post from installation position into soil as the mobile machine moves forward. The tool may further comprise soil pushers adapted to push soil against a bottom edge of installed fence as the mobile machine moves forward.
[0019] In yet another aspect, the invention is a tool for installing rolled-up fencing without attached posts and digging holes for or pounding in fence posts, comprising: (a) at least one attachment mount adapted to attach to an attachment base on a mobile machine; (b) coupled to at least one attachment mount, a vertical sliding guide with a slider disposed with no obstruction on a vertical line from the slider to soil when the tool is mounted on a mobile machine; and (c) coupled to at least one attachment mount, a fence dispenser adapted to hold vertically a roll of fence material and allow the fence material to feed off the roll proximate the vertical line. The tool attachment system may further comprise a powered auger mountable on the slider adapted to drill a hole suitable for a fence post when sliding down the sliding guide. It may also comprise a pounding face mountable on the slider adapted to pound a fence post when sliding down the sliding guide and/or a fence stretcher.
BRIEF DESCRIPTION OF THE FIGURES
[0020] FIG. 1 shows a prior art sidewalk grader.
[0021] FIG. 2 shows a mounting base 66 and tool's mating attachment surface 74 , as well as components of a tool that includes automatic leveling components.
[0022] FIG. 3 shows a quick coupling components for coupling hydraulic lines to a detachable tool.
[0023] FIGS. 4A and 4B show wireless components for controlling a detachable tool from the cab.
[0024] FIG. 5 shows an improvement that allows the detachable tool to remain plumb as relevant elevations change.
[0025] FIG. 6 shows a curb and gutter extruder.
[0026] FIG. 7 shows an extruder for a second curb.
[0027] FIG. 8 shows a laterally extendable edge blade.
[0028] FIG. 9 shows a detachable trencher added to the end of the blade.
[0029] FIG. 10 shows grading base rock with the sidewalk grading blade.
[0030] FIG. 11 shows paving with a paver detachable tool.
[0031] FIGS. 12 and 13 show adjustable tools for paving.
[0032] FIGS. 14A, 14B, 14C, 15A, 15B, 15C, 16A, 16B and 16C show a hydraulic hose reel adapted to carry two hydraulic hoses in the tool mounting base and a side blade which extends horizontally out of an end of the tool mounting base.
[0033] FIGS. 16C and 17A, 17B and 17C show a multi-coupling plate and how retainers of the tool mount may be powered with a hydraulic cylinder.
[0034] FIGS. 18A, 18B and 19 show arms connecting the tool attachment base to the machine that constrain the tool attachment base to move up and down without significant rotation out of plumb.
[0035] FIGS. 20, 21A, 21B and 22 show a silt fence installer attachments.
[0036] FIGS. 23, 24, 25, 26A and 26B show a horizontally extendable low profile side blade attachment.
[0037] FIG. 27 shows a laterally extendable blade.
[0038] FIGS. 28 and 29 show a trencher attachment.
[0039] FIG. 30 shows a materials bin attachment.
[0040] FIG. 31 shows a roller attachment.
DETAILED DESCRIPTION
The Prior Art
[0041] Referring to FIG. 1 of the drawings which shows the prior art sidewalk grading machine, numeral 20 generally designates the sidewalk grading blade and support structure, called the sidewalk grader 20 . The sidewalk grader 20 is used to grade sidewalk base material 22 , which sometimes includes crushed rock 24 , to a predetermined specified grade and elevation to form the base 26 of a designed sidewalk (not illustrated). Typically, the sidewalk grader 20 accommodates grading activity for sidewalks that extend adjacent to and along an existing road structure 30 of the type that incorporates a curb 32 as a border.
[0042] More specifically, the sidewalk grader 20 comprises a tracking assembly 34 adapted for fixable engagement with a vertically movable accessory 36 extending from below the swivel in a piece of construction excavation equipment 38 . Commonly, a vertically adjustable backfill blade extending from a common compact excavator 42 is effective 36 for this purpose. When a compact excavator 42 is used, the bucket 43 thereof, can be very useful to either remove or add additional sidewalk base material 22 depending on the condition of the site reserved for the sidewalk. In addition, as the sidewalk grader 20 advances along the road structure 30 , the bucket 43 can be used to break-up native hard-pan type soil, and to remove large rocks and the like.
[0043] The construction equipment 38 is generally positioned to move forward over an existing road structure 30 to advance the sidewalk grader 20 in a direction along the existing road structure 30 , substantially parallel thereto. This forward movement is indicated by arrow 46 . Importantly, the excavation equipment 38 so provided is disposed and operated over an existing road structure 30 thereby minimizing the impact it has on the base 26 . Accordingly, the tracking assembly 34 is configured to extend from the vertically movable accessory 36 in a transverse direction to the course of advancement (indicated by an arrow 46 ), transversely across the road structure 30 and the curb 32 thereof.
[0044] In addition, the tracking assembly 34 further comprises a vertically adjustable tracking means 48 disposed for engagement with the top surface of the curb 32 portion of the road structure 30 . With this configuration, the top surface 50 of the curb 32 provides a point of reference for operation of the sidewalk grader 20 .
[0045] A grading assembly 54 is mounted and fixed to the tracking assembly 34 so that the grading assembly 54 extends outward, beyond the curb 32 , positioned over the location of the area reserved for the designed sidewalk and base 26 thereof. More specifically, the grading assembly 54 comprises a frame 56 , and a grading blade 58 rotatingly mounted to the frame 56 to permit adjustment of slope of the grading blade 58 according to the specified sidewalk design grade. In order to lock or fix the rotation of the grading blade 58 in relation to the frame 56 , according to a predetermined grade, a fixing means 60 for fixing the blade rotation is provided.
[0046] As noted above, the tracking means 48 is vertically adjustable. This feature is provided to enable the tracking means 48 to engage with the top surface 50 of a curb 32 to provide a relative reference, or point of reference, for precise vertical and horizontal adjustment of the sidewalk grader 20 , to position the grading assembly 54 , and for maintaining the grading assembly in the desired position in relation to the curb as the sidewalk grader 20 advances along the existing road structure 30 as indicated by arrow 46 .
[0047] Because the top surface 50 of the curb 32 is usually rough concrete, the preferred tracking means 48 is constructed for rolling engagement along the top surface 50 of the curb 32 , such as a wheel 94 .
[0048] In a simplified embodiment of the sidewalk grader 20 , the tracking assembly 34 comprises a pivot joint 64 , disposed adjacent the backfill blade to enable the sidewalk grader 20 to fold from a first unfolded position to a folded position. An additional pivot joint 65 is provided to form an additional folding point to fold the sidewalk grader 20 for storage and transportation. As will be discussed more fully below, a second pivot joint 65 can provide an additional pivot axis for up and down movement of the grading assembly 54 to provide greater flexibility thereof.
[0049] A cylinder support 82 is fabricated from solid steel for strength and is welded directly to the support tube 76 . At the top of the cylinder support 82 is an upper eye to provide a connection point for the upper portion of a vertical hydraulic cylinder. Similarly, at the opposing end, its ram is connected to a vertically movable wheel carriage having a wheel 94 . With this arrangement, the ram 88 can be operated to vertically adjust the wheel 94 to the proper elevation to rest on the top surface 50 of curb 32 to track the curb 32 as the sidewalk grader 20 advances along the road structure 30 . Adjusting the vertical hydraulic cylinder causes pivoting of the blade 58 rather than vertical movement of the blade.
[0050] As the sidewalk grader 20 advances along the road structure 30 , the wheel 94 should be adjustable between a first lower limit and a second upper limit, thereby lowering the sidewalk grader 20 to enable the sidewalk grader 20 to follow the curb 32 as it drops to an area reserved for a driveway (not illustrated), i.e., where the curb transitions downward and fades into the driveway. This movement causes pivoting of the blade 58 in an arc, such that its distant end moves more than its nearer end, rather than vertical movement of the blade.
[0051] To compensate for the pivoting of the blade, as shown in FIG. 5 , a slope control system including a slope sensor 220 , a pivot 180 , and a hydraulic cylinder 226 (all not shown in FIG. 1 ) were added to the prior art system. This slope control system compensates for any deviation in slope of the grading blade 58 caused by bumps in the road structure 30 , change in slope of the road structure, and excavator load changes and the like. Accordingly, the slope sensor senses any change in slope and communicates the change to a control box which then signals an electronically controlled valve stack to activate the hydraulic slope control link to compensate for the change. In this way, the grading blade 58 is automatically controlled to provide a smoothly graded base 26 for the sidewalk.
Converting the Excavator to a Multi-Attachment Side Tool Carrier
[0052] As described below, as an improvement over the above described prior art, the present invention encompasses a tool carrying and controlling system wherein an operator can control a swiveling tool and either a first attachable linear acting controllable tool or a second attachable linear acting controllable tool to operate in coordination with the first tool. For use in this system, the excavator is modified to include a side tool mounting base or support 66 affixed below the swivel 10 for attaching any linear acting tool via a mating surface 74 , and a set of hydraulic line quick couplers 494 are mounted proximate to the side mounting base 66 as shown in FIG. 2 . The couplers may be ganged as shown in FIG. 3 . The quick coupler hydraulic connections may be color-coded to correspond to the function control buttons on a Suregrip handle 465 in the cab with corresponding colors as shown in FIG. 4A . Attachment hydraulic hoses may also have corresponding colors.
[0053] On the excavator, the two hydraulic hoses that operate the stock backfill blade are rerouted to an electronically controlled valve stack with proportional and/or on/off sections for supplying hydraulic pressure to any number of attachment hydraulic circuits. Accordingly, the tool support mount 66 on one end of the backfill blade is now connected to, and controlled by the valve stack. In this way, the operator can electronically control the valve stack from within the cab of the excavator, above the swivel 10 , to control all hydraulic circuits below the swivel that effect any attachment function. The valve stack is located between the lower side of the swivel and the quick couplers, and any number of hoses are routed from the valve stack to the set of hydraulic couplers for the side attachment.
[0054] Electric control wires from the cab to the valve stack may couple the two together as in the prior art. However, this limits rotation of the swivel 10 and risks damaging the wires. An improvement is to pass the control wires through the swivel with slip rings, an electromechanical device that allows the transmission of power and electrical signals from a stationary to a rotating structure, also called a rotary electrical joint, collector or electric swivel.
[0055] Alternatively, A transmitter/receiver mounted in the cab can transmit all commands from an installed control handle mounted on the right or left joystick as well as any other switches or any controls in the machine's cab. A receiver/transmitter capable of driving the hydraulic valve stack decodes the signal and controls the valve stack. A hydraulic generator that is installed in the return hydraulic line generates power to keep a large capacitor charged. This capacitor supplies power to operate the electric control valves and supplies power to the wireless receiver/transmitter module. A battery may be used instead of a capacitor. The battery can be charged as mentioned above or removed each night and charged the conventional way.
[0056] As another alternative, instead of manifolding one hydraulic circuit into many with a control valve stack placed below the swivel 10 and then routing electric or wireless controls through or around the swivel, the excavator swivel can be modified to add more hydraulic circuits through the swivel, allowing the valve stack to be placed above the swivel.
[0057] As a further improvement to the prior art side tool system, a vertical slider, shown in FIG. 5 , may be inserted into the beam structure between the excavator and the tool. This prevents relative vertical movement from inducing a pivoting movement. This slider may be inserted at joint 64 in FIG. 1 . It retains the hinge feature of prior joint 64 to allow folding of the beam. The slider may be hydraulically actuated, as shown in FIG. 5 , or it may slide by itself vertically, perhaps using the wheels on the curb or other datum line to force vertical movement. The vertical slider constrains the tool to move straight up and down and not swing in an arc, as in the prior art.
[0058] For use with this multi-tool carrier, several linear acting attachable side tools are described below.
Curb or Curb and Gutter Extruder
[0059] On a road and sidewalk construction job, the first linear acting tool that is useful when mounted on the side tool carrier described above is a curb and gutter extruder as shown in FIG. 6 .
[0060] After a first curb is extruded and hardened, the extruder head may be changed to extrude a second curb on the far side of the sidewalk grade as shown in FIG. 7 . A trimmerhead 430 and auger 435 can be used in conjunction with or ahead of the curb and gutter extruder.
[0061] As shown in FIG. 6 , a sonar sensor 525 may be set up on an arm 520 to actuate controllers that adjust height and lateral location relative to a string 522 set up as a datum line.
Sidewalk Grader Improvements
[0062] The next tool to be used on the job is a sidewalk grader. As an improvement to the prior art grader, the blade width may be made adjustable with a sliding blade extension 304 guided by guide bars 315 and 316 and actuated by a hydraulic cylinder 318 as shown in FIG. 8 .
[0063] As another improvement, a detachable fin 302 shown in FIG. 8 may be added to the distant end of the blade.
[0064] As another improvement, a detachable trencher 382 shown in FIG. 9 may be added to the distant end of the blade to create a trench for placing sidewalk edging stones. For use in the same pass, a windrow forming attachment 380 may be added to pile displaced material in a windrow 384 .
[0065] Then a second curb may be extruded as shown in FIG. 7 or sidewalk edging stones 385 may be placed in the trench as shown as shown in FIG. 10 . Base rock 387 is then placed in the sidewalk grade, and the base rock is graded with the sidewalk grading blade, as shown in FIG. 10 . An edging backfill attachment 386 may be added to the end of the blade to pull the windrow 384 against the edging stones 385 or extruded curb.
[0066] Also, a sonar sensing and guiding system may be added to sense the curb top or the gutter or a guide string. A laser sensor may be added to sense a laser beam for guidance.
Paver
[0067] Now the grade is ready for paving with a paver as shown in FIGS. 11, 12, and 13 (cross section). The paver components are attached to the grading blade to add an auger 342 and a smoothing plate 351 plus smoothing plate extension 352 . A vibrator 308 helps smooth the material, whether cement or asphalt, and, when used for asphalt, heaters 335 , 336 , and 337 keep the smoothing plate warm. If electric heaters are used, they may be driven by a generator 301 which may be mounted on the excavator blade 40 .
Reel for Auxiliary Hydraulic Hoses
[0068] FIGS. 14A, 14C, 15A, 15B and 16A show a hydraulic hose reel 651 adapted to carry two hydraulic hoses in the tool mounting base (which is preferably also an earth moving blade) for connecting any tool that needs hydraulic power.
Horizontally Extendable Side Blade
[0069] FIGS. 14B, 14C, 15B, 15C, 15D, 16A, and 16B show a side blade which extends horizontally out of an end of the tool mounting base (which is preferably also an earth moving blade). The side blade 861 is also shown in FIGS. 23, 24, 25 26 A, 26 B, and 27 .
Multi-Coupling Plate
[0070] FIG. 3 shows a fixed hydraulic multi-coupling plate 871 and a mating mobile hydraulic multi-coupling plate 870 .
[0071] FIGS. 16C, 17B, and 17C show a multi-coupling plate 871 mounted on the tool mounting base (which is preferably also an earth moving blade). This prevents hydraulic hoses from being incorrectly coupled. As shown in these figures, it also is engaged by the action of engaging a tool mount 872 with a tool multi-coupling plate 870 onto the mounting base. Thus, one action both attaches the tool and couples hydraulic lines for actuating the tool.
[0072] FIGS. 16C and 17C show how retainers 873 of the tool mount 66 may be powered with a hydraulic cylinder 874 . The retainers 873 engage and retain steel pins 875 with are part of the tool mount 872 . A third pin 876 may be added beside the multi-coupler to ensure alignment:
[0000] Tool Attachment Base that Stays Plumb
[0073] The tool attachment base 66 is preferably a central earth-moving blade on an excavator. However, as shown in FIG. 18A , the standard blade rotates out of plumb as the blade is raised and lowered. For use of the blade as a tool attachment base, it is preferable to replace the blade with a blade designed to stay plumb as the blade is raised and lowered.
[0074] There are two ways to achieve this objective. First, the blade may be designed with upper and lower pivot points connected by arms to upper and lower pivot points on the machine, with the blade pivot points located such that the four pivot points always form a parallelogram. A hydraulic cylinder is then coupled to apply forces to opposite corners of the parallelogram to raise and lower the blade.
[0075] Alternatively, the blade may be designed as shown in FIGS. 18B and 19 . As shown, a first arm connecting the blade to the machine via couplings 918 and 919 includes an intermediate coupling 901 between a first portion of the arm 912 and a second portion of the arm 913 . The first portion is affixed with a pivot 915 to a second arm 914 which couples the blade to the machine via couplings 920 and 921 , and the first portion 912 includes a lever arm 917 between the intermediate coupling 911 and the pivot 915 wherein the length and angle of the lever arm is determined so as to constrain the tool attachment base 66 to move up and down without significant rotation out of plumb.
[0076] In either case, the design may be described more generally as follows: at least two arms, each having a first end and a second end, with rotatable couplings at the first ends for attaching to the machine; rotatable couplings on the second ends coupled to a tool attachment base; and the at least four couplings each having a location when the attachment base is mounted on a machine via the couplings wherein geometric relationships between the locations of the couplings constrains the tool attachment base to move up and down without significant rotation out of plumb.
Silt Fence Installer
[0077] Often when a silt fence must be installed it is important not to disturb ground on one side. The bucket 43 of an excavator is useful for preparing the area while the machine moves forward installing the fence 602 as shown in FIG. 20 . The silt fence installer attachment includes a fence roll support bar 608 that supports a roll of fencing material 602 . The fencing material is fed off the roll, down around a direction changing diagonal edge (not visible). Surrounding the fencing as it goes around the direction changing edge are two sides 604 of a direction changing chamber. The sides join at a plowing edge 618 that cuts into the ground as the machine moves forward. A skid or wheels 606 may be adjusted up or down to change the depth of the cut made by the plowing edge 618 .
[0000] Silt Fence with Attached Posts Installer
[0078] FIG. 21A shows another form of silt fence installer. In this case, the silt fence is supplied on a roll 801 with stiff posts 802 attached to the fence material every 2-4 feet. The posts extend below the fence material at the bottom by 3-12 inches. A plowing edge 803 digs a trench to a preferred depth for the silt fence material.
[0079] As the fencing with posts unrolls, it is inserted into the trench with the post bottoms at the bottom of the trench and the fence material above the bottom by 3-12 inches. Then a post pusher 804 pushes on the tops of the posts to push them into the soil at the bottom of the trench to a preferred depth, typically until the fence material touches the bottom of the trench. Hydraulic cylinders adjust a height of a leading edge of the post pusher and a height of a trailing edge of the post pusher to push the posts to the desired depth.
[0080] In a preferred embodiment, a steel U channel with extending fins extends from a trailing edge of the plow 802 to keep the trench open until the fence is seated. A bottom of the U channel supports and guides the post bottoms as they descend to the bottom of the trench. Then the fins hold back soil until the posts are pushed to a desired depth.
[0081] Finally, rotatable discs 807 push the soil to close the trench against the fence material.
[0082] The same fence installer side-tool attachment can be used to install fences that do not include buried material by setting tool height so that no trench is dug and using fencing where the posts extend below the material by 8-24 inches,
[0083] Preferred structure for the fencing material 801 is woven with loose warp and weft parallel and perpendicular to the fence bottom and top so that it will easily skew to parallelogram orientation to allow material coming off the roll to easily descend to installed height and then the material reorients to roughly square as it is seated.
Fence and Non-Attached Posts Installer
[0084] FIG. 22 shows another form of fence installer. In this case, the fence is supplied on a roll 831 without posts. The posts are robust and require an auger 832 mounted on a vertical sliding base 834 mounted on a vertical slide 833 to drill holes, or require a hydraulic post pounding face (not shown) mounted on the sliding base 834 to pound them in. The attachment may include a fence stretcher 835 .
Horizontally Extendable Low Profile Side Blade
[0085] FIG. 23 shows a horizontally extendable low profile side blade attachment 861 that can clear debris under guard rails. As shown in FIG. 24 , the low profile blade slides horizontally in or out using pipe guides 862 . A similar horizontally extendable blade 864 is also shown in FIG. 25 . The pipes guides 865 are shown in a side view in FIG. 26B , and in a top view in FIG. 26A .
Side Roller
[0086] It is sometimes advantageous to be able to roll a surface to one side of a road grade, such as in a sidewalk grade. A side roller attachment, as shown in FIG. 31 , mounted on the modified excavator does the job. The roller may include a vibrator 730 .
Red Zone Auto Controls
[0087] A system with a programmable controller in the cab with a custom graphic display can be used to create a “Red Zone” that the excavator components cannot enter, thereby protecting the tool and people near it or using it. Inclinometers, potentiometers, rotation sensors, and cylinder stroke sensors are some of the means to indicate to the controller the position of the cab, arm 11 , boom, and bucket, to enable the machine to stay out of the “Red Zone”. When the machine enters the “Red Zone” the pilot valve cuts the oil supply between the excavator control handles and the excavator control valve.
[0088] In particular, the controller can be programmed to give specific directions for each attachment using a look-up table for each attachment to specify:
location of “Red Zone”, restriction on flow rate and psi of hydraulic oil to each hydraulic actuator, down to zero when appropriate, allowed characteristics of each function of each hydraulic actuator of the excavator or the tool, limitations on or specification of track speed and direction (the Leica Sonar system can read a string line and direct the controller to drive the machine's direction and speed automatically) as with the side grader and the curb and gutter extruder; and alignment of control handle buttons to correspond with attachment functions.
[0094] IFM Electronics makes a suitable inclinometer, model EC 2045, and cylinder stroke sensors. They also offer a suitable programmable controller, model CR 1050.
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An excavator machine with a side mounted silt fence installing tool mounted below the swivel. The excavator has a swiveling and articulating tool and an operator's seat above the swivel. An articulating arm is attached above the swivel so the operator may operate swiveling and articulating tool in a coordinated way with the silt fence installer to accomplish a job more efficiently than it could be accomplished using tools separately mounted one at a time.
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This application is a continuation of application Ser. No. 08/336,203, filed Nov. 4, 1994, U.S. Pat. No. 5,564,384.
BACKGROUND FOR THE INVENTION
1. Field of the Invention
The present invention relates to an intake system of an internal combustion engine including a fuel injection valve for injecting fuel to an intake port of the engine, and an intake air-flow deflection mechanism which serves to deflect flow of intake air so as to produce vortex flow in a cylinder of the engine, and more particularly, to an intake system appropriate for lean-burn operation of an internal combustion engine.
2. Description of the Prior Art
In a conventional intake system of an internal combustion engine, as disclosed in Japanese Patent Unexamined Publication No. 60-230543, flow of intake air is deflected. However, according to the conventional system, strong vortex flow is not produced in a cylinder of the engine because the deflected intake air flow lack orientation or directivity. Further, since fuel is sprayed into the deflected air flow, the direction of injection of the fuel is unfavorably changed so that the fuel cannot be supplied to a target position. Consequently, the fuel sticks to a wall of an intake pipe and flows into the cylinder in the state of liquid, which results in non-uniformity of the fuel-air mixture distribution in the cylinder. Thus, lean-burn operation of the engine cannot be realized.
In view of the above, the present invention aims to prevent non-uniformity of the fuel-air mixture distribution in a cylinder of an internal combustion engine, unlike the prior art, so as to realize uniformity of the distributed fuel-air mixture, and to improve ignitability of the mixture at the time of lean-burn operation of the engine, by selecting the direction of supply of sprayed fuel in order to partially concentrate the mixture flow rich in the fuel in the vicinity of an ignition plug in the cylinder.
Further, the invention aims to prevent the fuel from being blown off by high-velocity air flow for producing tumble flow in the cylinder, which tumble flow accelerates combustion of the mixture in the cylinder.
SUMMARY OF THE INVENTION
In an intake system of an internal combustion engine according to the invention, a high-velocity air flow supply device which supplies to an intake port portion high-velocity air flow for producing tumble flow in a cylinder of the engine, is provided for supplying the high-velocity air flow having orientation at a target position of an intake valve portion, thereby producing strong tumble flow in the cylinder. A position of an injection port of the high-velocity air flow supply device is so selected that the high-velocity air flow having the specific orientation may not blow off the fuel. Further, a nozzle hole or holes of a fuel injection valve is so constructed as to minimize the angle of spray of the fuel, in order to prevent the fuel from being blown off by the orientated high-velocity air flow and from sticking to a wall of an intake pipe.
The high-velocity air flow having an orientation enters the cylinder through the intake port during an intake stroke of the engine, so that strong tumble flow is produced in the cylinder. This tumble flow is reserved until during a compression stroke of the engine to thereby accelerate the combustion of the mixture after the ignition. Further, because the fuel is supplied above the intake valve, the fuel collides with the high-velocity air flow above the intake valve, so as to be atomized. The atomized fuel is dispersed in the cylinder while it is being conveyed by the tumble flow in the cylinder. The mixture is thus distributed uniformly in the cylinder.
According to the invention, because the fuel-air mixture is uniformly distributed or stratified in the cylinder, the ignitability of the mixture can be improved. Further, the combustion of the mixture is accelerated by the tumble flow produced in the cylinder so that stable combustion of lean mixture can be realized. Therefore, fuel consumption is suppressed and the amount of HC or NOx can be remarkably reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is an elevational side view showing an intake system of an internal combustion engine according to a first embodiment of the present invention; FIG. 1B is an elevational front view showing the same in cross section;
FIG. 2 is a diagram showing the structure of an intake port portion in the first embodiment from a first direction;
FIG. 3 is a diagram showing the structure of the intake port portion in the first embodiment from a second direction;
FIG. 4 is a diagram showing the structure of the intake port portion in the first embodiment;
FIG. 5 is a diagram showing the structure of the intake port portion and a combustion chamber in the first embodiment;
FIG. 6 is a diagram showing the structure of the intake port portion and the combustion chamber in the first embodiment;
FIG. 7 is a diagram showing the operation during a compression stroke of the engine;
FIG. 8 is a diagram showing the structure of an intake port portion according to a second embodiment of the present invention;
FIG. 9 is a diagram showing the structure of the intake port portion and a combustion chamber in the second embodiment;
FIG. 10 is a diagram showing the structure of an intake port portion and a combustion chamber according to a third embodiment of the invention;
FIG. 11 is a diagram showing the structure of the intake port portion and the combustion chamber in the third embodiment at one point in the combustion cycle;
FIG. 12 is a diagram showing the structure of the intake port portion and the combustion chamber in the third embodiment at a second point in the combustion cycle;
FIG. 13 is a diagram showing the operation during a compression stroke of the engine at a third point in the combustion cycle;
FIG. 14 is a diagram showing the structure of an intake port portion and a combustion chamber according to a fourth embodiment of the invention;
FIGS. 15A to 15C are diagrams of an injector valve;
FIGS. 16A and 16B are enlarged views of fuel injection holes of an injector valve;
FIGS. 17A and 17B are enlarged views of fuel injection holes of an injector valve;
FIG. 18 is a diagram showing the structure of an intake port portion according to a fifth embodiment of the invention;
FIG. 19 is a diagram showing the structure of the intake port portion and a combustion chamber in the fifth embodiment;
FIG. 20 is a diagram showing the structure of an intake port portion according to a sixth embodiment of the invention; and
FIG. 21 is a diagram showing the structure of an intake port portion according to a seventh embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be hereinafter described with reference to the attached drawings.
The structure of a first embodiment of the invention is shown in FIGS. 1A and 1B. In FIGS. 1A and 1B, reference numeral 1 denotes one half (e.g., a left bank) of an engine with a V-shape cylinder arrangement. When an intake cam 12 is operated, an intake valve 14 is opened, and a piston 20 is lowered. Accordingly, intake air 2 is supplied via an air cleaner 3 for removing dirt and dust from the air, an air metering section 5 for measuring the rate of the intake air, a throttle valve 6 for controlling an operation condition of the engine, and a collector 7. The intake air 2 is further supplied to a combustion chamber 19 of each air cylinder through an individual intake pipe 8 connected with an intake port 17 of the air cylinder. At this time, fuel is injected to the combustion chamber 19 from a fuel injection device 21. After the air is sucked into the combustion chamber 19, the intake valve 14 is closed, and the piston 20 is raised to compress the mixture of the air and the fuel. The fuel-air mixture is exploded by an ignition plug 16, and the piston 20 is pressed down. When an exhaust cam 13 is operated to open an exhaust valve 15, exhaust gas after the combustion is discharged out of an exhaust port 18. The individual intake pipe 8 connected with the intake port 17 of each air cylinder includes a flow dividing valve 9 and passages 10 for bypassing the intake air 2 from the collector 7 which is located upstream of the flow dividing valve 9. The bypass passages 10 supply the air to the intake port 17 from the collector 7 when the flow dividing valve 9 is closed. By passing the air through the (two) passages 10 each having a diameter of 8 mm which is sufficiently smaller than that of the flow dividing valve 9 (about 40 mm), the velocity of the intake air 2 is increased. That is to say, the velocity of the air flowing through the intake port 17 and the intake valve 14 is increased so that air flow can be formed in the combustion chamber 19. The flow dividing valve 9 can be opened/closed by driving a step motor 11 in response to a control signal from a control unit 4. When the opening degree of the throttle valve 6 is large, the opening degree of the flow dividing valve 9 is also large, thereby obtaining a high charging efficiency.
A portion of this system in the vicinity of the individual intake pipe 8 and the intake port 17 of each air cylinder is shown in FIG. 2 more specifically. In FIG. 2, the combustion chamber 19 of the engine 1 (on the right side of the dashed line) and the individual intake pipe 8 (on the left side of the dashed line) are viewed from the top, whereas the exhaust valve 15 and the exhaust port 18 are omitted from the illustration. During an intake stroke of the engine, the intake air 2 from the collector 7 is introduced into the combustion chamber 19 via a main intake passage 22 or the bypass passages 10. During low-load operation of the engine, the flow dividing valve 9 is closed, and the air which has bypassed the flow dividing valve 9 flows into the intake port 17 and the combustion chamber 19 at high velocity, and forms air flow called tumbles and swirls in the combustion chamber 19. The flow dividing valve 9 is opened/closed when the step motor 11 is driven in response to a control signal from the control unit 4. During high-load operation of the engine, the flow dividing valve 9 is opened so that a high charging efficiency can be obtained. Further, during middle-load operation of the engine, the flow dividing valve 9 is half-opened, thus regulating the ratio of the inflow rate Qb of the air through the bypass passages 10 and the inflow rate Qm of the air through the main intake passage 22 (the flow division ratio).
FIG. 3 is a diagram of the combustion chamber 19 of the engine 1, as viewed from the main intake passage 22. In FIG. 3, reference numerals 14a and 14b (hereinafter 14) denote the intake valve, and 16 denotes the ignition plug, whereas the exhaust valve 15 and the exhaust port 18 are omitted from the illustration. The bypass passages 10 (omitted from FIG. 3) attached to the individual intake pipe 8 have nozzle holes which are beforehand adjusted to face directions 1, 2 or 3 shown in FIG. 3. The directions 1 extend toward valve gaps formed between a central partition wall 26 and stems of the intake valve 14 when the intake valve 14 is lifted to the maximum degree. The directions 2 extend toward valve gaps defined between outer-side walls of the intake port 17 and the stems of the intake valve 14 when the intake valve 14 is lifted to the maximum degree. The directions 3 extend toward the proximal ends of the stems of the intake valve 14. When the nozzle holes face the directions 1, high-velocity air flow which has been supplied from the bypass passages 10 forms vertical vortex flow called tumbles in the combustion chamber 19. When the nozzle holes face the directions 2, high-velocity air flow which has been supplied from the bypass passages 10 whirls along the inner wall of the combustion chamber 19 and forms horizontal vortex flow called swirls in the combustion chamber 19. The directions 3 are provided to achieve both these effects of the directions 1 and 2. The foregoing vortex flow efficiently improves mixing of the air and fuel in the combustion chamber 19.
FIG. 4, similar to FIG. 3, is a diagram of the combustion chamber 19, as viewed from the main intake passage 22. In FIG. 4, reference numerals 14a and 14b ("14") denote the intake valve, and 16 denotes the ignition plug, whereas the exhaust valve 15 and the exhaust port 18 are omitted from the illustration. An explanation will be given on the case where the nozzle holes of the bypass passages 10 are adjusted to face the directions 1. During low-load operation of the engine, the flow dividing valve 9 (omitted from FIG. 4) is closed, and consequently, the air in the collector 7 passes through the bypass passages 10. Since the nozzle holes of the bypass passages 10 face the directions 1, high-velocity air flow is supplied into the combustion chamber 19 and forms tumble flow, as described above. At this time, the fuel injection device 21 injects fuel 23 on the basis of a control signal from the control unit 4. In order to promote vaporization and atomization of the injected fuel 23, the fuel 23 is injected toward tapered portions of the intake valve 14. The fuel 23 which has collided with the tapered portions of the intake valve 14 is partially vaporized and diffused, and is mixed with the air. The rest of the fuel 23 flows into the combustion chamber 19 in the state of liquid and is vaporized and diffused in the combustion chamber 19.
FIG. 5 is a vertical cross-sectional view of the engine 1 during an intake stroke, from which the exhaust valve 15 and the exhaust port 18 are omitted. Reference numeral 20 denotes the piston. The fuel 23, which has been injected from the fuel injection device 21 and collided with the intake valve 14 so as to be atomized, is blown off by high-velocity air flow from the bypass passages 10 in such a manner that the fuel 23 flows into the combustion chamber 19 from the side of the intake valve 14 closer to the ignition plug 16. Tumble flow 24 is formed in the combustion chamber 19.
FIG. 6 is a vertical cross-sectional view of the engine 1 during a compression stroke, from which the exhaust valve 15 and the exhaust port 18 are omitted. Reference numeral 20 denotes the piston. The tumble flow 24 which has been formed in the combustion chamber 19 during the intake stroke of the engine continues to exist during the compression stroke, and consequently, sprayed fuel 23 is blown outside of the tumble flow 24.
FIG. 7, similar to FIG. 6, is a vertical cross-sectional view of the engine 1 during the compression stroke. In a late stage of the compression stroke, the sprayed fuel 23 blown off by the tumble flows 24 exists in a peripheral portion of the combustion chamber 19.
A second embodiment of the present invention is shown in FIG. 8. FIG. 8 is a diagram of a combustion chamber 19 of an engine 1, as viewed from a main intake passage 22. In FIG. 8, reference numeral 14 denotes an intake valve, and 16 denotes an ignition plug whereas an exhaust valve 15 and an exhaust port 18 are omitted from the illustration. An explanation will be given on the case where nozzle holes of bypass passages 10 (omitted from FIG. 8) attached to an individual intake pipe 8 are adjusted to face the directions 1 shown in FIG. 3, with a fuel injection device 21 being arranged to inject fuel between a central partition wall 26 and stems of the intake valve 14 and to cause the fuel to collide with tapered portions of the general intake valve 14.
FIG. 9 is a vertical cross-sectional view of the engine 1 of this embodiment during an intake stroke, from which the exhaust valve is omitted. Fuel 23 injected from the fuel injection device 21 collides with the tapered portions of the intake valve 14 and is atomized. The atomized fuel 23 is blown into the combustion chamber 19 by high-velocity air flow from the bypass passages 10. At this time, because the fuel 23 collides with the intake valve 14, the amount of fuel 23 which directly flows into the combustion chamber 19 through valve gaps and reaches the inner wall of the combustion chamber 19 in the state of liquid is lessened. Moreover, tumble flow 24 is formed in the combustion chamber 19, and therefore, the atomized fuel 23 is efficiently mixed with the air and uniformly distributed.
A third embodiment of the invention is shown in FIG. 10. FIG. 10 is a vertical cross-sectional view of the engine 1, from which an exhaust valve 15 and the exhaust port 18 are omitted. Reference numeral 20 denotes a piston. A fuel injection device 21 is attached to an engine head 25, and arranged at an angle in the vicinity of the combustion chamber 19.
FIG. 11 is a vertical cross-sectional view of the engine 1 during an intake stroke, from which the exhaust valve 15 and the exhaust port 18 are omitted. Reference numeral 20 denotes the piston. Fuel 23, which has been injected from the fuel injection device 21 and collided with the intake valve 14 so as to be atomized, flows into the combustion chamber 19 from the side of the intake valve 14 closer to the fuel injection device 21. On the other hand, high-velocity air flow from bypass passages 10 is supplied into the combustion chamber 19 from the side of the intake valve 14 closer to the ignition plug 16 and forms tumble flow 24 in the combustion chamber 19.
FIG. 12 is a vertical cross-sectional view of the engine 1 during a compression stroke, from which the exhaust valve 15 and the exhaust port 18 are omitted. Reference numeral 20 denotes the piston. The fuel 23, which has been injected from the fuel injection device 21 and collided with the intake valve 14 so as to be atomized, is included by the tumble flow 24 which has been formed during the intake stroke.
FIG. 13 is a vertical cross-sectional view of the engine 1 in a late stage of the compression stroke. The sprayed fuel 23, which has been included by the tumble flow 24 during the compression stroke, continues to be distributed in the vicinity of the ignition plug 16 even after the tumble flow 24 disappears. This distribution is advantageous for reliable ignition in lean-burn operation.
A fourth embodiment of the invention is shown in FIGS. 14 to 17. FIG. 14 is a vertical cross-sectional view of the engine, from which the exhaust valve is omitted. The direction of fuel injection by an injector 12 differs from the direction of the central axis of the injector valve 12, as shown in FIGS. 15 to 17, so that even if the injector 12 is located in the conventional position, the above-described effect can be obtained, i.e., sprayed fuel is collided with the side of an intake valve closer to an intake port, and the sprayed fuel is included by tumble flow, thereby improving the ignitability at the time of lean-burn operation. FIG. 15A shows an injector having one nozzle hole 120. FIG. 15B is an enlarged view showing the nozzle hole 120 and its neighboring portion. As viewed from this side, fuel is injected in the same direction as the central axis 121 of the injector valve. However, as viewed from a different side like FIG. 15C, the central axis 121 of the injector valve extends in a direction different from the injection direction 122 of the fuel. Thus, when the nozzle hole of the fuel extends in a direction different from that of the central axis of the injector valve, the sprayed fuel can be supplied to a desired position without considering the layout of an intake pipe and the injector valve.
FIGS. 16A and 16B show an injector having two nozzle holes 123(a) and 123(b). This injector is of the structure of an injector valve for atomization in two directions corresponding to a dual intake valve cylinder engine. FIG. 16B is a vertical cross-sectional view of the nozzle hole in two directions. As shown in FIG. 16B, the central axis 121 of the injector valve extends in the direction different from a direction 122 of the nozzle holes. In this case, the two nozzle holes likewise extend in the direction 122.
FIGS. 17A and 17B show the structure of an injector valve for introducing the air 123 to nozzle holes 124 and atomizing fuel 125. In this case, as shown in FIG. 17B, a fuel injection hole of a main body of the injector valve or a metering hole 127 extends in the same direction as that of the central axis 121 of the injector valve. However, the nozzle holes 124 of an adaptor 126 for introducing the air and dividing atomization into two directions extend in a direction different from that of the central axis 121 of the injector valve. With such an arrangement, the atomized fuel can be supplied to a desired position in a direction different from that of the central axis of the injector valve.
A fifth embodiment of the invention is shown in FIG. 18. A flow dividing valve 106 is provided for closing an intake passage 107 of an intake port. By closing the flow dividing valve 106, high-velocity directive air flows are injected from passages 100. In order to aim the air flows at valve gaps at positions 110 between a central partition wall 108 and stems 109 of intake valves 101, outlets 104 of the passages 100 are opened toward the positions 110. However, if these outlets are located close to an intake pipe wall 105, areas of negative pressure are formed on the wall side, and the air flows are deflected toward the wall side. In such a condition, the air flows are dispersed and become no longer directive so that the air flows can not be aimed at the positions 110. Therefore, the outlets 104 of the passages 100 are located apart from the wall 105 so as to prevent generation of the above-mentioned wall-side air flows. With such an arrangement, the air flows injected from the outlets 104 are supplied to the predetermined positions 110 while their directions are maintained. Consequently, vortex flows are formed in the cylinder. In this embodiment, the outlets 104 of the passages 100 are projected in the air-flow directions, to thereby locate the outlets 104 apart from the wall.
FIG. 19 is a vertical cross-sectional view of the engine. An air flow 111 injected from each of the passages 100 is designed to enter the cylinder 112 from a gap between the intake valve 101 and a valve seat 102. In this case, tumble flow is formed in the cylinder 112 more easily when the air flow 111 is designed to collide with a cylinder wall 103.
A sixth embodiment of the invention is shown in FIG. 20. In order to locate outlets 104 of passages 100 apart from the wall 105, projections 113 are formed on the wall instead of projecting the outlets 104, as shown in FIG. 18. With such an arrangement, directivity of the air flows can be maintained without projecting the outlets 104 excessively toward the intake passage 114.
A seventh embodiment of the invention is shown in FIG. 21. In order to form vortex flow of the air in a cylinder, a valve 115 is provided in an intake passage. In such a system, the direction of an injector valve 116 is restricted in relation to the layout of the intake pipe, and consequently, it is difficult to supply sprayed fuel to a desired position. However, by use of the injector valves shown in FIGS. 15A-15C, FIGS. 16A, 16B, and FIGS. 17A, 17B, the direction of the sprayed fuel can be changed freely so that the injector valves can be provided at desired positions. In FIG. 21, the central axis of the injector valve extends in a direction A, but the injection direction of the sprayed fuel extends in a direction B.
The valve 115 is closed at the learn-burn operation, as shown by a solid line in FIG. 21. Thus, as shown by an arrow C in FIG. 21, the air flow is deflected to produce vortex flow in the cylinder of the engine. At the full load operation, the valve 115 is opened, as shown by a broken line in FIG. 21.
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An air intake system for an internal combustion engine uniformly distributes the fuel-air mixture in the cylinder, and concentrates the mixture in the vicinity of an ignition plug in the cylinder by selecting the direction of supply of sprayed fuel, thereby improving ignitability of the mixture at the time of lean-burn operation. The system produces tumble flow in the cylinder for accelerating combustion and provides lean-burn operation, thereby suppressing consumption of the fuel and reducing the amount of exhaust gas. The fuel is injected by a fuel injection valve and collides with an intake valve, before being atomized. The atomized fuel flows into the cylinder from the side of the intake valve closer to the fuel injection valve. On the other hand, high-velocity air flow from bypass passages enters the cylinder from the side of the intake valve closer to the ignition plug, so as to produce tumble flow in the cylinder.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to battery pack connectors and, more specifically, to an apparatus and method for connecting and securing a battery pack to a battery powered vehicle and/or to a battery charging device.
2. Description of the Prior Art
Currently, the installation and removal of a battery pack from a battery powered vehicle and/or from a battery charging device is potentially hazardous to the individual installing or removing the battery pack. This is due to the close body and eye contact that is required by the individual during the installation and removal process. Existing battery pack connectors require the battery pack installer to place his or her hands on or near the battery cables as well as the battery connectors during the installation and removal process. As the battery cables and connectors become older, the insulation on the battery cables begin to deteriorate, thereby reducing the resistance in the battery cables. The deteriorated insulation raises the potential of the installer getting an electrical shock from the battery pack during the installation and removal process.
Another problem with current battery connectors is that most connectors require the battery installer to manually connect the battery pack to the battery powered vehicle and/or to the battery charging device. Connections that are dependent on the battery installer's strength for proper fitness and tightness may result in poor and inconsistent operation of the battery powered vehicle as well as inconsistent charging of the battery pack from the battery charging device. This is due to the fact that an installer who is unable to completely tighten the battery connector will not get a proper connection between the battery pack and the battery powered vehicle and/or the battery charging device, whereas an installer who overly tightens the battery connector may damage the connector, as well as the battery pack's terminal, thereby leading to inconsistent operation and/or charging of the battery pack. Incomplete and loose electrical connections between the battery packs and the battery connectors have been known to cause the battery connectors to burn up, thereby causing the battery packs to explode.
A further problem with devices that are currently being used for installing and removing battery packs is that these devices do not work very effectively in securing and holding the battery packs in position. Devices such as pins, bolts, springs, and other hardware devices are currently being used to secure the battery packs once the battery packs are connected to the battery powered vehicle and/or the battery charging device. Many times during the installation and removal process these securing devices are lost, damaged, or incorrectly used. Even when correctly used, bolts and nuts have a tendency to become cross-threaded or damaged, and springs have a tendency to become stretched, thereby losing their elasticity. Therefore, over time, these devices lose their ability to hold the battery packs in place.
Therefore, a need existed to provide an improved apparatus that is capable of connecting and securing a battery pack to a battery powered vehicle and/or a battery charging device. The improved battery connecting and securing apparatus must eliminate the use of the battery installer's hands on or near the battery cables or any other current carrying devices during the installation and removal process. The improved battery connecting and securing apparatus must also ensure that a proper connection is made between the battery pack and the battery powered vehicle as well as between the battery pack and the battery charging device. Finally, the improved battery connecting and securing device must be able to ensure that the battery packs do not move when the battery packs are connected to the battery powered vehicle and/or the battery charging device.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved apparatus and method for connecting and securing a battery pack in a battery powered vehicle and/or a battery charging device.
It is another object of the present invention to provide an improved apparatus and method for connecting and securing a battery pack in a battery powered vehicle and/or a battery charging device that will not require the battery pack installer to use his or her hands on or near the battery cables or any other current carrying devices.
It is still a further object of the present invention to provide an improved apparatus and method for connecting and securing a battery pack in a battery powered vehicle and/or a battery charging device that will hold the battery pack in position once the battery pack is connected to the battery powered vehicle and/or the battery charging device.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with one embodiment of the present invention, an apparatus for connecting and securing a battery pack of a battery powered vehicle is disclosed. The apparatus comprises a frame located around a perimeter portion of the battery pack. A first connector is slidably coupled to the frame in order to facilitate coupling of the battery pack. A second connector is coupled to the first connector and to the battery powered vehicle for coupling the battery pack to the battery powered vehicle. A handle is pivotally coupled to the frame and the first connector for slidably coupling the first connector to the second connector.
In accordance with another embodiment of the present invention, an apparatus for connecting and securing a battery pack of a battery powered vehicle is disclosed. The apparatus comprises a frame located around a perimeter portion of the battery pack; first connector means slidably coupled to the frame for facilitating coupling of the battery pack; second connector means coupled to the first connector and to a battery charging device for coupling the battery pack to the battery charging device; and a handle pivotally coupled to said frame and said first connector means for slidably coupling said first connector means to said second connector means.
In accordance with another embodiment of the present invention, a method for connecting and securing a battery pack of a battery powered vehicle is disclosed, comprising the steps of providing an apparatus for connecting and securing the battery pack of a battery powered vehicle, the apparatus comprising a frame located around a perimeter portion of said battery pack, first connector means slidably coupled to said frame for facilitating coupling of said battery pack, second connector means coupled to said first connector means and said battery powered vehicle for coupling said battery pack to said battery powered vehicle, and handle means pivotally coupled to said frame and said first connector means for coupling said first connector means to said second connector means and for securing said battery pack from moving while said first connector is connected to said second connector; and moving said handle means to a closed position so that said first connector means is connected to said second connector means.
In accordance with still another embodiment of the present invention, a method for connecting and securing a battery pack of a battery powered vehicle is disclosed, comprising the steps of providing an apparatus for connecting and securing a battery pack of a battery powered vehicle, the apparatus comprising a frame located around a perimeter portion of said battery pack, first connector means slidably coupled to said frame for facilitating coupling of said battery pack, second connector means coupled to said first connector means and to a battery charging device for coupling said battery pack to said battery charging device, and handle means pivotally coupled to said frame and said first connector means for coupling said first connector means to said second connector means; and moving said handle means to a closed position so that said first connector means is connected to said second connector means.
The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the battery connecting and securing apparatus of the present invention.
FIG. 2 is a side view of the battery connecting and securing apparatus of the present invention.
FIG. 3 is a top view of the battery connecting and securing apparatus of the present invention.
FIG. 4 is a front view of the battery connecting and securing apparatus of the present invention.
FIG. 5 is a perspective view of the battery connecting and securing apparatus located on a battery changing station.
FIG. 6 is a perspective view of the battery connecting and securing device coupled to a battery charging device of the battery changing station of FIG. 5.
FIG. 7A is a front view of a safety latch used in the present invention.
FIG. 7B is a cross-sectional view of the safety latch of FIG. 7A taken along line 7B--7B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-4, a battery connecting and securing apparatus 10 (hereinafter apparatus 10) is shown. The apparatus 10 is comprised of a frame 12 which is located around a perimeter portion of a battery pack 14. The frame 12 is preferably made of angle iron and can be designed to fit a variety of different size battery packs 14. The frame 12 may be easily installed or removed from the battery pack 14 by simply clipping the frame 12 onto a top section of the battery pack 14. The frame 12 is designed to allow easy access to the top of the battery pack 14 to allow an individual ample space for servicing of the battery pack 14.
A first connector 16 is slidably coupled to a top section of the frame 12. The battery pack 14 is coupled to one end 16A of the first connector 16. A second connector 18 is coupled to either a battery powered vehicle (not shown) or a battery charging device (not shown). The first connector 16 and the second connector 18 are preferably a water proof electrical type battery connector which will ensure a clean and environmentally protected connection. The first connector 16 and the second connector 18 have recessed current carrying surfaces to reduce the possibility of unintentional contact. In the preferred embodiment, the first connector 16 is a female type electrical connector and the second connector 18 is a male type electrical connector.
A handle 20 is pivotally coupled to the frame 12 and to the first connector 16. By moving the handle 20 downward to the closed position, the first connector 16 is slidably coupled to the second connector 18 thereby connecting the battery pack 14 to either the battery powered vehicle or the battery charging station depending on where the second connector 18 is coupled.
The second connector 18 is coupled to either the battery powered vehicle or the battery charging station via rubber vibration isolators 22. The rubber vibration isolators 22 act as an adjustment mechanism which allows the second connector 18 to adjust position in order to allow the second connector 18 to align with the first connector 16 when the first connector 16 is slidably coupled to the second connector 18.
The handle 20 is also coupled to at least one lock down rod 24. When the handle 20 is moved downward to the closed position, the lock down rod 24 also moves downward through an opening 26 in the frame 12 and onto a platform (not shown) of either the battery powered vehicle or the battery charging station. The lock down rod 24 secures the battery pack 14 to the platform, thus ensuring that the battery pack 14 does not move once the handle 20 is moved to the closed position and the first connector 16 is coupled to the second connector 18. When the handle 20 is moved upwards to the open position, the lock down rod 24 is retracted, thereby allowing the battery pack 14 to be moved. In the preferred embodiment, a lock down rod 24 is located on each side of the handle 20.
The opening 26 is positioned so least one lock down rod 24 is moved to a side of the opening 26 and positioned on the frame 12 when the handle 20 is moved to the open position. The lock down rod 24 rests on the frame 12, thereby preventing the movement of the handle 20 to the closed position without first realigning the lock down rod 24 with the opening 26.
A safety rod 28 is also coupled to the handle 20. When the handle 20 is moved to the closed position, the safety rod 28 moves downward through a second opening 30 in the frame 12. The safety rod 28 is lowered to a position that will prevent a lifting device (not shown) from being positioned underneath the battery pack 14, thus preventing the lifting device from moving the battery pack 14. When the handle 20 is raised to the open position, the safety rod 28 is retracted. This allows the transfer device to be placed underneath the battery pack 14 for lifting and moving of the battery pack 14.
A safety latch 32 is slidably coupled to the frame 12. The safety latch 32 is designed to prevent accidental closure or opening of the handle 20.
Referring to FIGS. 7A and 7B, the safety latch 32 comprises a channel 32A that runs longitudinally along a section of the safety latch 32. A holding device 32B is coupled to the frame 12 and is designed to hold the safety latch 32 in a normally closed position. A stopping device 32C is also coupled to the frame 12 and is designed to prevent the safety latch 32 from being raised to too high of a position. In order to move the handle 20 to the closed position, the safety latch 32 must be moved upwards along the channel 32A and held before moving the handle 20 downward to the closed position. Once the handle 20 is in the closed position, the safety latch 32 can be released thereby automatically locking the handle 20 in the closed position. The handle 20 cannot be moved to the open position without first lifting the safety latch 32 and then raising the handle 20.
FIGS. 5 and 6 show how the apparatus 10 may be used. The apparatus 10 is clipped onto a battery pack 14. In this particular embodiment, the battery pack 14 is positioned on a battery changing station 40. The second connector 18 is coupled to a battery charging device (not shown). The battery pack 14 is moved to a battery charging stall 42 via a lifting and moving device 44. Once the battery pack is positioned in the battery charging stall 42, the lifting and moving device 44 is deactivated and removed thereby lowering the battery pack 14 into the battery charging stall 42 (see FIG. 6). Once the battery pack 14 is lowered into the battery charging stall 42, the handle 20 of apparatus 10 may be closed. The movement of the handle 20 to the closed position couples the battery pack 14 to the battery charging device, thereby allowing the battery pack 14 to be recharged. It should be noted that the safety latch 32 must be raised and the lock down rod 24 realigned with opening 26 prior to the handle 20 being lowered to the closed position. Once the battery pack 14 is recharged, the handle may be raised (the operator first needs to raise the safety latch 32 prior to raising the handle 20), thereby disconnecting the battery pack 14 from the battery charging device. The battery pack 14 may be moved via the lifting and moving device 44 and placed in a battery powered vehicle (not shown). The battery pack 14 may then be coupled to the battery powered vehicle (a second connector 18 must be coupled to the battery powered vehicle in order to connect the apparatus 10 to the battery powered vehicle) by raising the safety latch 32, aligning the lock down rod 24 with opening 26 and lowering the handle 20 to the closed position.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.
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The present invention relates to an apparatus that connects and secures a battery pack to a battery powered vehicle and/or a battery charging device. The apparatus eliminates the use of the installer's hands on or near the battery cables or any other current carrying devices. The apparatus is comprised of a frame located around a perimeter portion of the battery pack, a first connector slidably coupled to the frame, a second connector coupled to the first connector and to a battery powered vehicle and/or a battery charging device, and a handle pivotally coupled to the frame and to the first connector for coupling the first connector to the second connector.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of U.S. patent application Ser. No. 11/865,525, filed Oct. 1, 2007, now pending, which is a continuation of U.S. patent application Ser. No. 11/210,715, filed Aug. 24, 2005, now U.S. Pat. No. 7,275,417, which is a continuation of U.S. patent application Ser. No. 10/935,024, filed Sep. 7, 2004, now U.S. Pat. No. 6,964,283, which is a continuation of U.S. patent application Ser. No. 10/180,047, filed Jun. 27, 2002, now U.S. Pat. No. 6,802,344, which is a divisional of U.S. patent application Ser. No. 09/725,727, filed Nov. 30, 2000, now U.S. Pat. No. 6,622,757, which relates to and claims priority to U.S. Provisional Patent Application Ser. No. 60/168,029, filed on Nov. 30, 1999, entitled “Fueling System Vapor Recovery Performance Monitor,” U.S. Provisional Patent Application Ser. No. 60/202,054, filed on May 5, 2000, entitled “Fueling System Vapor Recovery Performance Monitor,” and U.S. Provisional Patent Application Ser. No. 60/202,659, filed on May 8, 2000, entitled “Method of Determining Failure of Fuel Vapor Recovery System.” Each of the foregoing applications is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a vapor recovery performance monitor for use in connection with gasoline dispensing facilities.
BACKGROUND OF THE INVENTION
[0003] Gasoline dispensing facilities (i.e. gasoline stations) often suffer from a loss of fuel to the atmosphere due to inadequate vapor collection during fuel dispensing activities, excess liquid fuel evaporation in the containment tank system, and inadequate reclamation of the vapors during tanker truck deliveries. Lost vapor is an air pollution problem which is monitored and regulated by both the federal government and state governments. Attempts to minimize losses to the atmosphere have been effected by various vapor recovery methods. Such methods include: “Stage-I vapor recovery” where vapors are returned from the underground fuel storage tank to the delivery truck; “Stage-II vapor recovery” where vapors are returned from the refueled vehicle tank to the underground storage tank; vapor processing where the fuel/air vapor mix from the underground storage tank is received and the vapor is liquefied and returned as liquid fuel to the underground storage tank; burning excess vapor off and venting the less polluting combustion products to the atmosphere; and other fuel/air mix separation methods.
[0004] A “balance” Stage-II Vapor Recovery System (VRS) may make use of a dispensing nozzle bellows seal to the vehicle tank filler pipe opening. This seal provides an enclosed space between the vehicle tank and the VRS. During fuel dispensing, the liquid fuel entering the vehicle tank creates a positive pressure which pushes out the ullage space vapors through the bellows sealed area into the nozzle vapor return port, through the dispensing nozzle and hoe paths, and on into the VRS.
[0005] It has been found that even with these measures, substantial amounts of hydrocarbon vapors are lost to the atmosphere, often due to poor equipment reliability and inadequate maintenance. This is especially true with Stage-II systems. One way to reduce this problem is to provide a vapor recovery system monitoring data acquisition and analysis system to provide notification when the system is not working as required. Such monitoring systems may be especially applicable to Stage-II systems.
[0006] When working properly, Stage-II vapor recovery results in equal exchanges of air or vapor (A) and liquid (L) between the main fuel storage tank and the consumer's gas tank. Ideally, Stage-II vapor recovery produces an A/L ratio very close to 1. In other words, returned vapor replaces an equal amount of liquid in the main fuel storage tank during refueling transactions. When the A/L ratio is close to 1, refueling vapors are collected, the ingress of fresh air into the storage tank is minimized and the accumulation of an excess of positive or negative pressure in the main fuel storage tank is prevented. This minimizes losses at the dispensing nozzle and evaporation and leakage of excess vapors from the containment storage tank. Measurement of the A/L ratio thus provides an indication of proper Stage-II vapor collection operation. A low ratio means that vapor is not moving properly through the dispensing nozzle, hose, or other part of the system back to the storage tank, possibly due to an obstruction or defective component.
[0007] Recently, the California Air Resources Board (CARB) has been producing new requirements for Enhanced Vapor Recovery (EVR) equipment. These include stringent vapor recovery system monitoring and In-Station Diagnostics (ISD) requirements to continuously determine whether or not the systems are working properly. CARB has proposed that, when the A/L ratio drops below a prescribed limit for a single or some sequence of fueling transactions, an alarm be issued and the underground storage tank pump be disabled to allow repair to prevent further significant vapor losses. The proposed regulations also specify an elaborate and expensive monitoring system with many sensors which will be difficult to wire to a common data acquisition system.
[0008] The CARB proposal requires that Air-to-Liquid (A/L) volume ratio sensors be installed at each dispensing hose or fuel dispensing point and pressure sensors be installed to measure the main fuel storage tank vapor space pressure. Note that the term ‘Air’ is used loosely here to refer to the air-vapor mix being returned from the refueled vehicle tank to the Underground storage tank. The sensors would be wired to a common data acquisition system used for data logging, storage, and limited pass/fail analysis. It is likely that such sensors would comprise Air Flow Sensors (AFS's).
[0009] A first embodiment of the present invention provides a more practical and less expensive solution than that proposed by CARB, which can substantially provide the monitoring capabilities needed. In this first embodiment of the present invention, the multiple AFS's called for by the CARB proposal may be replaced by fewer, or only one, AFS in conjunction with a more sophisticated AFS data analysis method.
[0010] With respect to use of vapor pressure sensors, CARB also proposes that these sensors be used to passively monitor the level of pressure in the main fuel storage tank vapor space, which is common to the fueling facility, to not only provide indication of proper operation of Stage-II vapor recovery methods, but also system containment integrity. This is done by monitoring the pressure patterns that occur within the storage tank during the various phases of storage tank and dispenser operation. The complexity of these patterns is a function of the type of Stage-II system in use.
[0011] CARB has proposed putting constraints on the pressure versus time relationships to identify when the vapor recovery system is causing undesirably high pressures for long enough time periods. when the vapor recovery system produces these elevated pressures, it may force significant amounts of vapor past the pressure relief valve at the end of the storage tank vent pipe or out of other leaky system valves and fittings and into the atmosphere as air pollution.
[0012] CARB proposes a passive test for identifying elevated storage tank pressures. The purpose of the passive test is to determine whether vapors are being properly retained in the storage tank vapor space. This is done by continuously monitoring and watching for evidence of a non-tight or improperly operated vapor recovery components by tracking small pressure levels over time and comparing them to prescribed operating requirements.
[0013] For instance, for a vapor recovery system that is intended to continuously maintain negative storage tank vapor space pressures, the CARB proposed requirements were (at one time) that an error condition would exist when pressure exceeds (i.e. is higher than) −0.1 inch water column (w.c.) for either more than one (1) consecutive hour, or more than 3 hours in any 24 hour period. An error condition would also exist when pressure exceeds (i.e. is higher than) +0.25 inches w.c. for either more than one (1) consecutive hour, or more than 3 hours in any 24 hour period. An error condition would also exist if pressure exceeded +1.0 inches w.c. for more than 1 hour in any 24 hour period. Determination of the foregoing error conditions requires frequent pressure measurements, data storage, and analysis. CARB has struggled with these requirements for a passive-type test and has changed them more than once.
[0014] In a second embodiment of the invention the CARB proposed passive pressure monitoring test may be augmented or replaced with an active pressure “tightness” or “leakage” test which provides a more definitive indication of system containment integrity. The active tightness test may only need to be run occasionally to find a break in the system. A once a day or once a month test is consistent with the intent of the variously proposed CARB test pass/fail criteria.
[0015] In yet another embodiment of the invention, the CARB proposed passive test for leakage may be replaced with an improved passive test for vapor leakage. Instead of measuring absolute pressure in the vapor containing elements of a facility, in the improved test changes in pressure over time are used to determine whether vapors are leaking from the system.
[0016] Both the aforementioned CARB methods for determining vapor recovery system performance and those of the invention may be detrimentally effected by the introduction of vehicles with Onboard Refueling Vapor Recovery (ORVR) devices that recover refueling vapors onboard the vehicle. Vapors produced as a result of dispensing fuel into an ORVR equipped vehicle are collected onboard, and accordingly, are not available to flow through a vapor return passage to an AFS for measurement. Thus, refueling an ORVR equipped vehicle results in a positive liquid fuel flow reading, but no return vapor flow reading (i.e. an A/L ratio equal to 0 or close thereto)—a condition that normally indicates vapor recovery malfunction. Because the vapor recovery system cannot distinguish between ORVR equipped vehicles and conventional vehicles, the vapor recovery system may be falsely determined to be malfunctioning when an ORVR equipped vehicle is refueled.
[0017] In the coming years, 2000 to 2020 and beyond, the proportion of ORVR vehicles in use will increase. Therefore this problem will be become more severe in the coming decades. If A/L sensing is to be used successfully for vapor recovery system monitoring, then a method is needed to distinguish between failed vapor recovery test events caused by an ORVR vapor-blocking vehicle and true failed vapor recovery test events (which can only occur for non-ORVR equipped vehicles).
OBJECTS OF THE INVENTION
[0018] It is therefore an object of the present invention to provide a method and system for determining acceptable performance of a vapor recovery system in a fueling facility.
[0019] It is another object of the present invention to provide a method and system for measuring the return flow of vapors from a dispensing point to a main fuel storage tank.
[0020] It is yet another object of the present invention to reduce the number of devices required to determine A/L ratios for individual dispensing points in a fueling facility.
[0021] It is still yet another object of the present invention to provide a method and system for determining the integrity of vapor containment in a main fuel storage tank.
[0022] It is still a further object of the present invention to provide a method and system for analyzing and indicating vapor recovery performance in a fueling facility.
[0023] It is still another object of the present invention to provide a system and method for determining true vapor recovery system failures.
[0024] It is yet another object of the present invention to provide a system and method for distinguishing between low A/L readings caused by a vapor recovery system failure and low A/L readings caused by the fueling of an ORVR-equipped vehicle.
[0025] Additional objects and advantages of the invention are set forth, in part, in the description which follows, and, in part, will be apparent to one of ordinary skill in the art from the description and/or from the practice of the invention.
SUMMARY OF THE INVENTION
[0026] In response to the foregoing challenges, applicants have developed an innovative system for monitoring vapor recovery in a liquid fuel dispensing facility having at least one fuel dispensing point connected to a main fuel storage system by a means for supplying liquid fuel to the dispensing point and a means for returning vapor from the dispensing point, said monitoring system comprising: a vapor flow sensor operatively connected to the means for returning vapor and adapted to indicate the amount of vapor flow through the means for returning vapor; a liquid fuel dispensing meter operatively connected to the means for supplying liquid fuel and adapted to indicate the amount of liquid fuel dispensed at the at least one fuel dispensing point; and a central electronic control and diagnostic arrangement having, a means for determining a ratio of vapor flow to dispensed liquid fuel for the at least one fuel dispensing point, said determining means receiving dispensed liquid fuel amount information from the liquid fuel dispensing meter and receiving vapor flow amount information from the vapor flow sensor, wherein the acceptability of vapor recovery for the fuel dispensing point is determined by said ratio of vapor flow to dispensed liquid fuel.
[0027] Applicants have also developed an innovative system for monitoring vapor recovery in a liquid fuel dispensing facility having at least two fuel dispensing points connected to a main fuel storage system by a vapor return pipeline, said monitoring system comprising: a vapor flow sensor operatively connected to the vapor return pipeline; means for determining dispensed liquid fuel amount information for each fuel dispensing point; and a means for determining a ratio of vapor flow to dispensed liquid fuel for the fuel dispensing points based on vapor flow sensor readings and dispensed liquid fuel amount information, wherein the acceptability of vapor recovery for the fuel dispensing points is determined by said ratio of vapor flow to dispensed liquid fuel.
[0028] Applicants have also developed an innovative method of monitoring vapor recovery in a liquid fuel dispensing facility having at least one fuel dispensing point connected to a main fuel storage system by a means for supplying liquid fuel to the dispensing point and a means for returning vapors from the dispensing point, said monitoring method comprising the steps of: determining at multiple times an amount of vapor flow through the means for returning vapors; determining at multiple times an amount of liquid fuel dispensed through the means for supplying liquid fuel; and determining a ratio of vapor flow to dispensed liquid fuel for the fuel dispensing point based on the amount of vapor flow through the means for returning vapors and the amount of liquid fuel dispensed through the means for supplying liquid fuel, wherein the acceptability of vapor recovery for the fuel dispensing point is determined by said ratio of vapor flow to dispensed liquid fuel.
[0029] Applicants have still further developed an innovative system for monitoring vapor containment in a liquid fuel dispensing facility having a main fuel storage system connected by a vent pipe-pressure relief valve arrangement to atmosphere, said monitoring system comprising: a pressure sensor operatively connected to the vent pipe; a vapor processor operatively connected to the vent pipe; and means for determining the acceptability of vapor containment in the main fuel storage system, said determining means being operatively connected to the pressure sensor to receive pressure level information therefrom and being operatively connected to the vapor processor to selectively cause the vapor processor to draw a negative pressure in the main fuel storage system.
[0030] Applicants have developed an innovative method of monitoring vapor containment in a liquid fuel dispensing facility having at least one main fuel storage tank connected by a vent pipe-pressure relief valve arrangement to atmosphere, said monitoring method comprising the steps of: identifying the start of an idle period for the liquid fuel dispensing facility; monitoring the liquid fuel dispensing facility to confirm maintenance of the idle period; determining whether pressure in the main fuel storage tank is equal or below a minimum level; selectively adjusting pressure in the main fuel storage tank to a preset lower level when the previously determined pressure is above the minimum level; monitoring variation of the pressure in the main fuel storage tank during the remainder of the idle period; determining the end of the idle period; and determining the acceptability of vapor containment in the main fuel storage tank based on the variation of the pressure during the idle period.
[0031] Applicants also developed an innovative method of determining vapor recovery system failures associated with a single fuel dispensing point, said method comprising the steps of: determining the vapor flow to dispensed fuel ratios for a plurality of fuel dispensing points; determining the number of vapor flow to dispensed fuel ratios that are below a preset minimum for each of the plurality of fuel dispensing points; determining the average number of vapor flow to dispensed fuel ratios below the preset minimum for the plurality of fuel dispensing points; and comparing the number vapor flow to dispensed fuel ratios below the preset minimum for each of the plurality of fuel dispensing points to the average number of vapor flow to dispensed fuel ratios below the present minimum to determine whether the vapor recovery system associated with each of the plurality of fuel dispensing points has failed.
[0032] 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. The accompanying drawings, which are incorporated herein by reference and which constitute a part of this specification, illustrate certain embodiments of the invention, and together with the detailed description serve to explain the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:
[0034] FIG. 1 is a schematic view of a fueling system vapor recovery performance monitor in accordance with an embodiment of the present invention.
[0035] FIG. 2 is a schematic view of a fueling system vapor recovery performance monitor in accordance with another embodiment of the present invention.
[0036] FIG. 3 is a graph used to convert vapor leakage rates based on ullage pressures.
DETAILED DESCRIPTION OF THE INVENTION
[0037] A first embodiment of the invention is described in connection with FIG. 1 , which shows a vapor recovery and containment monitoring system for use in a liquid fuel dispensing facility 10 . The dispensing facility 10 may include a station house 100 , one or more fuel dispenser units 200 , a main fuel storage system 300 , means for connecting the dispenser units to the main fuel storage system 400 , and one or more vapor (or air) flow sensors (AFS's) 500 .
[0038] The station house 100 may include a central electronic control and diagnostic arrangement 110 that includes a dispenser controller 120 , dispenser current loop interface wiring 130 connecting the dispenser controller 120 with the dispenser unit(s) 200 , and a combined data acquisition system/in-station diagnostic monitor 140 . The dispenser controller 120 may be electrically connected to the monitor 140 by a first wiring bus 122 . The interface wiring 130 may be electrically connected to the monitor 140 by a second wiring bus 132 . The monitor 140 may include standard computer storage and central processing capabilities, keyboard input device(s), and audio and visual output interfaces among other conventional features.
[0039] The fuel dispenser units 200 may be provided in the form of conventional “gas pumps.” Each fuel dispenser unit 200 may include one or more fuel dispensing points typically defined by the nozzles 210 . The fuel dispenser units 200 may include one coaxial vapor/liquid splitter 260 , one vapor return passage 220 , and one fuel supply passage 230 per nozzle 210 . The vapor return passages 220 may be joined together before connecting with a common vapor return pipe 410 . The units 200 may also include one liquid fuel dispensing meter 240 per nozzle 210 . The liquid fuel dispensing meters 240 may provide dispensed liquid fuel amount information to the dispenser controller 120 via the liquid fuel dispensing meter interface 270 and interface wiring 130 .
[0040] The main fuel storage system 300 may include one or more main fuel storage tanks 310 . It is appreciated that the storage tanks 310 may typically be provided underground, however, underground placement of the tank is not required for application of the invention. It is also appreciated that the storage tank 310 shown in FIGS. 1 and 2 may represent a grouping of multiple storage tanks tied together into a storage tank network. Each storage tank 310 , or a grouping of storage tanks, may be connected to the atmosphere by a vent pipe 320 . The vent pipe 320 may terminate in a pressure relief valve 330 . A vapor processor 340 may be connected to the vent pipe 320 intermediate of the storage tank 310 and the pressure relief valve 330 . A pressure sensor 350 may also be operatively connected to the vent pipe 320 . Alternately, it may be connected directly to the storage tank 310 or the vapor return pipe 410 below or near to the dispenser 200 since the pressure is normally substantially the same at all these points in the vapor containment system. The storage tank 310 may also include an Automatic Tank Gauging System (ATGS) 360 used to provide information regarding the fuel level in the storage tank. The vapor processor 340 , the pressure sensor 350 , and the automatic tank gauging system 360 may be electrically connected to the monitor 140 by third, fourth, and fifth wiring busses 342 , 352 , and 362 , respectively. The storage tank 310 may also include a fill pipe and fill tube 370 to provide a means to fill the tank with fuel and a submersible pump 380 to supply the dispensers 200 with fuel from the storage tank 310 .
[0041] The means for connecting the dispenser units and the main fuel storage system 400 may include one or more vapor return pipelines 410 and one or more fuel supply pipelines 420 . The vapor return pipelines 410 and the fuel supply pipelines 420 are connected to the vapor return passages 220 and fuel supply passages 230 , respectively, associated with multiple fuel dispensing points 210 . As such, a “vapor return pipeline” designates any return pipeline that carries the return vapor of two or more vapor return passages 220 .
[0042] The AFS 500 is operatively connected to a vapor return pipeline 410 . A basic premise of the system 10 is that it includes at most one AFS 500 (also referred to more broadly as vapor flow sensors) for each fuel dispenser unit 200 . Thus, the AFS 500 must be operatively connected to the vapor return system downstream of the vapor return passages 220 . If such were not the case, the system would include one AFS 500 per nozzle 210 which violates the basic premise of the invention. Each AFS 500 may be electrically connected to the monitor 140 by a sixth wiring bus 502 .
[0043] In order to determine the acceptability of the performance of vapor recovery in the facility 10 , the ratio of vapor flow to dispensed liquid fuel is determined for each fuel dispensing point 210 included in the facility. This ratio may be used to determine if the fuel dispensing point 210 in question is in fact recovering an equal volume of vapor for each unit volume of liquid fuel dispensed by the dispensing point 210 .
[0044] In the embodiment of the invention shown in FIG. 1 , each dispensing point 210 is served by an AFS 500 that is shared with at least one other dispensing point 210 . Mathematical data processing (described below) is used to determine an approximation of the vapor flow associated with each dispensing point 210 . The amount of fuel dispensed by each dispensing point 210 is known from the liquid fuel dispensing meter 240 associated with each dispensing unit. Amount of fuel (i.e. fuel volume) information may be transmitted from each dispensing meter 240 to the dispenser controller 120 for use by the monitor 140 . In an alternative embodiment of the invention, the dispensing meters 240 may be directly connected to the monitor 140 to provide the amount of fuel information used to determine the A/L ratio for each dispensing point 210 .
[0045] Each AFS 500 measures multiple (at least two or more) dispensing point return vapor flows. In the embodiment of the invention shown in FIG. 1 , a single AFS 500 measures all the dispensing point vapor flows for the facility 10 . In the case of a single AFS per facility 10 , the AFS is installed in the single common vapor return pipeline which runs between all the dispensers as a group, which are all tied together into a common dispenser manifold pipe, and all the main fuel storage tanks as a group, which are all tied together in a common tank manifold pipe. Various groupings of combinations of feed dispensing point air flow's per AFS are possible which fall between these two extremes described.
[0046] With reference to a second embodiment of the invention shown in FIG. 2 , it is appreciated that multiple AFS's 500 could be deployed to measure various groupings of dispensing point 210 vapor flows, down to a minimum of only two dispensing point vapor flows. The latter example may be realized by installing one AFS 500 in each dispenser housing 200 , which typically contains two dispensing point's 210 (one dispensing point per dispenser side) or up to 6 dispensing points (hoses) in Multi-Product Dispensers (MPD's) (3 per side). The vapor flows piped through the vapor return passage 220 may be tied together to feed the single AFS 500 in the dispenser housing.
[0047] As stated above, the monitor 140 may connect to the dispenser controller 120 , directly to the current loop interface wiring 130 or directly to the liquid fuel dispensing meter 240 to access the liquid fuel flow volume readings. The monitor 140 may also be connected to each AFS 500 at the facility 10 so as to be supplied with vapor flow amount (i.e. vapor volume) information. The liquid fuel flow volume readings are individualized fuel volume amounts associated with each dispensing point 210 . The vapor flow volume readings are aggregate amounts resulting from various groupings of dispensing point 210 vapor flows, which therefore require mathematical analysis to separate or identify the amounts attributable to the individual dispensing points 210 . This analysis may be accomplished by the monitor 140 which may include processing means. Once the vapor flow information is determined for each dispensing point 210 , the A/L ratios for each dispensing point may be determined and a pass/fail determination may be made for each dispensing point based on the magnitude of the ratio. It is known that the ratio may vary from 0 (bad) to around 1 (good), to a little greater than 1 (which, depending upon the facility 10 design, can be either good or bad), to much greater than 1 (typically bad). This ratio information may be provided to the facility operator via an audio signal and/or a visual signal through the monitor 140 . The ratio information may also result in the automatic shut down of a dispensing point 210 , or a recommendation for dispensing point shut down.
[0048] The embodiments of the invention shown in FIGS. 1 and 2 may provide a significant improvement over known systems due to the replacement of the multiple AFS's 500 (one per dispensing point, typically anywhere from 10 or 12 up to 30 or more per site) and their associated wiring with a single, or fewer AFS's 500 (about ½ as many or less, depending upon dispensing point groupings).
[0049] With reference to the embodiments of the invention shown in both FIGS. 1 and 2 , the mathematical analysis performed in the monitor 140 is designed to find correlations between aggregate vapor volume measured during AFS 500 ‘busy periods’ and individual dispensing point 210 dispensed liquid fuel volume readings. The analysis is done separately for each AFS 500 and it's associated dispensing point group (two or more dispensing point's). The end result is a set of estimated dispensing point A/L ratios, one ratio per dispensing point. After a group of AFS 500 busy period data records are accumulated, a series of mathematical steps accomplish this beginning with a simple, 1-variable function solution and ending with more complex function solutions until all ratios are determined. If a ratio can be determined in an earlier step, it is not necessary to estimate it in a subsequent step (it can be set as a constant in later steps to simplify computation of any remaining unknown ratios). The sequence of solvable function types are:
[0050] Type 1: A single linear function with one unknown for any AFS busy records with only 1 active dispensing point.
[0051] Type 2: Two linear functions with two unknowns for any pair of similar AFS busy records with 2 (identical) active dispensing point's (two simultaneous equations with two unknowns).
[0052] Type 3: Three or more linear functions each with two or more unknowns for any remaining (unsolved) set of AFS busy records (at least as many functions as unknowns).
[0053] Each AFS 500 busy period data record is formed after the AFS becomes idle by recording the aggregate vapor volume, A, and the individual metered liquid volumes, L m , where the subscript, m, denotes the dispensing point or meter number. This number ranges from 1 to M total meters. Idle detection can be done by various means, including:
[0054] 1) the monitor 140 can track reported dispenser meter 240 start/stop events from the dispenser controller 120 , the dispenser current loop wiring 130 , or directly from the liquid fuel dispensing meter 240 ; or
[0055] 2) the Automatic Tank Gauging System 360 can provide main fuel storage tank 310 liquid fuel levels to the monitor 140 for detection of static level conditions (no ongoing dispensing) in all the storage tanks 310 .
[0056] The latter method (No. 2) can be used if it is desired that all AFS's 500 be idle prior to forming AFS busy data records. In the case of a single AFS 500 per facility 10 (shown in FIG. 1 ), this method can always be used.
[0057] The simple form of the relationship between A, L, and the A/L ratio, R, for an AFS busy record with one (1) active dispensing point is:
[0000] A=L m R m
[0058] so the simple solution for function type 1 is:
[0000]
R
m
=A/L
m
[0000] where R m is the estimated A/L ratio for active dispensing point (meter), m.
[0059] In the more general case, each AFS busy period data record, n, has a measured aggregate vapor volume, A n , and the individual metered liquid fuel volumes, L nm , where the first subscript, n, denotes the data record number and the second subscript, m, denotes the dispensing point or meter number as before. The record number, n, ranges from 1 to N total records.
[0060] The generalized form of the relationship between A n , L nm , and R m for multiple-dispensing point records is:
[0000]
A
n
=L
n1
R
1
+L
n2
R
2
+L
n3
R
3
+ . . . L
nm
R
m
[0061] In the case of a pair of similar busy records with 2 active dispensing point's (same 2 dispensing point's in both records) the relationships are:
[0000]
A
1
=L
11
R
1
+L
12
R
2
[0000]
A
2
=L
21
R
1
+L
22
R
2
[0062] so the solutions for functions of type 2 are:
[0000] R 1 =( A 1 L 22 −A 2 L 12 )/( L 11 L 22 −L 12 L 21 )
[0000] R 2 =( A 2 L 11 −A 1 L 21 )/( L 11 L 22 −L 12 L 21 )
[0063] Functions of type 3 can be solved as a least squares problem using standard matrix arithmetic.
[0064] Example record data set with subscript notation:
[0000]
n
A n
L n1
L n2
L n3
etc . . .
L nM
1
18
0
12
6
etc . . .
0
2
33
10
15
0
etc . . .
8
3
21
7
0
0
etc . . .
14
etc . . .
N
18
0
0
18
etc . . .
0
[0065] For the entire data set, the matrix relationship is:
[0000]
[
A
1
A
2
A
3
⋮
A
n
]
=
[
L
11
L
12
…
L
1
m
L
21
L
22
…
L
2
m
L
31
L
32
…
L
3
m
⋮
⋮
⋮
⋮
L
n
1
L
n
2
…
L
n
m
]
[
R
1
R
2
⋮
R
m
]
or
A
=
LR
[0066] The solution for the ratio vector, R, is:
[0000] R =( L T L ) −1 L T A
[0000] where the first term is the inverse of the transposed n×m matrix, L, times itself which results in an m x m matrix, the middle term is the transposed matrix, L, which is an m×n matrix, and the last term is the vector A of length n, all of which results in the vector R, of length m (one A/L ratio per meter).
[0067] This approach can provide good estimates of the true A/L ratios, even with excessive variability (noise) in the sensor readings. More records result in better estimates for a given level of variability but there must be at least as many records as unknowns for minimal performance.
[0068] Dispensing point ratio solutions are based on the simplest function type possible. As a data set is processed and ratio solutions are determined, they are in turn used to simplify solutions for remaining records in any record set. As an example, if two records exist in a set, one of type 1 (a single active dispensing point busy period), and a second with two active dispensing points, one of which is the same dispensing point as in the first record, the first record is solved directly as a type 1 function and it's ratio result is used to simplify the function for the second record. This produces a second type 1 function.
[0069] Example records (2):
[0000]
n
A n
L n1
L n2
1
5
—
10
2
19.5
12
15
[0070] Initial functions:
[0000] A 1 =L 12 R 2 5=10R 2
[0000] A 2 =L 21 R 1 +L 22 R 2 19.5=12 R 1 +15 R 2
[0071] Solve first, substitute solution in second to simplify:
[0000] 5=10 R 2 R 2 =5/10=0.5
[0000] 19.5=12 R 1 +15 R 2 19.5+12 R 1 +15*0.5=12 R 1 +7.5
[0072] Solve second as a type 1 function:
[0000] 19.5=12 R 1 +7.5 12=12 R 1 R 1 =12/12=1.0
[0073] This simplification method is used at each step of the data set solution process:
[0074] Step 1: Form simple (1-dispensing point) or generalized function forms for each record.
[0075] Step 2: Solve all Type 1 functions.
[0076] Step 3: Substitute solutions from prior step into remaining set of functions.
[0077] Step 4: Reduce all functions to simpler forms and repeat from step 2.
[0078] Step 5: Find and solve any Type 2 function pairs.
[0079] Step 6: Substitute solutions from prior step into remaining set of functions.
[0080] Step 7: Reduce all functions to simpler forms and repeat from step 2.
[0081] Step 8: If possible, solve remaining functions as a Type 3 least squares problem.
[0082] Step 9: If step 8 is not possible, wait for more data records to solve the remaining functions.
[0083] Alternatively, replace the 9-step sequence with steps 8 and 9 alone. This approach has the benefit of always averaging or reducing the effects of variability in the sensor readings.
[0084] The various embodiments of the invention discussed herein may also be used to detect vapor recovery equipment failures. Stage-II vapor recovery equipment failures can have two distinct effects on patterns of A/L ratios. The failures are determined by identifying these patterns in the solved ratio set. The first type of failure involves a dispensing point nozzle 210 , a hose 212 , or vapor return passage 220 path restriction, or a vacuum assist pump failure which blocks or reduces air-vapor flow. The above solution methods may be used to identify this type of failure by identification of one dispensing point with a consistently lowered ratio.
[0085] The second type of failure that can occur involves a dispensing point 210 with a defective air valve which does not close properly to block reverse vapor flow (i.e. out of the nozzle) when the dispensing point is idle. In such a case the ratio for the defective dispensing point will not be affected because when the dispensing point is active, the vapor flow is normal. However, when idle, vapors from other active dispensing points can be pushed past the defective air valve, out of the leaky dispensing point nozzle, and into the atmosphere. The active dispensing point(s) AFS 500 may or may not register the amount of lost vapor, depending upon whether the leaking dispensing point is part of the AFS group (won't register) or not (will register). If not, the idle AFS 500 will register reverse vapor flow. In that case, the leaking dispensing point can be detected by the reverse flow signal when it should be idle.
[0086] Using the above solution methods described in connection with the first and second embodiments of the invention, when the leaking dispensing point is a member of the active AFS 500 group it results in lowered ratios for all dispensing points in the group except for the leaking dispensing point. Also, the lowered ratios vary depending upon the number of active dispensing point's during each busy period. When more (good) dispensing point's are active in an AFS 500 group, the lost vapor effect is shared in the solution, resulting in less depression of the individual ratios. Furthermore, if only part of the vapors escape to the atmosphere, the effect is reduced, resulting in less depression of the individual ratios. Accordingly, a post-solution analysis may be conducted on the ratio patterns to determine the likely failure type, active dispensing point restriction or idle dispensing point leak.
[0087] A third embodiment of the invention concerns the use of a single vapor pressure sensor 350 (same as CARB requirement) to actively determine the tightness of the overall vapor containing elements of the facility including the fuel storage system 300 , (which includes the vent pipe 320 , pressure relief valve 330 , etc.), the vapor return pipelines 410 , the vapor/liquid splitter 260 , the vapor return passages 220 , the dispenser hose 212 , the nozzle 210 , etc. The vapor pressure sensor 350 may be connected anywhere in the fuel storage system 300 or the pipeline system 400 , which includes but is not limited to the storage tank 310 vapor-space, the common vapor return pipeline 410 , or the storage tank vent pipe 320 . The vapor pressure sensor 350 may be used periodically to actively measure the leakage of vapors from the overall system instead of constantly measuring for leakage amount.
[0088] The method in accordance with the third embodiment of the invention may be carried out as follows. The monitor 140 may be connected to and access pressure readings from the vapor pressure sensor 350 . The monitor 140 controls the active test which is initiated by determining an idle period during which none of the dispensing units 200 are in operation (similar to the A/L detection method using either dispensing meter events or ATGS tank levels). The idle condition may be continuously monitored and the test aborted if any dispensing units go into operation during the test. During the idle period the vapor pressure sensor 350 is used to determine the pressure in the system (i.e. the pressure in the storage tank 310 ). If the pressure is not adequately negative (vacuum) for the test, the vapor processor 340 may be turned on to draw a negative pressure in the storage tank 310 as it processes vapors. If the vapor processor 340 is used, the monitor 140 may be used to monitor the vapor pressure readings until they become adequately negative, typically −2 or −3 inches w.c. Once the vapor pressure is adequately negative, the vapor processor 340 may be turned off. Thereafter the vapor pressure sensor 350 readings may be monitored during the remaining idle time. If the system is adequately tight, the negative pressure readings should hold or degrade only slowly. If the negative pressure degrades too rapidly toward zero, the monitor 140 may indicate that the system has failed the leakage test. A pass/fail threshold is used to make this determination. It can be set as a percentage of the initial negative pressure amount based on the desired detection sensitivity and should be related to the amount of air inflow detected relative to total storage tank 310 vapor space (uliage volume).
[0089] In an alternative of the third embodiment of the invention, a single or multiple AFS's 500 located in the common or multiple vapor return pipeline(s) (same as A/L detection equipment) may be included to conduct an improved active test for system tightness. While a pressure sensor 350 alone suffices for conducting a tightness test, AFS 500 readings can add to the amount of information available to augment test sensitivity and confirm the tightness condition or help locate the source of a leak. Any air inflow from a leak point will register as flow on the AFS(s) 500 . Flow and flow direction are a general indicator of the location of the source of incoming air (which dispensers and/or tanks/vents). Note that the AFS 500 readings are generally the more sensitive indicator of vapor recovery system tightness failure since negative pressure degradation is small due to the small amount of air inflow over seconds or minutes of time relative to the generally large storage tank vapor-space volumes. For significant negative pressure degradation, the amount of air inflow needs to be a significant portion of the storage tank vapor-space volume which can be in the thousands or tens of thousands of gallons.
[0090] The optional AFS(s) 500 , and dispenser controller 120 , dispenser current loop 130 , or optional ATGS 360 are connected to the monitor 140 which acquires and processes the data from the devices to conduct the tightness test and also controls (on/off) the vapor processor 340 . Note that only one vapor pressure sensor 350 is needed for multiple storage tanks 310 as long as they share a common vapor recovery system so that their vapor spaces are connected (piped) together.
[0091] In another alternative embodiment of the invention, the ATGS 360 may not be required to conduct an active test for system tightness. In this case, the idle state of the vapor recovery system during which the tightness test is conducted must be determined by (lack of) fueling meter 240 activity and a precise estimation of leak rate is not possible since tank 310 vapor ullage space volume is not known. Instead, a general pass/fail indication can be provided when the pressure decays at a preset rate during a test period.
[0092] In yet another embodiment of the present invention, the systems shown in FIGS. 1 and 2 may be used to conduct an improved passive vapor containment test. This test uses pressure in the vapor containing elements of the facility, barometric pressure, and ullage space measurements to calculate the change in pressure over time for the vapor containing elements of the facility. This calculation, which is not usually based on data collected when the facility is operating at −2 to −3 inches w.c., may then be normalized to indicate leakage rates for a facility held at −2 to −3 inches w.c.
[0093] This passive method may be initiated by monitoring the pressure of the main fuel storage system 300 or any vapor containing element of the facility 10 between fuel dispensing periods with the pressure sensor 350 . Pressure data derived from sequential groupings of monitored pressures and ullage determinations derived from the ATGS 360 readings are recorded at periodic intervals by monitor 140 . The derived recorded data permits the determination of rate of change of pressure, p rate , versus time, t, obtained from a linear regression model:
[0000]
p=p
rate
·t
[0000] within each interval, the main storage system 300 total ullage volume, V ullage represented by the sum of the individual storage tank 310 ullage volumes, V ullage :
[0000] V ullage =v ullage1 +v ullage2 + . . . +v ullageN for tanks 1 to N
[0000] where v ullage =(tank capacity)−(volume of fuel in tank)
obtained from the ATGS 360 , and the average pressure, p avg over each interval:
[0000] p avg =( p 1 +p 2 + . . . +p N )/ N for pressure samples 1 to N in the interval
[0000] are recorded if the correlation to the linear model is acceptable, generally based on high correlation between pressure with respect to time and the model.
[0094] Upon collection of a daily sample of such records, the product of pressure rate and the total ullage volume, p rate ·V ullage , is sorted by the associated average pressure, p avg , and grouped into equally spaced average pressure ranges. A collection of averages of the products, (p rate V ullage ) avg , within each group:
[0000] ( p rate V ullage )avg=(( p rate ·V ullage ) 1 +( p rate ·V ullage ) 2 + . . . +( p rate ·V ullage ) N )/ N
[0000] for products 1 to N in each group. The midpoints of the average pressure ranges, p mid , within each group are used with a linear regression model to estimate the rate of change of pressure times ullage volume, P rate V at a selected test pressure, p test , of, say, 2 inches of water column, if the correlation to the linear model:
[0000] P rate V =(P rate V) slope p test
[0000] is acceptable generally based on high correlation between the average products, (p rate V ullage ) avg , with respect to midpoint pressures, p mid , and the model. A typical graph of this model for a tank system is shown in FIG. 3 . It is noted that the curve must cross the origin which indicates no rate of change of pressure, thus no leakage, when there is zero pressure drop across any leakage path, since for leakage to occur a pressure driving force is needed regardless of ullage volume.
[0095] The regression yields the slope coefficient, (P rate V) slope , which is used to calculate the estimated pressure times ullage volume, P rate V at a selected test pressure, p test , of, say, 2 inches of water column at which a leakage test failure rate can be defined, similar to the standard CARB TP-201.3 test procedure. In other words, if there is a leakage path and if the pressure in the ullage space of the tank system is set to 2″ wcg (water column gauge) (above ambient pressure), the tank will leak at the estimated rate, v rate , of:
[0000] v rate =P rate V ( p test )/ p
[0000] where p is the absolute pressure in the tank ullage space, typically 410″ wca (water column absolute) (assuming ambient is 408″ wca). This can be interpreted to mean that the rate of volume vapor loss from a leaking tank is equal to the proportional rate of change of absolute pressure times the total ullage volume. Note that p test is a gauge pressure (referenced to ambient) and p is an absolute pressure (referenced to a vacuum). This relationship is derived from the ideal gas law, which governs the relationship between pressure, p, and volume, v, in an enclosed space at low pressures and temperatures:
[0000]
p·v=n·R·T
[0000] where n is moles of gas, R is the universal gas constant, and T is absolute temperature. Replacing n with mass per molecular weight (MW):
[0000] p·v=m·R·T /MW
[0000] Rearranging terms and replacing constant terms with k:
[0000] m=k·p where k=v ·MW/( R·T )
[0000] Rate of mass loss due to a leak from an enclosed space is found by forming the relationship of the difference between the ending and starting mass divided by starting mass and the time period of the loss:
[0000] ( m 2− m 1)/ m 1· t =( k·p 2− k·p 1)/ k·p 1· t
[0000] Δ m /( m 1· t )=( p 2− p 1)/ p 1· t
[0000] Δ m /( m 1· t )=Δ p/p 1· t
[0000] Δ m/t=Δp·m 1/ p 1· t
[0000] The last form describes the rate of mass loss as a function of starting mass times proportional pressure change rate over the test period. To find volume loss rate, relate mass and volume by mass density, ρ:
[0000] ρ= m/v or m=ρ·v so m 1=ρ1· v and mass loss: Δ m=ρ·Δv
[0000] Substituting in above equation:
[0000] ρ·Δ v/t=Δp·ρ 1· v/p 1· t
[0000] Assuming mass density does not change appreciably:
[0000] Δ v/t=Δp·v/p 1· t where ρ1≈ρ
[0000] Dropping the subscript and using notation for volume loss rate, v rate :
[0000]
v
rate
=Δp·v/p·t
[0000] which can be interpreted to mean that the volume loss rate is the proportional change of pressure times volume per unit time. But part of this expression is the calculated value derived from measurements in the above section:
[0000] v rate =P rate V/p where v rate =Δp·v/t at the selected test pressure, 2″ wcg
[0096] Using the above example, the volume leak rate, v rate , is:
[0000] v rate =P rate V/p= 6000/410=14.6 CFH or cubic feet per hour at 2″ wcg
[0097] As described above, in yet another embodiment of the invention, the system may also perform a method of distinguishing between true vapor recovery failure events and ORVR equipped vehicle refueling events. Identifying a false vapor recovery system failure due to refueling an ORVR-equipped vehicle may be accomplished by applying standard statistical concepts to a group of dispensing or refueling events from all the dispensing points 210 at a dispensing facility 10 to identify true failed vapor collection dispensing points as opposed to failed tests due to ORVR vapor-blocking activity.
[0098] There are two assumptions that may be made as a predicate to determining true failed vapor collection: (1) that ORVR and non-ORVR activity occurs somewhat randomly amongst all the dispensing points; and (2) that average ORVR activity does not reach 100% of all refueling events (a maximum of 80% can be assumed). Given these assumptions, a group of vapor collection event A/L measurements taken from all the dispensing points 210 at a dispensing facility 10 may be used to make the following determinations:
[0099] 1) Determine if the proportions of failed (close to zero A/L) and non-failed events are statistically different at individual dispensing points relative to their expected proportions, due to the activity of ORVR vehicles, derived from all the dispensing points; and
[0100] 2) Determine if the proportion of the failed (close to zero) events at each dispensing point are statistically different from the proportion of the failed events derived from all the dispensing points, which are largely due to the effect of ORVR vehicles.
[0101] As a result of these determinations, the A/L ratio measurements may be used to test for blockage or leakage caused vapor recovery failure, with a mix of ORVR and non-ORVR vehicle activity.
[0102] On a regular (e.g. daily) basis, each dispensing point 210 may have a number of A/L determinations associated with it. It is presumed that there are k dispensing points 210 and the i th dispensing point has n i A/L ratio determinations. Let X i be the number of A/L determinations for dispensing point I that indicate a “zero” or “blocked” A/L ratio. The assumption is that fueling an ORVR vehicle will result in a zero or blocked A/L ratio. The total number of A/L determinations for the site is:
[0000] n=Σn i
[0000] and the total number of zero A/L ratios is:
[0000] X=ΣX i
[0103] An overall test can be conducted to determine whether there are any significant differences in the proportion of A/L ratios indicating blocked vapor flow among the dispensing points 210 . This can be accomplished using a chi-squared test on the table of data from the k dispensers:
[0000] Dispenser 1 Dispenser 2 Dispenser k Total Number X1 X2 . . . Xk X blocked Not blocked n1-X1 n2-X2 . . . nk-Xk N-X Number n1 n2 . . . nk N
The chi-squared statistic is given
[0000] by: X 2 =Σ( O i −E i ) 2 /E i
[0000] where O i is the number observed in each cell of the table and E i is the expected number in that cell. The data in the cells indicate the number of A/L ratios that indicate a “blocked” condition for each dispensing point and the number of A/L ratios indicating a “not blocked” condition for that dispenser. The expected number “blocked” ratios for dispenser I is:
[0000] E i1 =n i ( X/N )
[0000] and the expected number of “not blocked” ratios for dispenser I is:
[0000] n i −E i
[0104] The summation is carried out over 2k cells. This statistic is compared to the critical value from a chi-squared table with k−1 degrees of freedom. If it is significant, there is evidence that the dispensers have different proportions of blocked A/L ratios, so that one or more would appear to be blocked on at least an intermittent basis.
[0105] In turn, an individual test can be performed for each dispenser. This tests whether each dispenser has a proportion of zero A/L ratios that exceeds the overall proportion for the station. The following equation may be used to compute the overall proportion of zero A/L ratios for the period:
[0000]
P=X/N
[0000] The following equation may be used to compute the proportion of zero A/L ratios for each dispenser:
[0000]
p
i
=x
i
/n
i
[0000] From the foregoing calculations, it may be concluded that there is evidence that dispenser I is blocked if:
[0000] p i >P+z α (0.16/ n i ) 1/2
[0000] where z α is the upper a percentage point from a standard normal distribution. If a 1% significance level is desired, z α is 2.326, for example, (or 1.645 for a 5% significance level). The number 0.16 in the formula results from assumption of the most conservative case; that 80% of the vehicles are ORVR vehicles. Once a truly blocked dispensing point is detected, an audio or visual signal may be provided by the monitor 140 to indicate this condition. Truly blocked dispensing points may also be automatically shut down as a result of such detection.
[0106] It will be apparent to those skilled in the art that various modifications and variations may be made in the preparation and configuration of the present invention without departing from the scope and spirit of the present invention. For example, various combinations of the methods described above may be implemented without implementing the full system shown FIGS. 1 and/or 2 . Thus, it is intended that the present invention cover the modifications and variations of the invention.
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A method and apparatus for monitoring and determining fuel vapor recovery performance is disclosed. The dispensing of liquid fuel into a tank by a conventional gas pump nozzle naturally displaces a mixture of air and fuel ullage vapor in the tank. These displaced vapors may be recovered at the dispensing point nozzle by a vapor recovery system. A properly functioning vapor recovery system recovers approximately one unit volume of vapor for every unit volume of dispensed liquid fuel. The ratio of recovered vapor to dispensed fuel is termed the A/L ratio, which should ideally be approximately equal to one (1). The A/L ratio, and thus the proper functioning of the vapor recovery system, may be determined by measuring liquid fuel flow and return vapor flow (using a vapor flow sensor) on a nozzle-by-nozzle basis. The disclosed methods and apparatus provide for the determination of A/L ratios for individual nozzles using a reduced number of vapor flow sensors. The disclosed methods and apparatus also provide for the determination of fuel dispensing system vapor containment integrity, and the differentiation of true vapor recovery failures as opposed to false failures resulting from the refueling of vehicles provided with onboard vapor recovery systems.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to an earphone plug, and more particularly to an earphone plug with a mode switching function, which is selectively applicable to mobile phones or music players by switching a control mode between a three-electrode mode and a four-electrode mode.
2. Related Art
Earphone is an indispensable accessory in portable electronic products for providing audio information. Earphone plugs are divided into conventional three-pole earphone plugs and conventional four-pole earphone plugs which are respectively applicable to portable electronic products with different functions. FIGS. 1 and 2 are respectively external views of a conventional three-pole earphone plug 1 and a conventional four-pole earphone plug 2 .
The three-pole earphone plug 1 includes three electrodes 1 a , 1 b , and 1 c , for respectively transmitting a left channel signal, a right channel signal, and a ground signal, so that the earphone plug 1 is applicable to a personal portable music device such as MP3 to provide stereo music information. However, the earphone plug 1 can only output sound due to the structural limit, and cannot provide sound receiving function, so that it cannot be used as a hand-free receiver for mobile phones.
The four-pole earphone plug 2 includes four electrodes 2 a , 2 b , 2 c , and 2 d , for respectively transmitting a left channel signal, a right channel signal, a microphone signal, and a ground signal, so that the earphone plug 2 can be used as a hand-free receiver for mobile phones. Accordingly, due to the structure, the earphone plug 2 with four electrodes cannot be used in conjunction with three-pole earphone jacks, so that consumers must take number of poles into consideration when choosing earphones. As conventional earphone plugs can only be fitted to corresponding earphone jacks, the use of earphones is limited, and the consumer must additionally buy different types of earphone plugs to meet requirements for different electronic products, especially when the earphone is used between products such as mobile phones and music devices, which will result in economic burden.
In order to solve the problem, an adapter has been available on the market, which is used for connection to a four-pole earphone plug, such that the earphone plug is applicable to a three-pole earphone jack, thereby eliminating the use limit of the four-pole earphone plug. However, there still exist problems that the consumers still have to spend money to purchase the adapter and the adapter may easily be lost which causes inconvenience in use.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to an earphone plug with a mode switching function, which includes a terminal and a switching device. The terminal has a plurality of electrodes for transmitting signals. The switching device is combined with the terminal, and is capable of switching between a first mode and a second mode, and part of the electrodes of the terminal are electrically connected together, so as to achieve mode switching to perform processing on different transmission signals.
In order to achieve the above objectives, according to the present invention, the terminal has a first electrode, a second electrode, a third electrode, and a fourth electrode, and further includes a first conductive member and a second conductive member, the switching device has a movable sleeve disposed at a rear end of the terminal, and the movable sleeve has a metal sheet for being pressed against the first conductive member and second conductive member when the earphone plug is switched from the first mode to the second mode, such that the first conductive member and the second conductive member are electrically connected, the corresponding third electrode and fourth electrode are conducted, and the earphone plug is switched from a four-electrode state to a three-electrode state. Therefore, the earphone plug of the present invention is applicable to mobile phones and music players at the same time.
In order to achieve the above objectives, according the present invention, a fixed sleeve is connected to the rear end of the terminal, a plastic member is embedded between the fixed sleeve and the terminal, the plastic member has a pair of stopping blocks, and the movable sleeve correspondingly has a pair of guide grooves disposed thereon, so as to limit the rotation position of the movable sleeve relative to the plastic member.
In order to achieve the above objectives, according the present invention, the fixed sleeve has a marking point, the movable sleeve has a bushing sleeved outside, and the bushing has an indication area corresponding to the marking point to indicate a position when switching.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given herein below for illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is an external view of a conventional three-pole earphone plug;
FIG. 2 is an external view of a conventional four-pole earphone plug;
FIG. 3 is an external view of an earphone plug with a mode switching function according to the invention;
FIG. 4 is an exploded view of the earphone plug with a mode switching function according to the invention;
FIG. 5 is a transverse sectional view (I) of the earphone plug with a mode switching function according to the invention;
FIG. 6 is a partial axial sectional view (I) of the earphone plug with a mode switching function according to the invention;
FIG. 7 is a transverse sectional view (II) of the earphone plug with a mode switching function according to the invention; and
FIG. 8 is a partial axial sectional view (II) of the earphone plug with a mode switching function according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of an earphone plug with a mode switching function in the present invention are described with reference to the accompanying drawings.
FIG. 3 is an external view of an earphone plug with a mode switching function according to the invention. Referring to FIG. 3 , the earphone plug 100 includes a terminal 10 , a switching device 20 , a fixed sleeve 30 , and a wire 40 .
FIG. 4 is an exploded view of the earphone plug with a mode switching function according to the invention. Referring to FIG. 4 , the terminal 10 has a first electrode 11 , a second electrode 12 , a third electrode 13 , and a fourth electrode 14 disposed thereon in sequence from left to right, and an insulating portion 15 connected to the rear of the fourth electrode 14 . The insulating portion 15 has a first terminal groove 16 , a second terminal groove 17 , a hollow terminal portion 18 , and a tail end 19 . The first terminal groove 16 and the second terminal groove 17 are clamped by a first conductive member 50 and a second conductive member 51 respectively.
The first conductive member 50 , the second conductive member 51 , the terminal portion 18 , and the tail end 19 serve as contact portions for electrical connection, to be welded and connected to a left channel signal line, a right channel signal line, a microphone signal line, and a ground signal line (not shown) in the wire 40 respectively. The first electrode 11 , the second electrode 12 , the third electrode 13 , and the fourth electrode 14 are electrically connected to the first conductive member 50 , the second conductive member 51 , the terminal portion 18 , and the tail end 19 respectively. The main structural feature of the terminal 10 in the present invention is a four-pole terminal in the prior art, and thus will not be described herein again.
The switching device 20 includes a movable sleeve 21 , which has a pair of hollow guide grooves 22 opened at transverse positions, and a pair of fastening grooves 23 disposed on an outer periphery at axial positions and in communication with the guide grooves 22 . The movable sleeve 21 has a combination groove 21 a disposed on an inner periphery, and the combination groove 21 a has a positioning portion 21 b recessed on two sides thereof respectively. The switching device 20 further includes a bushing 24 , which has a pair of fastening blocks 25 disposed on an inner surface thereof to fit the fastening grooves 23 of the movable sleeve 21 , and an indication area 26 disposed on an outer periphery thereof. In addition, the switching device 20 further includes a revised U-shaped elastic metal sheet 27 fixed into the combination groove 21 a of the movable sleeve 21 in a mechanical manner or other equivalent manners, and the metal sheet 27 has a first contact 271 and a second contact 272 disposed thereon, and two foot portions 273 disposed on two sides thereof. The foot portions 273 can be combined with the positioning portion 21 b.
The wire 40 extends though one end of the fixed sleeve 30 , and a plastic member 31 is combined with the other end of the fixed sleeve 30 . The plastic member 31 is embedded between the insulating portion 15 of the terminal 10 and the fixed sleeve 30 , and has a first perforation 32 , a second perforation 33 , and a pair of stopping blocks 34 disposed at an end on an outer periphery. When the plastic member 31 is sleeved on the insulating portion 15 of the terminal 10 , the first perforation 32 and the second perforation 33 fit the first conductive member 50 and the second conductive member 51 , so that the first conductive member 50 and the second conductive member 51 partially protrude from the outer periphery of the plastic member 31 . The fixed sleeve 30 is provided to assemble the movable sleeve 21 , and the stopping blocks 34 of the fixed sleeve 30 are placed in the guide grooves 22 of the movable sleeve 21 , so as to limit the displacement when the movable sleeve 21 rotates relative to the fixed sleeve 30 in a transverse direction. When the movable sleeve 21 rotates relative to the fixed sleeve 30 , the metal sheet 27 of the movable sleeve 21 selectively contacts the first conductive member 50 and the second conductive member 51 . Through the fitting of the fastening blocks 25 of the bushing 24 and the fastening grooves 23 of the movable sleeve 21 , the user can directly control the bushing 24 to drive the movable sleeve 21 to perform switching action. Furthermore, a marking point 35 is disposed on an outer surface of the fixed sleeve 30 , for alignment with the indication area 26 of the bushing 24 to indicate the state position. For example, in the invention, if the marking point 35 and the indication area 26 are separated, a first mode is indicated, and if they are aligned, a second mode is indicated.
It should be noted that, a magnetic ring 60 is disposed inside the plastic member 31 , for eliminating noise of the earphone plug 100 .
FIG. 5 is a transverse sectional view (I) of the earphone plug with a mode switching function according to the invention. Referring to FIG. 5 , the earphone plug 100 is in the first mode, and the metal sheet 27 of the movable sleeve 21 is away from the first conductive member 50 of the terminal 10 without contact there-between.
FIG. 6 is an axial sectional view (I) of the earphone plug with a mode switching function according to the invention. Referring to FIG. 6 , as the first conductive member 50 and the second conductive member 51 are respectively in an independent state when the earphone plug 100 of the invention is in the first mode, the terminal 10 is in communication with the left channel signal line, the right channel signal line, the microphone signal line, and the ground signal line of the wire 40 , and the earphone plug 100 is correspondingly applicable to four-electrode earphone jacks, especially mobile phones with a voice call function. It should be mentioned that, in the invention, an annular bump 251 is disposed transversally on an inner periphery of the bushing 24 , and is positioned in the guide grooves 22 of the movable sleeve 21 for secure positioning.
FIG. 7 is a transverse sectional view (II) of the earphone plug with a mode switching function according to the invention. Referring to FIG. 7 , the bushing 24 is controlled to drive the movable sleeve 21 to rotate, such that the earphone plug 100 is switched from the first mode to the second mode, and the metal sheet 27 of the movable sleeve 21 contacts the first conductive member 50 .
FIG. 8 is an axial sectional view (II) of the earphone plug with a mode switching function according to the invention. Due to the displacement of the movable sleeve 21 , the first contact 271 and second contact 272 of the metal sheet 27 contact the first conductive member 50 and the second conductive member 51 respectively, such that the first conductive member 50 and the second conductive member 51 are electrically connected. In this way, the corresponding electrodes are in communication, the microphone signal and the ground signal of the earphone plug 100 are switched into an independent ground signal, and the earphone plug 100 is correspondingly applicable to three-electrode earphone jacks, especially music players such as MP3s.
Although the switching device 20 in the invention switches the mode by rotation, the switching device 20 can also change the mode by other equivalent or similar means, for example, sliding operation, which also falls within the technical scope of the invention.
In the earphone plug with a mode switching function of the invention, a switching device with a metal sheet is used, during the rotation relative to a terminal, the metal sheet is pressed against the first conductive member and the second conductive member at the rear end of the terminal, and the first conductive member and the second conductive member are electrically connected, such that the earphone plug is switched from the original first four-electrode mode (with dual channel signals, a microphone signal, and a ground signal) to the second three-electrode mode (with dual channel signals and a ground signal). In this way, the earphone plug of the invention is applicable to music players with three-electrode jacks and mobile phones with four-electrode jacks, and thus is an earphone plug with a dual-mode switching function, so as to provide ease of use for earphone products and meet the requirements of consumers.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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An earphone plug with a mode switching function is presented. The earphone plug includes a terminal and a switching device. The terminal has a plurality of electrodes to transmit signals. The switching device is combined with the terminal, and is capable of switching between a first mode and a second mode, and part of the electrodes of the terminal are electrically connected together, so as to achieve mode switching to perform processing on different transmission signals.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to an electrical power feedthrough. More specifically, the present invention relates to a sealing method and apparatus for an electrical penetrator in an electrical power feedthrough system in a subsea environment.
BACKGROUND
[0002] In subsea production, electrically operated apparatuses below sea level are typically supplied by power from sea- or land-based host facilities. The power is provided from the external sources to the subsea devices via cable conductors to submerged process control equipment, pumps and compressors, transformers, motors, and other electrically operated equipment. As these components are disposed subsea and are typically enclosed and protected by water-proof pressure vessels, power is provided by means of a cable termination and connector, which may be an electrical penetrator, designed to penetrate and provide power through a bulkhead.
[0003] In existing penetrator assemblies, the conductor pin of the penetrator is embedded in an insulator body, which may be seated in a penetrator housing and is sealed against the penetrator housing by means of O-rings, or other types of seals. In submerged applications the electrical penetrator must be protected from the ingress of water. At operational water depths down to and below 1,000 meters the penetrator and subsea device are both subjected to immense external pressure. This pressure requires a penetrator structure that is adapted to operate despite high external pressures and differential pressures over seals.
[0004] In one embodiment an electrical penetrator may be used to power subsea electric submersible pump (ESP) equipment and the like which pump hydrocarbons in oil well installations, and also in other applications such as high pressure downhole electrical penetrations and other penetrations to provide power to various types of subsea equipment. The penetrator extends through the wall or bulkhead of the vessel in which the equipment is located, and is normally connected to power cables at one end for connecting the equipment to an external power source. In an ESP application, the connection or penetrator cannot be isolated from the pumping pressure for practical reasons. This creates an extreme environment for the connector or penetrator in terms of pressure, temperature, and high voltage. The penetrator must transfer power to the motor as well as maintaining a pressure barrier for both internal pressure created by the ESP and external pressure caused by the depth in seawater. The temperatures are increased due to fluid temperatures as well as resistive heating of the electrical elements. These penetrators must also be able to resist sustained intense heat from a hydrocarbon fire and maintain both electrical connectivity and seal integrity in high temperature and material stress situations.
[0005] In a typical electrical penetrator or feed through a set of seals and/or o-rings are used to prevent the ingress of external fluids into the subsea device and to prevent internal fluids from escaping. The seals must be qualified to show that they meet certain standards such as those set by the American Petroleum Institute (“API”) for subsea oil and gas applications. Such standards may include API 6A and API 17D. Seals used with electrical penetrators may also be qualified to prove that they pass extended pressure and heat cycles, and “make or break” testing cycles where alternating pressures are applied to the seals. These qualification measures are expensive and time consuming. It may be difficult to find or design a seal suitable for a particular electrical penetrator.
[0006] Furthermore, seals such as those described above may need to be replaced or may fail. Problems also exist with the installation and replacement of these seals and o-rings. The seals or o-rings may become damaged, dislodged, or may shift in the seal housings. Any of these issues may cause a leak or seal failure, resulting in damaged equipment, production downtime, and lengthy and expensive repair and replacement procedures.
[0007] Existing systems, apparatuses, and methods for electrical penetrators and penetrator assemblies are known and are described in at least U.S. Pat. No. 8,287,295, entitled ELECTRICAL PENETRATOR ASSEMBLY (Sivik et al.), and U.S. Pat. No. 8,968,018, entitled ELECTRICAL PENETRATOR ASSEMBLY (Sivik et al.), each of which are incorporated by reference herein in their entirety.
[0008] What is needed is a sealing method for an electrical penetrator or set of electrical penetrators that does not require a set of o-rings or seals and that can provide a hermetic seal under extreme pressures and temperatures in a subsea environment.
SUMMARY OF THE INVENTION
[0009] The sealing method and apparatus of the present invention are an unexpected result from the design, testing, and qualification of traditional sealing elements. The present invention provides a ceramic penetrator sealing method and apparatus that does not require additional o-rings or seals. The present invention creates a hermetic seal by applying radial and axial forces to a metallic supporting apparatus compressed onto ceramic core. Utilizing high axial or radial compressive forces on a ceramic component forms a hermetic seal without the necessity of o-rings or additional metal or elastomeric seals. The metal supporting apparatus and ceramic core may be installed into a pressure containing apparatus to form a high pressure seal. The unique loading of forces (axial and radial, or axial compression), allow the present invention to withstand high pressures from multiple directions. The geometry at which the ceramic and metal interface at a certain constant pressure load form the hermetic seal. It was discovered that when applying sufficient foot-pound torquing force to a nut/bolt pair that a substantial compressive force or clamping force was generated such that the axial and/or radial forces exerted on the ceramic core by the metallic fixture or supporting apparatus creating a hermetic seal about a shoulder on the ceramic core. The angled, raised shoulders are critical to forming the hermetic seal. The ceramic core may be surrounded by a metallic sleeve. The hermetic seal may be formed about the angled shoulders with an intermediate metallic sleeve between the ceramic core and fixture, or may be formed without the metallic sleeve. The amount of force required to form the seal is not dependent on the external surroundings or conditions including external pressure conditions.
[0010] In one embodiment, a ceramic cylindrical core is disposed into a formed slot in a metallic supporting apparatus, the slot having machined dimensions to fit the exterior geometry of the ceramic core. A set of top and bottom metallic plates are installed at both ends of the ceramic core and compressed together with high compressive forces. The compressive forces on the opposite facing metallic plates apply compressive forces on the ceramic shoulders of the core. These compressive forces act on the ceramic core and the metallic supporting apparatus with very specific geometry, inducing both an axial and radial load on the ceramic core, metallic supporting apparatus, and metallic plates. The present invention solves the problem of sealing off gas and liquid mediums from infiltrating between ceramic and metallic substrates. The sealing mechanism does not rely on known sealing methods including o-rings, metal seals, and over molds. The present invention uses a combination of geometries and compressive force on ceramic and metal faces, which are placed in compression against each other, to create a high reliability seal. The seal provided by the system and method of the present invention requires a ceramic core in contact with a metallic supporting apparatus with a specific amount of compression applied in both axial and radial, or axial directions. The sealing apparatus of the present invention is not a separate element or component, but is the result of bringing materials, which may in one embodiment be ceramic-to-metal interface, together under pressure and compression at a favorable geometric interface.
[0011] In a first embodiment, the present invention provides a sealing apparatus comprising: a central element having a first end and second end and being substantially cylindrical and having a raised central portion, the raised central portion having a first and second shoulder; a first fixture, the first fixture having a first and second side and having an opening adapted to fit around the first end of the central element and to surround and abut the first shoulder of the central element; a second fixture, the second fixture having a first and second side and having an opening adapted to fit around the second end of the central element and to surround and abut the second shoulder of the central element; wherein a set of forces are constantly applied to the first and second fixture to form a seal about the raised central portion of the central element.
[0012] The invention according to the first embodiment may further comprise a third fixture, the third fixture having a first side and a second side and being disposed at the second side of the second fixture. The apparatus may further comprise wherein the first fixture is further adapted to abut the front of the third fixture; and the second fixture further is adapted to abut the rear of the third fixture; wherein the set of forces applied to the first and second fixtures compress said first and second fixtures to the respective first and second shoulders of the central element and the front and back of the third fixture. The central element may comprise a ceramic material. The set of forces may be applied by, for example, a set of nuts and bolts and may be a 96,000 pound clamping force on the apparatus. For example, in the testing arrangement shown in FIGS. 3 and 4 , each nut and bolt pair in the set of eight nut and bolt pairs may apply a 12,000 pound clamping force on the apparatus. The first and second shoulders may be angled from the central element at an angle of greater than 0° but less than 90° and the set of forces comprise both radial and axial compressive forces. The first and second shoulders may be angled from the central element at an angle of 90° and the set of forces comprise axial compressive forces.
[0013] In a second embodiment, the present invention provides a method for forming a seal around an element, the method comprising: applying a compressive force to a first sealing element and a second sealing element, the first and second sealing elements surrounding a central element, the central element having a raised central portion; wherein the first sealing element abuts a first shoulder of the raised central portion of the central element and the second sealing element abuts a second shoulder of the raised central portion of the central element forming a hermetic seal about first and second shoulders of the central element.
[0014] The method may further comprise, positioning a third sealing element about the exterior raised central portion of the central element, the third sealing element disposed between the first sealing element and the second sealing element. The compressive force may be applied to the first and second sealing elements compress said first and second sealing elements to the respective first and second shoulders of the central element and to the third sealing element. The central element may comprise a ceramic material. The compressive force may be applied by, for example, a set of nuts and bolts and may be a 96,000 pound clamping force. For example, each nut and bolt pair in the set of eight nut and bolt pairs may apply a 12,000 pound clamping force. The first and second shoulders may be angled from the central element at an angle of greater than 0° but less than 90° and the compressive force comprises both radial and axial compressive forces. The first and second shoulders may be angled from the central element at an angle of 90° and the compressive force comprises only axial compressive forces.
[0015] In another embodiment, the present invention provides a sealing apparatus for use in subsea environments exposed to demanding differential pressure conditions, the apparatus comprising: a central element having a first end and second end and being substantially cylindrical and having a raised central portion, the raised central portion being ceramic and having first and second shoulders; a first fixture having an opening adapted to receive the first end of the central element and a metallic seal surface geometrically configured to abut the first shoulder of the central element; a second fixture having an opening adapted to receive the second end of the central element and a metallic seal surface geometrically configured to abut the second shoulder of the central element; and a means for applying a set of forces to the first and second fixtures to form a seal about the raised central portion of the central element by urging the respective metallic seal surfaces into engagement with the respective first and second shoulders of the raised central portion, the set of forces collectively applying a minimum of 90,000 pound clamping force.
[0016] The apparatus may further comprise a third fixture, the third fixture having a first side and a second side and being disposed at the second side of the second fixture. The apparatus may further comprise wherein: the first fixture further adapted to abut the front of the third fixture; and the second fixture further adapted to abut the rear of the third fixture; wherein the set of forces applied to the first and second fixtures compress said first and second fixtures to the respective first and second shoulders of the central element and the front and back of the third fixture. The apparatus may further comprise wherein the central element comprises a ceramic material having a metallic sleeve disposed about the raised central portion. The apparatus may further comprise wherein the set of forces collectively apply a 96,000 pound clamping force. The apparatus may further comprise wherein the means for applying the set of forces comprises a set of nut and bolt pairs. The apparatus may further comprise wherein each nut and bolt pair in the set of nut and bolt pairs applies a 12,000 pound clamping force. The apparatus may further comprise wherein the first and second shoulders are angled from the central element at an angle of greater than 0° but less than 90° and the set of forces comprise both radial and axial compressive forces. The apparatus may further comprise wherein the first and second shoulders are angled from the central element at an angle of 90° and the set of forces are axial compressive forces. The apparatus may further comprise wherein the central element comprises a communications component having terminal ends that extend beyond the first and second fixtures. The apparatus may further comprise further comprising a means for preventing excessive set of forces being applied to the first and second fixtures. The apparatus may further comprise a means to prevent overtightening of the nuts of the nut and bolt pairs, or may alternatively comprise a means to limit tightening to a certain pre-defined specification.
[0017] In another embodiment, the present invention provides a method for forming a seal around a communications component disposed in high differential pressure undersea environment, the method comprising: applying a compressive force to a first sealing element and a second sealing element, the first and second sealing elements surrounding and abutting a raised central portion of the communications component; and wherein the first sealing element abuts a first shoulder of the raised central portion of the communications component and the second sealing element abuts a second shoulder of the raised central portion of the communications component thereby forming a hermetic seal about first and second shoulders of the central element.
[0018] The method may further comprise positioning a third sealing element about the exterior raised central portion of the communications component, the third sealing element disposed between the first sealing element and the second sealing element. The method may further comprise wherein the compressive force applied to the first and second sealing elements compress said first and second sealing elements to the respective first and second shoulders of the communications component and to the third sealing element. The method may further comprise wherein the raised central portion of the communications component comprises a ceramic material. The method may further comprise wherein the compressive force is applied by a set of nut and bolt pairs. The method may further comprise wherein the compressive force is a minimum 90,000 pound clamping force. The method may further comprise wherein each nut and bolt pair in an N-number of sets of nut and bolt pairs applies a minimum (1/N*90,000) pounds of clamping force. The method may further comprise wherein the first and second shoulders are angled from the central portion at an angle of greater than 0° but less than 90° and the compressive force comprises both radial and axial compressive forces. The method may further comprise wherein the first and second shoulders are angled from the central portion at an angle of 90° and the compressive force comprises only axial compressive forces.
[0019] In yet another embodiment, the present invention provides an electrical plug for use in undersea environments exposed to demanding differential pressure conditions, the plug comprising: a set of electrical penetrators, each electrical penetrator in the set of electrical penetrators comprising: a two piece substantially cylindrical body having a first and a second end, and having a first body portion and a second body portion, each of the first and second body portions comprising a ceramic insulator, a raised central portion, the raised central portion being ceramic and having first and second shoulders; a conductor disposed within the first and second body portions; a sealing sleeve joining the first and second body portions; and a set of metallic end sleeves disposed at the first and second ends of the cylindrical body, joining the conductor to the first and second body portions; wherein the conductor extends beyond the first and second ends of the two piece cylindrical body; a cable, the cable comprising a cable pigtail having a set of pigtail ends, each pigtail end in the set of pigtail ends being terminated at the conductor at the first end of an electrical penetrator in the set of electrical penetrators; a first fixture having an opening adapted to receive the first end of the central element and a metallic seal surface geometrically configured to abut the first shoulder of the central element; a second fixture having an opening adapted to receive the second end of the central element and a metallic seal surface geometrically configured to abut the second shoulder of the central element; a means for applying a set of forces to the first and second fixtures to form a seal about the raised central portion of the central element by urging the respective metallic seal surfaces into engagement with the respective first and second shoulders of the raised central portion, the set of forces collectively applying a minimum of 90,000 pound clamping force; and wherein the electrical plug is adapted to mate with an electrical receptacle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In order to facilitate a full understanding of the present invention, reference is now made to the accompanying drawings, in which like elements are referenced with like numerals. These drawings should not be construed as limiting the present invention, but are intended to be exemplary and for reference.
[0021] FIG. 1 provides a schematic cross-section of a first embodiment of a sealing apparatus wherein the shoulder angle on the ceramic core is less than 90 degrees in accordance with the present invention.
[0022] FIG. 2 provides a schematic cross section of a second embodiment of a sealing apparatus wherein the shoulder angle of the ceramic core is 90 degrees in accordance with the present invention.
[0023] FIG. 3 provides a cross-section of a ceramic core in a sealing apparatus compressed between a set of test fixtures in accordance with the first embodiment of the present invention.
[0024] FIG. 4 provides a plan view of the exterior of a first end of an exemplary sealing apparatus having a set of eight nuts and bolts in accordance with the first embodiment of the present invention.
[0025] FIG. 5 provides a partial cross-section view of a dry-mate plug having a set of ceramic penetrators sealed in accordance with the first embodiment of the present invention.
DETAILED DESCRIPTION
[0026] The present invention will now be described in more detail with reference to exemplary embodiments as shown in the accompanying drawings. While the present invention is described herein with reference to the exemplary embodiments, it should be understood that the present invention is not limited to such exemplary embodiments. Those possessing ordinary skill in the art and having access to the teachings herein will recognize additional implementations, modifications, and embodiments, as well as other applications for use of the invention, which are fully contemplated herein as within the scope of the present invention as disclosed and claimed herein, and with respect to which the present invention could be of significant utility.
[0027] With reference to FIG. 1 , a schematic cross-section of a first embodiment of a sealing apparatus 100 in accordance with the present invention is provided. The sealing apparatus 100 comprises a first fixture 120 and a second fixture 122 providing compressing forces F on the ceramic core 102 . The ceramic core 102 has a first end 112 , a second end 110 , and a raised central portion 130 . The ceramic core 102 has body 101 that is substantially cylindrical and is adapted to be disposed within the interior of first fixture 120 and second fixture 122 . The raised central portion 130 has a first shoulder 114 and a second shoulder 116 . The first shoulder 114 is adapted to be in physical contact with the interior 121 of the first fixture 120 and the second shoulder 116 is adapted to be in physical contact with the interior 123 of the second fixture 122 . The first 120 and second shoulder 122 provide a set of compressing forces F on the shoulders 114 and 116 of the raised central portion 130 of the ceramic core 102 .
[0028] The forces F may comprise both radial and axial compressive forces based on the degree, α, of the angle 118 . The degree α of the angle 118 must be greater than 0, and the shoulder angle 118 on the ceramic core 102 is less than 90 degrees. The geometry of the shoulders 114 and 116 of the raised central portion 130 and of the interiors 121 and 123 of the respective first 120 and second 122 fixtures with the compressive force F creates a heretic seal about the ceramic core 102 at the abutment of the shoulders 114 and 116 of the raised central portion 130 and of the interiors 121 and 123 of the respective first 120 and second 122 fixtures. The heretic seal is maintained through the constant application of a compressive force on the ceramic core 102 by the first 120 and second 122 fixtures.
[0029] With reference to FIG. 2 , a schematic cross section of a second embodiment of a sealing apparatus 200 wherein the shoulder angle 218 of the ceramic core 202 is 90 degrees in accordance with the present invention is provided. The sealing apparatus 200 comprises a first fixture 220 and a second fixture 222 providing compressing forces F on the ceramic core 202 . The ceramic core 202 has a first end 212 , a second end 210 , and a raised central portion 230 . The ceramic core 202 has body 201 that is substantially cylindrical and is adapted to be disposed within the interior of first fixture 220 and second fixture 222 . The raised central portion 230 has a first shoulder 214 and a second shoulder 216 . The first shoulder 214 is adapted to be in physical contact with the interior 221 of the first fixture 220 and the second shoulder 216 is adapted to be in physical contact with the interior 223 of the second fixture 222 . The first 220 and second shoulder 222 provide a set of compressing forces F on the shoulders 214 and 216 of the raised central portion 230 of the ceramic core 202 .
[0030] The ceramic core 202 of the apparatus 200 differs from the core 102 of the apparatus 100 shown in FIG. 1 in the angle 218 of the first shoulder 214 and second shoulder 216 relative to the body 201 the ceramic core 202 . The angle 218 for the first shoulder 214 and second shoulder 216 is 90 degrees at a right angle from the body 201 of the ceramic core 202 . This configuration creates only axial compressive forces when compressed by compressive force F by the first fixture 220 and second fixture 222 . The compressive force F creates a hermetic seal about the raised central portion 230 at the abutment of the first shoulder 214 and second shoulder 216 with the interior 221 of the first fixture 220 and the interior 223 of the second fixture 222 . The first end 212 and second end 210 of the ceramic core 202 may protrude beyond the fixtures 220 and 222 .
[0031] With reference now to FIG. 3 , a cross-section of a ceramic core 102 in a sealing apparatus 300 compressed between a set of fixtures 302 , 304 , and 306 in accordance with the present invention is provided. The body 101 of the ceramic core 102 is disposed within the interior 301 of the first 302 and second 304 fixtures of the sealing apparatus 300 . The first fixture 302 and second fixture 304 are in direct physical contact with the first shoulder 114 and second shoulder 116 of the raised central portion 130 respectively. Compressive force is applied by a set of nuts and bolts 314 compressing the exterior of the first fixture 302 and third fixture 306 . The set of nuts and bolts 314 may apply a total of 96,000 lbs of compressive force on the apparatus 300 . Each nut 312 and bolt 310 in the set of nuts and bolts 314 may be tightened to apply a 12,000 lb clamping force on the apparatus 300 which in turn applies axial and radial compressive forces on the ceramic core 102 . In this configuration, wherein the angle 118 at the shoulders 114 and 116 is greater than 0 but less than 90, the compressing force applied by the set of nuts and bolts 314 applies both radial and axial compressing forces on the shoulders 114 and 116 . This compressing force about the shoulders 114 and 116 of the raised central portion 130 creates a ceramic-to-metal seal between the shoulders 114 and 116 and the first fixture 302 and second fixture 304 . The third fixture 306 applies the compressing force to the second fixture 304 by way of the set of nuts and bolts 314 . In some configurations only the first fixture 302 and second fixture 304 may be present or required to form a hermetic seal about the ceramic core 102 . The sealing apparatus 300 in the embodiment shown in FIG. 3 is a testing apparatus used to qualify the seal formed about the ceramic core 102 by the first fixture 302 and second fixture 304 . However, the same or similar configuration may be employed to create a hermetic seal about a ceramic core similar to the ceramic core 102 shown in FIG. 3 without the exact first fixture 302 and second fixture 304 shown in the apparatus 300 . To form the hermetic seal about the ceramic core 102 an angled geometry of the shoulders 114 and 116 and the first fixture 302 and second fixture 304 is required along with a high compressive force.
[0032] With reference to FIG. 4 , a plan view of the exterior of a first end 402 of the sealing apparatus 300 in accordance with the present invention is provided. The cross-section shown in FIG. 3 is a cross-section at the axis A shown in FIG. 4 . The set of nuts and bolts 314 is shown at the exterior of the first fixture 302 of the apparatus 300 . The set of nuts and bolts 314 are not required to create the hermetic seal about the ceramic core 102 as shown in FIG. 3 , however, a similar compressing force must be constantly applied to form the hermetic seal about the ceramic core 102 . A set of ports 400 may be disposed on the exterior of the apparatus 300 to provide for pressurizing or depressurizing the apparatus or for measuring conditions within the apparatus 300 .
[0033] With reference now to FIG. 5 , a partial cross-section view of a dry-mate plug 500 having a set of ceramic penetrators 502 sealed in accordance with the first embodiment of the present invention is provided. The embodiment shown in FIG. 5 depicts an application for the ceramic-to-metal seal of the claimed invention as used in a dry-mate plug 500 . The ceramic penetrator 502 may comprise an assembly as described in U.S. patent application Ser. No. 14/979,269, Attorney Docket No. 113084.010US1, and U.S. patent application Ser. No. 14/979,296, Attorney Docket No. 113084.010US2, which are incorporated herein by reference in their entirety. The ceramic penetrator 502 disposed within the dry-mate plug 500 forms a pressure barrier between exterior conditions and the interior 560 of the plug 500 . A set of cable pigtails are terminated at a pigtail end (not shown) of the conductor 511 at the first end 512 of ceramic penetrator 502 , and may also be covered by an insulating boot 570 . The first shoulder 514 and second shoulder 516 of the raised central portion 530 are angled at an angle of less than 90 but greater than 0 degrees and abut the interior of the first fixture 522 and second fixture 524 . A compressive force applied by the first fixture 522 and second fixture 524 on the first shoulder 514 and second shoulder 516 forms a hermetic seal. The seal formed by the compressive forces may be supplemented by a set of rubberized or metal seals 550 , 552 , and 554 and by a sealing boot 556 . The additional sealing elements 550 , 552 , 554 and sealing boot 556 are not required to form a hermetic seal about the ceramic penetrator 502 .
[0034] While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concept described. In implementation, the inventive concepts may be automatically or semi-automatically, i.e., with some degree of human intervention, performed. Also, the present invention is not to be limited in scope by the specific embodiments described herein. It is fully contemplated that other various embodiments of and modifications to the present invention, in addition to those described herein, will become apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the following appended claims. Further, although the present invention has been described herein in the context of particular embodiments and implementations and applications and in particular environments, those of ordinary skill in the art will appreciate that its usefulness is not limited thereto and that the present invention can be beneficially applied in any number of ways and environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present invention as disclosed herein.
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The present invention provides a system and method for providing a seal for an electrical penetrator in a subsea environment. More specifically, the present invention provides for a system for creating a seal about an electrical penetrator without using o-rings or independent seals. The present invention provides for a set of supporting apparatuses to be placed in compression about a central ceramic penetrator element. The geometry of the central ceramic penetrator element and the interior of the supporting apparatuses forms a hermetic seal when under a constant radial and axial, or axial compressive force.
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FIELD OF THE DISCLOSURE
[0001] The present invention relates to side-by-side all terrain vehicles having at least two rows of seating areas.
BACKGROUND
[0002] Generally, all terrain vehicles (“ATVs”) and utility vehicles (“UVs”) are used to carry one or two passengers and a small amount of cargo over a variety of terrains. Due to increasing recreational interest in ATVs, specialty ATVs, such as those used for trail riding, racing, and cargo hauling have entered the market place. Most ATVs include seating for up to two passengers which are either seated side-by-side or with the passenger positioned behind the driver of the ATV. Side-by-side ATVs, in which the driver and passenger are seated beside each other on laterally spaced apart seats, have become popular because of the ability to allow the passenger to share the driver's viewpoint. It has also become common for riders to customize their vehicles and adding a second row of seats, for example by replacing a utility bed at the rear of the vehicle.
SUMMARY
[0003] According to an illustrative embodiment of the present disclosure, a utility vehicle is shown comprising a frame extending in a generally longitudinal direction, a drive train supported by the frame and a plurality of wheels operably coupled to the frame. A first seating area is positioned at a first longitudinal position and a second seating area is positioned at a second longitudinal position. The second seating area is rearward of the first seating area and being profiled such that the hip pivot axis (H-point) of a passenger in the second seating area is higher than the hip pivot axis of a person in the first seating area.
[0004] According to a further illustrative embodiment of the present disclosure, a utility vehicle is shown which comprises a frame extending in a generally longitudinal direction, a drive train supported by the frame, and a plurality of wheels operably coupled to the frame. A front axle is coupled to one or more of the plurality of wheels and a rear axle is coupled to one or more of the plurality of wheels. A first seating area is comprised of side-by-side seat positions at a first longitudinal position. A second seating area is comprised of side-by-side seat positions at a second longitudinal position, where the second longitudinal position positions the hip pivot axis (H-point) of a passenger in the second seating area, either above or longitudinally forward of, a centerline of the rear axle.
[0005] According to a further illustrative embodiment of the present disclosure, a utility vehicle is shown which comprises a frame extending in a generally longitudinal direction, a drive train supported by the frame, the drive train comprising an engine and a plurality of wheels operably coupled to the frame. A front axle is coupled to one or more of the plurality of wheels and a rear axle is coupled to one or more of the plurality of wheels. A first seating area is positioned at a first longitudinal position and a second seating area is positioned at a second longitudinal position, where a passenger seating position is below a top plane of the engine.
[0006] According to yet a further illustrative embodiment of the present disclosure, a utility vehicle is shown which comprises a frame extending in a generally longitudinal direction, a drive train supported by the frame and a plurality of wheels operably coupled to the frame. A first seating area is positioned at a first longitudinal position and a second seating area is positioned rearward of the first seating area. A roll cage is substantially covering the first and second seating areas, the roll cage comprising a front section, a center section and a rear section, the front, center and rear sections being coupled to each other and to the frame.
[0007] According to yet a further illustrative embodiment of the present disclosure, a utility vehicle is shown which comprises a frame extending in a generally longitudinal direction, a drive train supported by the frame and a plurality of wheels operably coupled to the frame. A first seating area is positioned at a first longitudinal position and a second seating area is positioned rearward of the first seating area. A hand hold bar is positioned behind the first seating area and a seat belt retractor is mounted to the hand hold bar at a position adjacent to the first seating area.
[0008] According to yet a further illustrative embodiment of the present disclosure, a utility vehicle is shown which comprises a frame extending in a generally longitudinal direction having at least one elongate frame tube assembly comprised of plural sections, a drive train supported by the frame and a frame tube coupler coupling the frame tube sections at a longitudinal position within 25% of the length of the frame at either end.
[0009] According to yet a further illustrative embodiment of the present disclosure, a utility vehicle is shown which comprises a frame extending in a generally longitudinal direction, and having at least one elongate frame tube assembly comprised of plural sections and a drive train supported by the frame. A frame tube coupler couples the frame tube sections, where the frame tube coupler comprises coupler sections associated with each coupler end, and the coupler sections have an alignment assembly for aligning the coupler sections to each other.
[0010] According to a further illustrative embodiment of the present disclosure, an utility vehicle includes a frame extending in a generally longitudinal direction, and having at least one elongate frame tube assembly comprised of plural sections and a drive train is supported by the frame. A frame tube coupler couples the frame tube sections, where the frame tube coupler comprises coupler sections associated with each coupler end, and the coupler sections having complementary interengagement elements. Fasteners retain the interengaging elements together, where the fasteners are in tension to force the complementary interengaging elements into engagement. In this manner, any shear force is substantially taken up by the complementary interengaging elements.
[0011] The above mentioned and other features of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a left front perspective view of the vehicle of the present disclosure;
[0013] FIG. 2 shows a left rear perspective view of the vehicle of FIG. 1 ;
[0014] FIG. 3 shows a left side view of the vehicle of FIG. 1 ;
[0015] FIG. 4 shows a top view of the vehicle of FIG. 1 ;
[0016] FIG. 5 shows a front view of the vehicle of FIG. 1 ;
[0017] FIG. 6 shows a rear view of the vehicle of FIG. 1 ;
[0018] FIG. 7 shows a left side view of the vehicle similar to that of FIG. 3 showing the chassis removed;
[0019] FIG. 8 shows the right side view of the vehicle of FIG. 7 ;
[0020] FIG. 9 is a front perspective view of the vehicle frame and roll cage;
[0021] FIG. 10 shows an enlarged view of the vehicle main frame;
[0022] FIG. 11 shows an enlarged view of the vehicle front frame;
[0023] FIG. 12 is a partially exploded and fragmented perspective view showing the coupler for coupling the main frame and front frame together;
[0024] FIG. 13 shows a top perspective view of the roll cage;
[0025] FIG. 14 shows a cross-sectional view through lines 12 - 12 of FIG. 3 ;
[0026] FIG. 15 shows an enlarged view of the seat belt retractor; and
[0027] FIG. 16 shows a perspective view of the seat poised for receipt in one of the seating areas.
[0028] Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0029] The embodiments disclosed below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. For example, while the following description refers primarily to UVs, certain features described herein may be applied to other applications such as ATVs, snowmobiles, motorcycles, mopeds, etc.
[0030] With reference first to FIGS. 1-6 , the vehicle of the present disclosure will be described. The vehicle is shown generally at 10 and is commonly referred to as an all terrain vehicle (ATV), a side-by-side vehicle (S×S) or a utility vehicle. As shown, vehicle 10 generally comprises a frame 12 ( FIG. 2 ) supported by ground engaging members 14 and 16 . As shown in this disclosure, ground engaging members 14 and 16 are comprised of wheels 18 and tires 20 ; and wheels 22 and tires 24 . Vehicle 10 further comprises a drivetrain 30 ( FIG. 2 ) operatively connected to frame 12 and drivingly connected to one or more of the ground engaging members 14 , 16 . In the present disclosure, the drivetrain 30 is comprised of a fuel-burning engine and transmission combination, together with a driveshaft extending between the drivetrain and the front ground engaging members 14 . However, any drivetrain could be contemplated such as hybrid, fuel cell or electric. The drivetrain 30 , the front and rear suspension assemblies, and steering assemblies are more thoroughly described in our pending applications Ser. Nos. 11/494,891 filed Jul. 28, 2006 and 11/494,890 filed Jul. 28, 2006, the subject matter of which is incorporated herein by reference.
[0031] As shown in FIGS. 1 and 2 , vehicle 10 further includes a body portion or chassis shown generally at 40 to include a hood 42 , front fender 44 , dash 46 , sideboard 48 , front floorboard 50 , rear sideboard 52 , rear floorboard 54 and rear cargo area 56 . As also shown, vehicle 10 is comprised of two seating areas, namely a front seating area 60 and a rear seating area 62 where front seating area 60 is comprised of side-by-side seats, shown as bucket seats 64 ; and rear seating area 62 is comprised of side-by-side seats, shown as bucket seats 66 . As shown best in FIG. 3 , front seats include a seat bottom 64 a and a seat back 64 b, while rear seat 66 includes a seat bottom 66 a and a seat back 66 b. Vehicle 10 also includes a roll cage 70 comprised of a front section 72 , a center section 74 , and a rear section 76 , where the front 72 , center 74 and rear 76 sections are attached to each other and to frame 12 as more fully described herein.
[0032] With respect now to FIGS. 7-12 , frame 12 will be described in greater detail. Frame 12 is generally comprised of a main frame section 80 and a front frame section 82 , where the two sections are interconnected by way of couplers 84 . With reference first to FIGS. 9 and 10 , the main frame section 80 is generally comprised of two longitudinal frame rails 90 interconnected by a plurality of struts such as 92 , 94 , 96 attaching frame rails 90 together in a predefined spaced-apart relation. Main frame section 80 also comprises a drivetrain mounting section 102 extending at a rear portion of main frame 80 .
[0033] With respect now to FIG. 10 , frame 80 also defines front seat support platform 110 and rear seat support platform 112 . Front seat support platform 110 includes a transversely extending tube 114 having legs 116 attached to outer frame rail 118 and inner legs 120 directly attached to frame tubes 90 . Frame tube 114 spans the distance across frame rails 118 and the frame tubes 90 . With reference still to FIG. 10 , frame tubes 114 include a latch hook 122 as described further herein. Front seat support platform 110 further includes a transverse frame member 124 which as best shown in FIG. 9 is attached to roll cage center section 74 as further described herein. Frame tube 124 includes latching pins 126 for inter-engagement with seats 64 .
[0034] With reference still to FIG. 10 , rear seat support platform 112 is comprised of frame tubes 130 which provide an elevated platform for transverse frame tubes 132 and 134 . Frame tubes 132 have latch hooks 136 (similar in nature to latch hooks 122 ) and frame tube 134 has latching pins 138 (similar to latching pins 126 ).
[0035] With respect still to FIG. 10 , main frame member 80 further includes roll cage mounting sections 150 and 152 . As shown, mounting section 150 includes a plate 154 on each side spanning tube 90 and frame rail 118 . Mounting section 152 is provided by a plate 156 provided on frame tube 158 which spans uprights 160 of frame rail 118 .
[0036] With respect now to FIG. 11 , front frame member 82 will be described in greater detail. Front frame member 82 includes frame tubes 170 which complement frame tubes 90 , and are held in a fixed relation by tubes 172 , 174 . Frame rails 178 are fixed in relation to frame tubes 170 by way of a strut 180 . Front frame 82 further comprises front roll cage mounting sections 182 comprising plates 184 positioned between cross tubes 186 , 188 , and elevated by way of uprights 192 , 194 .
[0037] As described, frame 80 is comprised of main frame member 90 and front frame member 82 . Splitting the frame into two separate modular subassemblies allows for easier processing of the entire vehicle 10 . Due to the load on the frame tubes 90 , 170 , the connection provided by coupler 84 takes place at a longitudinal position from either end of the frame 80 , within a distance from the end, of approximately 30% of the length of frame 80 . The coupler 84 could also be placed at the rear of frame tubes 90 .
[0038] With reference now to FIG. 12 , frame tube coupler 84 is shown poised for receipt within frame tubes 90 , 170 . As shown, coupler 84 is comprised of individual coupler members 200 . The coupler members 200 are identical, and each comprises a tube connecting section 202 and an alignment or interengaging section 204 . The interengaging sections 204 include interengaging elements, shown here as projections 206 and recesses 208 . Projections 206 are shown as frusto-conical in shape, and recesses have a complementary frusto-conical recessed configuration. The interengaging sections 204 further comprise apertures 216 which self align with apertures 216 in the opposite interengaging section 204 when complementary projections 206 and recesses 208 align. As also shown in FIG. 12 , tube connecting sections 202 include legs 210 and stand-offs 212 . Finally, a connecting bracket 220 is provided for connecting frame rails 118 and 178 .
[0039] To connect main frame member 80 and front frame member 82 , the individual coupler members 200 are each inserted into respective ends of the frame tubes 90 , 170 until such time as stand-offs 212 abut an end edge of the frame tubes 90 , 170 . Stand-off 212 leaves a weld gap for welding the individual couplers 200 to the frame tubes 90 , 170 . The individual couplers 200 are shown welded in place to respective frame tubes 90 , 170 in FIGS. 10 and 11 .
[0040] Coupler 84 allows alignment of frame tubes 90 and 170 as individual couplers 200 are each aligned with respective frame tubes 90 , 170 and individual couplers 200 are alignable to each other. Couplers 84 also allow alignment of frame tubes 90 , 170 when the main frame 80 and front frame 82 are not themselves perfectly aligned. That is, once individual coupler members are close to alignment, fasteners (not shown) are positioned into and through complementary apertures 216 , whereby the fasteners may be drawn tight until the projections and recesses are in engagement with each other. This aligns the tubes 90 , 170 . At the same time, any shear forces on the coupler 84 is taken up through the projections and recesses, not through the fasteners.
[0041] With respect now to FIG. 13 , roll cage 70 is shown comprised of front 72 , center 74 and rear 76 roll cage sections; and are shown connected at connection joints 230 and 232 . Such joints are known in the industry.
[0042] Front roll cage section 72 is comprised of uprights 234 , transverse sections 236 , and longitudinally extending sections 238 . Mounts 240 are provided at the front and extend from uprights 234 . It should be appreciated that mounts 240 cooperate with mounting sections 182 ( FIG. 11 ) by way of fasteners (not shown).
[0043] Center roll cage section 74 is comprised of uprights 246 , transverse section 248 and longitudinally extending sections 250 . Mounts 252 are provided at the lower end of upright 246 and is comprised of stand-offs 254 and mounting brackets 256 . It should be appreciated that mounting brackets 256 cooperate with mounting section 150 ( FIG. 10 ) by way of fasteners (not shown).
[0044] Rear roll cage section 76 is comprised of uprights 260 , transverse section 262 , and longitudinally extending section 264 . Mounts 268 are provided at the lower end of uprights 260 which cooperate with mounting sections 152 ( FIG. 10 ).
[0045] Roll cage assembly 70 comprises ergonomic features for the driver and passengers. First, supports 276 are provided on uprights 246 extending forwardly. These supports are positioned adjacent to seats 64 , as shown in FIGS. 1 and 2 , and enclose the driver and front passenger. Second, supports 280 are provided between uprights 246 and 260 , and include an upper portion 282 , lower portion 284 and transition portion 286 . As shown in FIG. 1 , support 280 is shown in position where lower portion extends across the entry spaced above floorboard 54 . Transition section 286 and upper portion 282 extend across the seat 66 and enclose the rear passengers. Finally, rear passenger hand bar 290 extends between uprights 246 , and as best shown in FIG. 14 , extends behind front seats 64 , as described below.
[0046] As shown in FIG. 14 , rear seat bottoms 66 a are shown elevated relative to front seat bottoms 64 a. Thus the rear passenger hand bar 290 , which extends behind front seat backs 64 b is positioned at shoulder height relative to the persons in front seats 64 . As shown best in FIG. 15 , seat belt retractor 300 is positioned on hand bar 290 , and is attached to bracket 302 which is connected between hand bar 290 and upright 246 . This places the seat belt retractor 300 in a convenient location for those in front seats 64 , yet keeps the retractor away from the rear passengers.
[0047] Vehicle 10 is also ergonomically designed for the rear passenger's riding experience. For example, and with respect still to FIG. 14 , uprights 246 are shown flaring outwardly. For example, uprights at the frame are spaced apart by a dimension of D 1 but extend upwardly to a dimension of D 2 which is larger than D 1 . This provides a spacing at 310 between uprights and seat backs 64 b providing extra room for the passenger's knees.
[0048] The vehicle design also provides easy ingress and egress. As shown best in FIG. 14 , the driver and front passenger may easily enter vehicle 10 without contacting longitudinally extending sections 238 . This is due to the fact that the distance (D 6 ) between sections 238 is less than the extreme position adjacent the top of uprights 234 (D 5 ) and is less than the distance between the extreme position adjacent the top of uprights 246 (D 4 ). This insetting of longitudinally extending sections 238 provides easy ingress. In a like manner relating to the rear passengers, and as best shown in FIGS. 4 , 6 and 14 , longitudinally extending section 264 are inset from extreme positions of both uprights 246 and 260 , that is D 6 is less than both D 2 and D 7 ( FIGS. 4 and 6 ). This provides easy ingress for rear passengers.
[0049] The design also provides an enhanced ride for the rear passenger. Due to the elevated rear seats 66 , the rear passengers can view over the top of the front seats 64 . As shown best in FIG. 7 , the elevation of the seats is such that the hip pivot axis (H-point) of the rear passenger (H 2 ) is higher than the H-point of the driver (H 1 ). Also, for ride purposes, the H-point of the rear passenger (H 2 ) is positioned either over, or forward of, the centerline of the rear axle. As shown best in FIG. 7 , H 2 and the axle centerline are spaced apart by a distance D 8 . Also, in order to enhance the ride of the rear passenger, as w ell as keep the center of gravity low, a seating position 310 of the rear passenger is positioned lower than a top 320 of the engine 322 . The seating position is the location on the seat having the highest distribution of load from the passenger while idle. This area is normally substantially adjacent to an intersecting line through the torso of the passenger and the seat bottom 66 a. In the illustrated embodiment of FIG. 7 , this distance is shown as D 9 . Finally, seating position 310 is also forward of, a forward most point 330 of engine 322 , and as shown best in FIG. 7 , this distance is depicted as D 10 . It should be appreciated that the seating positions could also be lower than the highest point 320 of engine 322 and behind the forward most point 330 , if the seats laterally straddled the engine 322 .
[0050] With respect now to FIG. 16 , the vehicle 10 provides enhanced serviceability and functionality. As shown, each seat 64 , 66 may be removed. The seat 64 is shown having a lower base 350 having locking feet 352 receivable under latch hook 122 and a latch 354 which is receivable over latching pin 126 . Latch release 356 releases latch 354 from the latch-locked condition. Latch 354 is substantially similar to the latch shown in pending U.S. application Ser. No. 12/246,948 filed Oct. 7, 2008 (This is the X2 seat). This provides access to a battery (not shown) in battery box 360 . Also as transverse tube 124 is bolted to stand-offs 254 ( FIG. 9 ), removal of tube 124 allows the molded covering 360 to be easily removed.
[0051] It should be appreciated that one or more of the rear seats 66 may be removed in an identical manner to that described with respect to front seats 64 . Removing one or more of the rear seats may be desired if extra storage space is required and the space is not required for a rider. Also, accessory mounts could be provided (having a similar construction and footprint to that of seat base 350 ) and snapped in place in one or both seat positions. For example, such accessories could include coolers, tool boxes, trunks, water tanks, fuel containers, camping/fishing gear, a dog crate/kennel, and the like. This enhances the functionality of vehicle 10 .
[0052] While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.
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The present invention relates to all terrain vehicles having at least a pair of laterally spaced apart seating surfaces. More particularly, the present invention relates to side-by-side all terrain vehicles having plural rows of seats.
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BACKGROUND OF THE INVENTION
The present invention relates generally to a voice response apparatus for performing a voice response service and more particularly, to a voice response apparatus for sending voice signals via communication lines such as common telephone lines.
With advancements in speech synthesizing technology and a speech recognizing technology in recent years, there are voice response systems capable of performing services such as reserving seats or inquiring into account balances through no human intermediary.
Such voice response systems consist of a voice response apparatus, telephones and telephone lines for transmitting data therebetween. In the voice response apparatus, several pieces of data for determining contents of the voice responses are prepared. The voice response apparatus selects the data in accordance with the information that the user inputs through the telephone and converts the selected data into voice signals transmitting the voice signals through the telephone.
The data prepared in the voice response apparatus take a variety of forms such as text data, waveforms, data into which the voice waveform is coded and data into which the voice waveform is parameterized by analysis. In the voice response apparatus, the data is converted into voice signals by use of a method corresponding to the data format. For example, the voice response apparatus having text data that determines contents of the response messages synthesizes the voice signals by a rule synthesizing method from the text data.
Further, the methods of inputting information from the user telephone comprises a method using tone signals and a method using a human voice uttered by the user. In a voice response apparatus using the latter method, speech recognition technology is used to judge the contents of the voice.
In such a voice response apparatus, a variety of contrivances are used to perform high-quality voice response. For example, a vice response apparatus disclosed in Japanese Patent Laid-Open Publication No. 59-181767 judges the transmission condition by detecting the level of voice signals from the telephone, and changes the level of voice signal transmission so as to output a fixed level voice from the telephone. Another voice response apparatus aiming at outputting a fixed level voice from the telephone is disclosed in Japanese Patent Laid-Open Publication No. 61-235940. The voice response apparatus in this Publication changes the transmitted level of voice signals in accordance with a depressed push button in the telephone.
Furthermore, a voice response apparatus capable of selecting a characteristic of the voice output and an utterance speed is disclosed in Japanese Patent Laid-Open Publication No. 4-175046. This voice response apparatus adopts voice synthesis based on a rule synthesizing method and it selects a set of parameters which are used in synthesizing voices, in accordance with the depressed push button.
Japanese Patent Laid-Open Publication No. 3-160868 discloses a voice response apparatus adopting a voice recognition technology. This voice response apparatus is prepared with two response sequences for the same service. In one response sequence, operating procedures are specified with which a numerical value of N figures is obtained in one step. And in another response sequence, operating procedures are specified with which the numerical value is obtained in N steps.
The voice response apparatus performs the service by obeying the response sequence in accordance with recognizability of words spoken by a user. When a user utters words in a recognizable form, the apparatus operates obeying the former response sequence and gets numerical data of some figures by one word. On the other hand, the apparatus operates obeying the latter response sequence to a user with low recognizability.
As explained above, the conventional voice response apparatuses have employed a variety of contrivances to provide the voice response service with a higher usability. In the case of a voice response service which employs a large-capacity database if there are a multiplicity of pieces of data in the database matching a retrieval condition, it follows that the information voice outputs beyond the recognizing ability of the given user, with the result that the information service does not function well and the apparatus outputting all data in the database that matches the retrieval condition.
Such a phenomenon can be prevented by repeating a question/answer process several times when offering the voice response service. If the voice response apparatus is constructed for that purpose, however, the user has to frequently respond (e.g. manipulate the push button) corresponding to a content of the inquiry provided by the voice response apparatus. Besides, the inquiries from the voice response apparatus often include some useless questions (to give an answer "Yes" in majority of cases), and, therefore, an effective voice response service can not be offered.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a voice response apparatus capable of actualizing an effective voice response service.
A voice response apparatus according to the present invention is an apparatus connected via a communication line to a user telephone. The voice response apparatus comprises a storage part, a transmitting unit and a control unit. The storage part stores narrative information of which the user should be notified. The transmitting unit generates a voice signal corresponding to narrative information stored in the storage part and transmits the generated voice signal onto the communication line. When position specifying data is input from the user telephone during the transmission of the narrative information, a control unit causes the transmitting unit to interrupt the transmission of the narrative information and to resume the transmission of the narrative information from a position specified by the position specifying data.
The voice response apparatus, according to the present invention, is capable of causing the transmitting unit to transmit narrative information from the position the user desires through the control unit.
Further, the narrative information can be composed of one or more pieces of document data the usage sequence of which is predetermined. In this case, the transmitting unit is constructed to generate the voice signals corresponding to each piece of document data constituting the narrative information in the order based on the usage sequence that is predetermined within the narrative information. Then, the control unit is constructed to receive an input position specifying data for specifying one piece of document data constituting the narrative information and resumes the transmission of the narrative information from the document data specified by document data specifying data.
In the case of adopting such a construction, the control procedures of the transmitting unit by the control unit can be simplified, and it is therefore possible to actualize the voice response apparatus capable of performing the effective voice response service.
According to the present voice response apparatus, any kind of signal may be used as position specifying data. When tone signals are employed as the position specifying data, it is feasible to actualize the voice response apparatus capable of performing the effective voice response service with a simple construction.
Further, the narrative information stored in the storage device may be composed of one or more pieces of document data the usage sequence of which is determined and output control data which determines whether or not each document data is output in the form of voice signals. In this case, the transmitting unit is constructed to generate the voice signals corresponding to each document data implying that the output control data is output in the form of the voice signals among the document data constituting the narrative information. Added further to the apparatus is a rewriting part for rewriting, when a predetermined piece of first indication data is input from the user telephone during the transmission of the narrative information by the transmitting unit, the output control data relative to the document data transmitted by the transmitting unit in the narrative information stored in the storage part into a piece of data indicating that the voice signal output is not performed. In this case, the voice output of unnecessary narrative information can be omitted.
When a predetermined piece of second indication data is input from the user telephone during the transmission of the narrative information by the transmitting unit, the rewriting part rewrites the content of the output control data relative to all the document data in the narrative information into a piece of data indicating that the voice signal output is performed.
Further, the storage part may store first narrative information and second narrative information used for the same service. In this instance, the transmitting unit is constructed to generate the voice signals corresponding to one of the first narrative information and the second narrative information stored in the storage part. Added then to the voice response apparatus is a switching unit for switching, when a predetermined piece of third indication data is input from the user telephone, the narrative information used for the transmission by the transmitting unit.
If constructed in this way, the content of the narrative information can be transmitted from the position that the user desires to the transmitting unit in a user-desired mode. Furthermore, a content specified in the second narrative information is a summary of a content specified in the first narrative information. With this arrangement, redundant voice output of the narration which is deemed useless to the user can be prevented.
Also, the transmitting unit is so constructed as to be capable of generating the voice signals having the same utterance speed based on the same narrative information. When receiving an indication to change the utterance speed from the user telephone during the transmission of the narrative information by the transmitting unit, the control unit will cause the transmitting unit to generate the voice signal having the utterance speed according to the user's indication. Therefore, the reading speed of the narration can be changed to a speed that the user desires.
Further, there may be used the narrative information the content of which is defined by the text data. In this instance, the voice response apparatus incorporates the transmitting unit for converting the narrative information into the voice signals by performing rule voice synthesis. Via this mechanism, any kind of narration can be voice-output, and the voice response apparatus can easily change the contents of the narration.
Furthermore, the storage part stores the narrative information the content of which is defined by the text data and the accumulation voice data. In this case, however, the transmitting unit converts the narrative information into the voice signals by performing rule voice synethesis. This is done when transmitting the narrative information the content of which is defined by the text data and to convert the narrative information into the voice signals by effecting waveform reproduction when transmitting the narrative information the content of which is defined by the accumulation voice data.
If the voice response apparatus is thus constructed, with respect to the narration requiring no change in the content, the content thereof is stored in the form of the accumulated voice data. When the narration requires a change of content, this changed content can be stored in the form of the text data. Accordingly, an average voice quality when offering the voice response service can be enhanced in terms of its understandability and naturalness as well.
Added to the voice response apparatus constructed to use the narrative information the content of which is defined by the text data are a database and retrieving part for creating a narrative information on the basis of a retrieval result of the database in accordance with a content of the indication from the user telephone and causing the storage part to store the thus created narrative information. If constructed in this way, the voice response apparatus capable of offering the data retrieval service can be obtained.
Added further to the voice response apparatus constructed to us the narrative information the content of which is defined by the text data is a facsimile signal transmitting part. The voice response apparatus can create image data on the basis of the narrative information to be transmitted by the transmitting unit and transmitting facsimile signals corresponding to the created image data onto the communication line.
In the case of taking this construction, the large-capacity data that are hard to recognize through the voice output can be output to the facsimile. For this reason, the voice response apparatus capable of offering the effective voice response service can be obtained.
Furthermore, when using the narrative information composed of one or more pieces of document data, the position specifying data the input of which is accepted by the control unit desirably contains the following: a portion of position specifying data for specifying the document data that is being transmitted; a portion of position specifying data for specifying a portion of document data next to the document data that is being transmitted; a portion of position specifying data for specifying a piece of document data positioned one anterior to the document data that is being transmitted; a portion of position specifying data for specifying the head document data of the narrative information that is being transmitted; and a portion of position specifying data for specifying the last document data of the narrative information that is being transmitted.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent during the following discussion in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram illustrating a construction of a voice response apparatus in a first embodiment of the present invention;
FIG. 2 is an explanatory chart showing operating contents of a voice synthesizing unit provided in the voice response apparatus in the first embodiment of the present invention;
FIG. 3 is an explanatory chart showing a structure of a result-of-retrieval file created in the voice response apparatus in the first embodiment of the present invention;
FIG. 4 is an explanatory chart showing an outline of a narration story file for a goods ordering service that is used in the voice response apparatus in the first embodiment of the present invention;
FIG. 5 is a flowchart showing operating procedures when implementing the goods ordering service in the voice response apparatus in the first embodiment of the present invention;
FIG. 6 is a diagram showing a signal sequence when implementing the goods ordering service in the voice response apparatus in the first embodiment of the present invention;
FIG. 7 is a diagram showing a signal sequence when a fault happens in the voice response apparatus in the first embodiment of the present invention;
FIG. 8 is an explanatory diagram illustrating a correspondence relationship of each push button of a user telephone versus an operating indication in the voice response apparatus in the first embodiment of the present invention;
FIG. 9 is a flowchart showing operating procedures of an execution procedure control part when giving an operating indication for controlling a reading mode in the voice response apparatus in the first embodiment of the present invention;
FIG. 10 is an explanatory diagram showing a relationship of a reading position control parameter versus a reading mode in the voice response apparatus in the first embodiment of the present invention;
FIG. 11 is a flowchart showing operating procedures of the execution procedure control part when giving an operating indication for controlling a reading position in the voice response apparatus in the first embodiment of the present invention;
FIG. 12 is an explanatory diagram showing one example of an operation result when giving an operating indication for controlling a reading portion in the voice response apparatus in the first embodiment of the present invention;
FIG. 13 is a block diagram illustrating a construction of the voice response apparatus in a second embodiment of the present invention; and
FIG. 14 is a characteristic comparative chart on the basis of a voice synthesizing method usable in the voice response apparatus according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A voice response apparatus according to the present invention will be discussed in detail with reference to the accompanying drawings.
First Embodiment
FIG. 1 illustrates a voice response apparatus in a first embodiment of the present invention. As depicted therein, a voice response apparatus 10 in accordance with this embodiment includes a transmitting/receiving unit 11, a voice synthesizing unit 12, an accumulated voice reproducing unit 13, a switching unit 14 and a control unit 15.
The transmitting/receiving unit 11 transmits and receives signals to and from user telephones 50 connected via telephone lines. This transmitting/receiving unit 11 also executes a process (so-called network control) for a call signal from the user telephone 50. Further, the transmitting/receiving unit 11, when receiving a tone signal 60 from the user telephone 50, generates a portion of push button data 61 defined as code data corresponding to that tone signal 60 and supplies the control unit 15 with the thus generated push button data 61.
The voice synthesizing unit 12 generates voice signals corresponding to the text data containing ideographs. The voice synthesizing unit 12 is constructed of a document analyzing part 31, a word dictionary 32, a read/prosodic symbol imparting part 33, an intonation generating part 34, a waveform synthesizing part 35 and a phonemic element file 36. Those respective parts operate as schematically shown in FIG. 2.
The document analyzing part 31 segments text data input via the switching unit 14 from the control unit 15 into words with reference to the kanji (Chinese ideographs) and also sets an articulation in a group of data-segmented words. The read/prosodic symbol imparting part 33 devoices vowels with respect to the text data undergoing the word segmentation and the articulation setting. Thereby the read/prosodic symbol imparting part imparts the read and the prosodic symbols representing pauses, intonations and accents of the articulations to the text data. The intonation generating part 34 generates an intonation pattern with respect to the input text data on the basis of various items of data supplied from the read/prosodic symbol imparting part 33. The waveform synthesizing part 35 synthesizes waveforms by reading necessary phonemic elements out of the phonemic element file 36 and outputs a result of the waveform synthesization in the form of a voice signal.
This voice synthesizing unit 12 is so constructed as to be capable of generating the voice signals at different reading speeds (utterance speeds) on the basis of the text data given. The voice synthesizing unit 12 generates a voice signal at a reading speed corresponding to a value of a parameter "F SPD " supplied for the control unit 15. Procedures of causing the voice synthesizing unit 12 to change the reading speed will hereinafter be described in detail.
The accumulated voice reproducing unit 13 converts voice coded data into a voice signal. The accumulated voice reproducing unit 13 is constructed of a voice expansion part 37 for expanding the voice coded data and a waveform regenerating part 38 for regenerating waveforms on the basis of the expanded voice coded data.
The voice signals output from the voice synthesizing unit and the accumulated voice reproducing unit 13 are input to the transmitting/receiving unit 11. The thus input voice signals are transmitted via the transmitting/receiving unit 11 onto a communication line and further transmitted to the user telephone 50.
The switching unit 14 supplies one of the voice synthesizing unit 12 and the accumulated voice reproducing unit 13 with the data from the control unit 15. The control unit 15 controls this switching unit 14.
The control unit 15 integrally controls the individual element of the present voice response apparatus 10 and is constructed of the respective function blocks which operate as will be explained below.
A retrieval database storage part 21 serves to store a variety of databases accessed when performing the voice response serves. A data access part 22 extracts the data satisfying a retrieval condition indicated by an execution procedure control part 29 out of the database stored in the retrieval database storage part 21.
A work file storage part 23 serves to temporarily store a work file that is used when the present voice response apparatus operates. The work file is created by a data processing part 24. For example, when the database access part 22 retrieves the database, the data processing part 24 creates a result-of-retrieval file defined as the work file used when synthesizing the voices on the basis of the result of that retrieval.
FIG. 3 illustrates a structure of the result-of-retrieval file. Referring to FIG. 3, respective items from Address to Ending Time are items contained in the database as a retrieval target. Further, Delete and SEQ are items added by the data processing part 24 when creating the result-of-retrieval file. Both of Delete and SEQ are items referred when voice-outputting contents of the result-of-retrieval file. Sequence data for designating sequence to output are written in the item SEQ when creating the file. Output control data for designating whether the voice signal should be output or not are written in the item Delete during an implementation of the voice response serve.
Referring back to FIG. 1, the explanation of the function blocks constituting the control unit 15 will continue.
A narration file storage part 25 is a storage part for storing a narration file, i.e., data which is the basis of the voice signals transmitted to the user telephone 50. The narration file is divided into a voice accumulation file in which contents of the voice signals are prescribed by the voice coded data and a text file in which the contents of the voice signals are prescribed by the text data. The narration file storage part 25 stores these two types of files with different terms of their data forms.
A document creating part 26 incorporates a function to output contents of the text file or the accumulation voice file stored in the narration storage part 25 and a function to create and output a document (text data) in a colloquial mode by combining several sets of text data. The document creating part 26 operates in accordance with an indication given from the execution procedure control part 29.
A narration story file storage part 27 stores a narration story file defined as model information on question/answer procedures conducted between the present voice response apparatus 10 and the user telephone 50. A narration story file relative to the services performed by the present voice response apparatus is stored beforehand in this narration story file storage part. The narration story file is a program file. Defined in the narration story file is a procedure of executing three kinds of basic processes named a narration reading process, a push button data reading process and a database access process.
A narration story analyzing part 28 reads the narration story file within the narration story file storage part 27 and converts this file into data in a mode understandable by the execution procedure control part 29. Then, the execution procedure control part 29 integrally controls the respective parts in accordance with the data output by the narration story analyzing part 28, thereby actualizing the voice response service between the user telephones 50.
Hereinafter, the narration reading process, the push button data reading process and the database access process will be explained in sequence with reference to FIG. 4. Note that FIG. 4 is a diagram schematically showing the contents of the narration story file used in the case of conducting a goods order receiving service in the present voice response apparatus. Referring to FIG. 4, in a procedure of a process classification being (1), the narration reading process is executed. In procedures of the process classification being (2) and (3), the push button data reading process and the database access process are respectively executed.
The Narration Reading Process is now explained.
The narration reading process is a process of outputting the voice signal to the user telephone 50. For indicating an execution of this process in the narration story file, information specifying the data as a basis of the voice signal is given in the form of an operand. The execution procedure control part 29 executes the narration reading process corresponding to a content of the operand.
For instance, as in the procedure 1, when a voice accumulation file name "open.pcm" is described as an operand, the execution procedure control part 29 controls the document creating part 26 and the switching unit 14, thereby supplying the accumulated voice reproducing unit 13 with contents of the designated voice accumulation file. Then, a voice signal corresponding to the content of the voice accumulation file is output to the accumulated voice reproducing unit 13 and transmitted therefrom to the transmitting/receiving unit 11.
Further, in the case of describing text data (procedures 2, 7, etc.) or a text file name (procedure number 17) as operand, the execution procedure control part 29 controls the document creating part 26 and the switching unit 14, thereby supplying the voice synthesizing unit 12 with the text data thereof or the contents (text data) of the text file containing the text file name thereof that is stored in the narration file storage part 25. Ensuingly, the voice signal corresponding to the text data is output to the voice synthesizing unit 12 and then transmitted therefrom to the transmitting/receiving unit 11.
It is to be noted that the variable name or the item name of the result-of-retrieval file can be described in the text data used as an operand according to the present voice response apparatus. If an indication containing such an operand is given, the execution procedure control part 29 causes the document creating part 26 to create the text data wherein a corresponding variable or an actual content of the item is inserted in an area described with the variable name or in the item name.
For instance, as in the procedure number 5, if variable names such as "Code-user" and "Name-user" are described in the text data, the execution procedure control part 29 controls the document creating part 26, so that the document creating part 26 creates a piece of text data (e.g., No. 651123, are you Tokkyo Taro?) by inserting contents of respective variables, 651123 and Tokkyo Taro in the areas written with the variable names.
When reading the content of the result-of-retrieval file shown in, e.g., FIG. 3, as an operand, there is described the file name of the text file having such a content that No. (SEQ), an address is (address), a number of employees (scale), an industrial classification is (industrial-classification), a type of job is (job-classification), wages from (minimum-wages) up to (maximum-wages) and duty hours from starting-time to ending time. If such an indication is given, the execution procedure control part 29 controls the document creating part 26 so as to create the text data wherein each item data of the result-of-retrieval file is inserted in the bracketed area. Then, it makes the voice synthesizing unit 12 synthesize the voice signal corresponding to the text data created by the document creating part 26.
Note that if the result-of-retrieval file includes plural sets of retrieved results, the execution procedure control part 29 converts the respective retrieved results stored in the result-of-retrieval file into voice signals in the sequence of values of (SEQ), thereby reading the result-of-retrieval file. The voice response apparatus reads the result-of-retrieval file excluding the retrieved result wherein the output control data indicating that no voice signal is outputted is written in the item Delete.
According to the present voice response apparatus, when indicating the execution of the narration reading process in the narration story file, the voice accumulation file name and the text data or two kinds of text file names can be described as the operand. The execution procedure control part 29 executes the narration reading process by use of the operand corresponding to a value of a parameter "F MODE " held therein.
In the present voice response apparatus, the content of each operand is set to read any one of the narration indicating the content of which the user is informed in detail and the narration as a summary thereof.
For example, if the content of the narration using one operand states: "We brief you on the present situation of the labor market. Incidentally, each value has already been seasonally adjusted. Looking at the nationwide labor market as of December in 1993, the effective job hunters decreased by 0.4% against the previous month, while the effective job offers decreased by 0.9% against the previous month. The effective job offer rate is 0.65 times, which is well balanced with the previous month. Let's itemizes this, the effective job offer rate of the part-time jobs is 1.03 times, but the effective job offer rate excluding the part-time jobs is 0.6 times. Further, the new job offers as of December decreased by 13.6% against the same month in the previous year." The content of another operand is set to narrate the following: Briefing the present labor market as of December in 1993, the effective job hunters decreased by 0.4% against the previous month, while the effective job offers decreased by 0.9% against the previous month. The effective job offer rate is 0.65 times."
According to the present voice response apparatus, if the user depresses a predetermined push button during the execution of the narration reading process, the operand is changed over (the value of the parameter "F MODE " is changed), and the narration reading mode is also changed. Further, if other push button is depressed, the narration reading mode is changed by varying the value of the above-mentioned parameter "F SPD ". Moreover, if another push button is depressed during the execution of the narration reading process, the apparatus starts to read the narration from a position corresponding to the depressed push button.
Those processes (the reading mode control process and the reading position control process) are executed in parallel to the narration reading process, but a detailed explanation will be given later.
The Push Button Data Reading Process is now explained.
A push button data reading process is a process of recognizing the push button selected on the user telephone 50. When indicating an execution of this process, a piece of information for designating how the obtained push button data is used is described in the narration story file.
In the case of employing the push button data in order to input the data, there are described variable names for storing a series of push button data and a piece of information for determining what condition to satisfy for completing the data input. The execution procedure control part 29 determines a delimiter of the data conforming to that indication and stores the obtained data corresponding to a designated variable.
For instance, when an indication as in the procedure 3 is to be given, the execution procedure control part 29 sequentially stores the push button data input. Then, when the sixth item of push button data is input, the six pieces of data stored therein are then stored in the variable "Code-user", thus finishing the procedure 3 (the operation proceeds to a next process).
In the case of using the push button data as a flag for a branch condition, as in procedure 6, a piece of information for indicating which number of the push button data and which corresponding procedure to execute is described in the narration story file. The execution procedure control part 29 makes branching in accordance with that indication.
The Database Access Process is now explained.
The database access process is a process of accessing the file within the voice response apparatus. This process is mainly used for accessing the database within the retrieval database storage part 21. When indicating an execution of this database access process, there is described what process to execute for which file (database) as an operand. On this occasion, if the number of pieces of data obtained as a result of the retrieval is determined, for example, as in the procedure 4, the variable "Name-user" for storing the retrieved result together with the retrieval condition is designated.
As in the case of the normal database retrieval, a name of the file for storing the retrieved result is designated. When receiving such a designation, the execution procedure control part 29 controls the database access part 22 and the data processing part 24 so that a retrieved result file (see FIG. 3) having the designated file name is created.
In the long run, when the narration story file shown in FIG. 4 is executed (when a goods ordering service is implemented), it follows that the present voice response apparatus operates as illustrated in FIGS. 5 and 6. Note that FIG. 5 of these Figures is a flowchart showing operating procedures of the present voice response apparatus when implementing the goods ordering service. Low-order two digits of numerical values contained in the symbols such as "S101"-"S122" shown in this flowchart are procedure numbers of the corresponding procedures in the narration story file shown in FIG. 4. FIG. 6 is a diagram showing a signal sequence of the voice signal and a tone signal that are transferred and received between the present voice response apparatus and the user telephone when implementing the goods ordering service.
As illustrated in FIG. 5, when implementing the goods ordering service, the voice response apparatus transmits a service guide narration by reproducing a content of "open.pcm" serving as a voice accumulation file (step S101). Then, a piece of text data (For Example: "Input the user's number, please.") is voice-signalized, thereby transmitting a user's number input guide narration (step (S102).
That is, as shown in FIG. 6, after connecting the line to the present voice response apparatus, the user telephone outputs voices of the service guide narration and the user's number input guide narration. Subsequently, as a response to those narrations, it follows that the user inputs a user's number (i.e., 651123) by operating the push button.
After transmitting the user's number input guide narration, the voice response apparatus shifts to a status of waiting for input of the push button and obtains a series of the push button data from the user telephone in the form of user's number (step S103). According to the procedure 3 of the narration story file, there is given an indication to determine the data input completion when six pieces of push button data are input. Accordingly, when the user depresses the push button in the sequence of 651123, the voice response apparatus determines that the data input is completed at such a stage that the sixth piece of data (3) is input. Then, the 6-digit data 651123obtained as a user's number, and step S104 is started.
In step S104, the database is retrieved by use of the user's number acquired in step S103, and a user's name corresponding to the user's number is retrieved. Subsequently, the voice response apparatus transmits a user confirming narration containing the user's number and the user's name to the user telephone (step S105).
As a result of this transmission, the user telephone outputs voices of the user confirming narration (e.g., No. 651123, are you Tokkyo Taro?). The user, after hearing this narration, depresses the push button "9" or "1", thereby giving an indication to the voice response apparatus as to whether or not the user's number is re-input.
The voice response apparatus, after transmitting the user confirming narration, has shifted to the status of waiting for the input of the push button data, and, when detecting that the push button "9" is depressed (step S106; 9), the processes from step S102 are to be reexecuted.
Further, when detecting that the push button "1" is depressed (step S106; 1), as shown in FIG. 6, there is transmitted a goods number input guide narration such as "Input the goods number, please." (step S107). Subsequently, the apparatus shifts to a status of waiting for an input of a goods number (step S108). In step S108, the individual pieces of push button data to be input are stored, and the number of inputs is counted in the voice response apparatus. As indicated by the procedure 8, the voice response apparatus, when the third push button data is input, determines that the input of the goods number is completed and obtains the 3-digit push button data as the goods number.
Next, the voice response apparatus retrieves a name of goods having the acquired goods number from a goods database (step S109). Then, the voice response apparatus transmits a goods number confirming narration containing the goods number and the goods name as a result of the retrieval (step S110). Thereafter, the apparatus shifts to a status of waiting for an input of the push button data, and when detecting that the push button "9" is depressed (step S111; 9), the processes from step S107 are to be reexecuted to re-input the goods number.
Further, when detecting that the push button "1" is depressed (step S111; 1), the apparatus transmits a number-of-orders input guide narration such as "Input the number of orders, please." (step S112). Thereafter, the apparatus shifts to a status of waiting the input of the push button data and acquires the number of orders (step S113). In this step S113, as indicated by the procedure 13, when the push button data corresponding to "#" is input, the apparatus determines that the input of the number of goods is completed.
After completing the input of the number of orders, the voice response apparatus stores the thus obtained number of orders by relating it to the goods number obtained in step S108 (step S114). The storage in this step S114, as indicated by the procedure 14 of FIG. 4, is performed by adding a piece of text data "I order Num-goods pieces of Name-goods having a Code-goods number." to a text file "order.txt". Transmitted subsequently is an input completion confirming narration "Is that all right?" (step S115).
Thereafter, the apparatus shifts to a status of awaiting input of indicating whether or not other goods are ordered, and, when detecting that the push button "9" is depressed (step S116; 9), the processes from step S107 are reexecuted to obtain the information on other goods to be ordered.
In the case of detecting that the push button "1" is depressed (step S116; 1), the content of the text file "order.txt" is voice-signalized, thereby transmitting a content-of-order narration (step S117). Thereafter, the apparatus transmits an order confirming narration "Can we send out the order?" (step S118).
For example, if only two pieces of goods with a goods number 321 are ordered, as shown in FIG. 6, after outputting voices of an input completion confirming narration, the user depresses the push button "1". In this case, the text file "order.txt" stores only the data about one type goods, and the content of the "order.txt" is voice-output as the content-of-order narration. The user, after hearing the content-of-order narration and the order confirming narration, depresses the push button "1" or "9", thus indicating whether or not sending out the order is executed with the content of the content-of-order narration.
The voice response apparatus, after transmitting the order confirming narration (step S118), shifts to a status of waiting for an input of push button data and transmits, when detecting that the push button "1" is depressed (step S119; 1), an order completion notifying narration indicating "The order has been sent out." (step S120). Subsequently, the content of the order is written to the goods database with reference to "order.txt" (step S121). Then, a service terminating narration is transmitted (step S122) by reproducing "close.pcm" as the accumulated voice file, thus finishing the goods ordering service.
Further, when detecting that the push button "9" is depressed (step S119; 9), the service terminating narration is transmitted without actually sending out the order (step S122), and the goods ordering service is finished. Then, as illustrated in FIG. 6, the line is disconnected.
Note that if the voice response service cannot continue due to a fault caused in the voice response apparatus, as illustrated in FIG. 10, the voice response apparatus notifies the user telephone of the occurrence of the fault at the stage of detecting the fault and disconnects the line.
Given hereinafter is a detailed explanation of a reading mode control process and a reading position control process that are executed in parallel to the narration reading process.
The Reading Mode Control Process is now explained.
According to the present voice response apparatus, the reading (uttering) mode is changed by switching a reading speed or a content of a document to be read. To start with, referring to FIG. 1, there will be explained how the reading speed or the content of the document to be read is changed in the present voice response apparatus.
The voice synthesizing unit 12 is, as explained above, constructed to make the reading speed variable. The voice synthesizing unit 12 receives a parameter "F SPD " for specifying the reading speed from the control unit 15 and reads the text data at a speed corresponding to this parameter.
Further, the content of the document to be read is varied by switching over the operand used when effecting the narration reading process. Information for specifying which operand to use is stored in the form of "F MODE " in the execution procedure control part 29. The execution procedure control part 29, when starting the narration reading process, refers to a value of the parameter "F MODE " and causes the document creating part 26 to use an operand corresponding to this value.
Referring to FIGS. 8 and 9 a procedure of changing the values of the parameters "F SPD " and "F MODE " will be explained. As illustrated in FIG. 8, a kind of operating indication (instruction to the voice response apparatus) is allocated to each of the push buttons of the user telephone 50. Among those operating indications, Switching, Fast Reading and Slow Reading allocated to the push buttons "1", "3" and "7" are defined as operating indications for controlling the reading mode. If the user depresses these push buttons during the execution of the narration reading process, the execution procedure control part 29, changes the reading mode (values of "F MODE " and "F SPD ") in accordance with the operating procedures shown in FIG. 9.
As shown in FIG. 9, if the push button data input during the execution of the narration reading process is "1" (step S201; 1), the execution procedure control part 29 sets "1-FMODE" to a content of "F MODE " (step S202) and finishes the process of inputting the push button data.
That is, when detecting the push button data "1", the execution procedure control part 29 only stores the fact that the content of "F MODE " is changed. Then, when the narration is read up to a predetermined delimiter, the execution procedure control part 29 indicates the document creating part 26 to change the reading mode (to change the operand in use).
Described, for instance, in the result-of-retrieval file shown in FIG. 3 is a file name of the text file having a content: "The number (SEQ) has an address of (address), (scale) employees, a sector of (industrial classification), a type of job as (job classification), wages of (minimum wages) through (maximum wages), duty hours from starting time to ending time" as a first operand. Further, as a second operand, there is described a file name of the text file having content of: "The number (SEQ) has an address of (address), a sector of (industrial classification), a type of job as (job classification), wages of minimum wages through maximum wages, duty hours from starting time to ending time. " It is considered that the user depressed the push button "1" during a read of the first retrieved result.
In this case, the execution procedure control part 29 does not change the reading mode up to the completion of outputting of such voices. For example: "The number one has an address of Shinjuku-ku, 100 employees, a sector of the construction industry, a type of job as a painter, wages of 375,000 through 470,000 Yen, duty hours from 9:00 a.m. to 6:00 p.m.." Then, after completing the voice outputting for the first retrieved result, the voice response apparatus changes the reading mode. In consequence, results of the second and subsequent retrievals are read in a mode using a second operand such as "The number two has an address of Nakano-ku, a sector of equipment enterprise, a type of job as a plumber, wages of 400,000 through 550,000 Yen, duty hours from 8:30 a.m. to 5:30 p.m.."
If the push button data is "3" (step S201; 3), the execution procedure control part 29 sets a smaller value of "F SPD +1" and "3" in "F SPD " (step S203). That is, the execution procedure control part 29, when the value of "F SPD " is 2 or under, increments this value by "1". Also, when the value of "F SPD " is "3", the execution procedure control part 29 does not change this value but keeps it. Then, the execution procedure control part 29 indicates the voice synthesizing unit 12 to change the reading speed so that the reading speed of the voice data output from the transmitting/receiving unit 11 becomes a speed corresponding to the value "F SPD " (step S205).
If the push button is "7" (step S201; 7), the larger value of "F SPD 1-" and "1" is set in "F SPD " (step S204). More specifically, if the value of "F SPD " is 2 or larger, this value is decremented by "1". Further, if the value of "F SPD " is 1, this value is not changed but kept as is. Given subsequently to the voice synthesizing unit 12 is an indication of changing the reading speed so that the reading speed of the voice data output from the transmitting receiving unit 11 becomes a speed corresponding to the value of "F SPD " (step S205).
It is to be noted that the change in "F MODE " in step S202 is, though not clearly shown in this flowchart, performed only when the narration reading process on the execution at that time contains two kinds of operand. Further, the processes of steps S203 through S205 are conducted only when the narration reading process on the execution at that time involves the use of the voice synthesizing unit 12.
As discussed above, according to the present voice response apparatus, when the user manipulates the push button to indicate Switching, the reading mode is switched. When the user indicates the Fast Reading or Slow Reading, the reading speed is varied higher or lower by one stage. That is, the present voice response apparatus is capable of reading using, as illustrated in FIG. 10, six types of reading modes by combining the reading modes with the reading speeds. Accordingly, the user of the present voice response apparatus selects the reading mode corresponding to the content of the narration that is being read and is thus able to utilize the voice response service.
The Reading Position Control Process is now explained.
Hereinafter, the reading position control process will be explained in greater detail with reference to FIGS. 8 through 11. Remaining seven operating indications (FIG. 8) allocated to the push buttons serve to control reading positions. Among those operating indications, when depressing the push buttons to which Head, Returning, Repeating, Sending and End are allocated, the execution procedure control part 29 operates as illustrated in FIG. 11.
In the case of detecting the push button "2" (Head) (step S301; Y), the execution procedure control part 29 sets "1" in a variable "j" for storing information specifying the data to be read next (step S302). Then, the document creating part 26 or the like is controlled, thereby interrupting the supply of the text data to the voice synthesizing unit 12 but converting the j-th data (e.g., the j-th retrieval result of the result-of-retrieval file) into a voice signal (step S311).
In this step S311, if the text data exclusive of the result-of-retrieval file is a target for reading, the execution procedure control part 29 controls the respective elements so that each document delimited by a period (.) in that text data is dealt with as a single piece of data and the j-th document is converted into the voice signals.
When detecting the push button data "4" (Returning) (step S303; Y), a value "j-1" obtained by subtracting "1" from the content of the variable "j" stored with the information for specifying the data that is now being read is set in the variable "j" (step S304), and the processing proceeds to step S311. When detecting the push button data "5" (Repeating) (step S305; Y), the value of the variable "j" is not varied, and the processing proceeds to step S311.
In the case of detecting the push button "6" (Sending) (step S307; Y), "j+1" is set in the variable "j" (step S308), and the processing proceeds to step S311. When detecting the push button data "8" (Last) (step S309; Y), a data total number "J max " (or a total number of documents contained in the text data) of the result-of-retrieval file that is a target for reading at present is set in the variable "j" (step S310), and the processing proceeds to step S311.
For example, when reading the 4th data of the result-of-retrieval file containing the seven pieces of data, and if the push button for controlling the reading positions thereof is depressed, as schematically illustrated in FIG. 12, the data are read sequentially from the head "data 1" in the case of that push button being "2". Then, when the push button is "4", the data "3" positioned one before the "data 4" that is being read at that time.
Further, if that push button is "5", it follows that the "data 4" is reread, and, when the push button is "6", reading the data is started from the "data 5" positioned one posterior thereto. Then, when the push button is "8", the data are read from the "data 7" defined as the last data.
Thus, the present voice response apparatus is constructed so as to stop the voice-outputting of the unnecessary data and to voice-output again the necessary data by manipulating the push button. Therefore, the user is capable of efficiently using the voice response services by use of those functions.
The five types of push buttons described above are constructed to always give the effective operating indications during the narration reading process.
In contrast with this, a (Delete) indication and a (Releasing) indications (see FIG. 8) allocated respectively to the push buttons "9" and "#" are the operating indications effective only in the case of reading the contents of the result-of-retrieval file. When detecting the depressions of those push buttons, the execution procedure control part 29 operates as follows.
When detecting the depression of the push button "9", the execution procedure control part 29 writes the output control information for indicating that the voices are not output in the item (Delete) of the data that is now being read. Further, when detecting the depression of the push button "#", the execution procedure control part 29 clears the content of each item (Delete) of the result-of-retrieval file that is now being read.
For instance, these two operating indications are used as follows.
When the contents of a result-of-retrieval file is started to be voice-outputted, the user, at first, depresses the push buttons "1" (Switching) and "3" (Fast Reading). In accordance with these instructions, the voice response apparatus starts to read the contents of the result-of-retrieval file fast in an essential point reading mode. Subsequently, the user decides whether or not that piece of data is required by hearing the read content. If the data is required, the user depresses the push button "6" (Sending). If the data is not required, the user depresses the push button "9" (Delete) and depresses the push button "6".
In the former case, the voice response apparatus omits the voice-outputting of the remaining parts in the data and starts voice-outputting the next data of the result-of-retrieval file. In the latter case, the apparatus writes an output control information indicating that no voice outputting in the (Delete) of corresponding data of the result-of-retrieval file and skips the voice-outputting the remaining parts of the data.
As already discussed above, in the narration reading process of the result-of-retrieval file, if the output control information indicating that no voice outputting exists in the (Delete), the read of the data is omitted. Accordingly, the user, by depressing the push button "2" (Head) after performing the above operations with respect to the series of data, can get essential information without hearing the whole contents of the result-of-retrieval file.
The Second Embodiment of the present invention is now explained.
FIG. 13 illustrates a construction of the voice response apparatus in accordance with a second embodiment of the present invention. As illustrated in FIG. 13, the voice response apparatus in the second embodiment has such a construction that a image data transmitting unit is added to the voice response apparatus in the first embodiment. This voice response apparatus 10 is connected to the user telephone 50 and a facsimile 51 as well.
The image data transmitting unit 16 is constructed of a image memory 41, a signal processing part 42 and a MODEM 43 and is provided between the transmitting/receiving unit 11 and the switching unit 14. The image data storage part 41 temporarily stores image data to be transmitted to he facsimile 51. The signal processing part 42 performs a process of reducing a redundancy contained in the image data stored in the image data storage part 41. The MODEM 43 modulates the image data processed by the signal processing part 42 and outputs the modulated image data.
Added to the control unit 15 is a function to convert the text data, which are to be output in the form of the voice signals, into image data and supply the image data storage part 41 with the thus converted image data. The control unit 15, if a predetermined condition is satisfied, executes the conversion into the image data. Thereafter, the control unit 15 controls the signal processing part 42 and the MODEM 43, whereby the image data stored in the image data storage part 41 are output to the facsimile 51.
A facsimile output indicating procedure used in the voice response apparatus in the second embodiment will hereinafter be explained.
The voice response apparatus in the second embodiment, when the user depresses the push button "*" during the narration reading process, stores the fact that the narration should be output to the facsimile. Then, if the facsimile output is indicated during an execution of the voice response service, there is effected a narration for making a prompt to input a facsimile number the finishing the voice response service, and the facsimile number is obtained from the push button data. Subsequently, after connecting a call to the facsimile number, the image data transmitting unit 16, whereby a content of the narration stored with the facsimile output being performed is outputted to the facsimile 51.
Thus, the voice response apparatus in the second embodiment is capable of outputting the content of the narration to the facsimile, and therefore, the user of the present voice response apparatus determines the data to be output in the essential point reading mode and examines the details of the content through the facsimile outputting.
Modified Examples of First and Second Embodiments are now presented.
According to the two kinds of embodiments discussed above, there are prepared the independent data for reading the whole documents and or the essential points, respectively. The voice response apparatus can be, however, constructed in such a way that control codes are included in the text data, and when reading the whole documents, all the text data is used; but when reading the essential points, only the portions designated by the control code are used.
One example of such a narration follows: "We brief you on the " CODE1 present situation of the labor market. "CODE2" Incidentally, each value has already been seasonally adjusted. Looking at the nationwide labor market "CODE1" as of December in 1993, the effective job hunters decreased by 0.4% against the previous month, while the effective job offers decreased by 0.9% against the previous month. The effective job offer rate id 0.65 times, "CODE2" which is well balanced with the previous month. Let's itemizes this, the effective job offer rate of the part-time jobs is 1.03 times, but the effective job offer rate excluding the part-time jobs is 0.6 times. Further, the new job offers as of December decreased by 13.6% against the same month in the previous year." Another example of such a narration is: "Present situation of the labor market. As of December in 1993, the effective job hunters decreased by 0.4% against the previous month, while the effective job offers decreased by 0.9% against the previous month. The effective job offer rate id 0.65 times." This second narration excludes the control codes "CODE1" and "CODE2" with the documents interposed between the control codes "CODE1" and "CODE2".
Further, through constructed to change the reading mode by independently changing the reading speed and the reading mode, the apparatus may be constructed so that one (or more) push button is allocated to each reading mode shown in FIG. 10, and the reading speed and the reading mode are simultaneously changed.
Further, the audio response apparatus in each embodiment is constructed so as not to control the reading speed and the reading position if the voice accumulation file is a target for reading the narration. The voice response apparatus can be, however, constructed so that a plurality of voice accumulation files having different reading speeds are prepared and selected for reproduction corresponding to the depressed push buttons. Furthermore, the plurality of voice accumulation files are prepared for one narrating process, and, with this preparation, the reading position may be controlled with respect to the voice accumulation file. Also, the reading position can be controlled with respect to segment the data stored in the voice accumulation file at unrecorded areas.
The voice response apparatus in the first and second embodiments involve the use of the voice synthesizing unit for synthesizing the voices by the rule synthesizing method. As illustrated in FIG. 14, however, the voice synthesis based on the rule synthesizing method is capable of expressing any kinds of narrations (an infinite number of vocabularies), inferior to others in terms of an understandability and naturalness. Further, when adopting the voice synthesis based on the rule synthesis method, the apparatus becomes complicated. As explained above, voice synthesis based on the rule synthesizing method has disadvantages as well as exhibiting advantages. The voice synthesis method adopted in the voice synthesis unit should be the one corresponding to an application for use. For example, if the content of the voice-outputted narration is limited, there is used the voice synthesis unit for synthesizing the voices by a recorded speech compiling method and a parameter editing method, whereby the audio response apparatus excellent in terms of economical property and recognizability as well can be formed.
The voice response apparatus in the second embodiment is constructed to output the data prepared for reading the narration to the facsimile. However, the audio response apparatus may be, as a matter of course, constructed to hold the image data (about e.g., a map) relative to the content of the response service and output the image data to the facsimile.
As this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description pending them, and all changes that fall within meets and bounds are therefore intended by the claims.
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A voice response apparatus and method in which narrative text contained in a database is presented to a user through a telephone. Based on user responses, the voice response apparatus selects only the appropriate text which matches the user's selection. The user has the option of listening to a human voice synthesized by the system reciting the text or having the text and corresponding graphics faxed to him. At any point during the recitation of text, the user may select certain options made available by the system. These options include among many: increasing the speed of the voice reciting the text; decreasing the speed of the voice reciting the text; listening to a summary of the text rather than the full text; discontinuing recitation of the text; and switching to a different text. The system, upon detection of a user option selection, marks a position in the text and continues the recitation from that point when appropriate depending on the option selected.
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[0001] This application is a continuation of application Ser. No. 15/090,417 filed Apr. 4, 2016, entitled IMPACT MARKING GARMENT, which is a continuation of application Ser. No. 14/622,689 filed Feb. 13, 2015, now U.S. Pat. No. 9,322,619, issued Apr. 26, 2016, entitled IMPACT MARKING GARMENT, which is a continuation of application Ser. No. 14/301,212 filed Jun. 10, 2014, now U.S. Pat. No. 8,984,663, issued Mar. 24, 2015, entitled IMPACT MARKING GARMENT, which is a continuation of application Ser. No. 13/006,419 filed Jan. 13, 2011, now U.S. Pat. No. 8,769,713, issued Jul. 8, 2014, entitled IMPACT MARKING VEST, all of which are fully incorporated herein by reference.
FIELD OF INVENTION
[0002] This invention relates to an apparatus for indicating the point of impact of a projectile fired from a non-lethal firearm. In particular, this invention relates to an addition to a traditional ballistics vest that will aid in true impact and directional assessment allowing for improved instruction during simulated force-on-force ballistics training.
BACKGROUND OF THE INVENTION
[0003] Over the past decade, force-on-force (FOF), or reality based lethal force simulation training, has become established within the Law Enforcement and Military communities as an essential training method. Generally, FOF training involves role playing participants that are armed with non-lethal marking or replica type firearms that fire 6 mm or 8 mm plastic projectiles. During the course of training, participants' reactions and tactics are analyzed and reviewed in order to better train the participants to function in a heightened adrenaline state and survive a potentially lethal confrontation.
[0004] Typically FOF training simulations require equipment consisting of two basic types: firearms modified to fire paint filled marking cartridges; or, replicas shooting plastic spheres (BBs) commonly referred to as “Airsoft” guns.
BRIEF SUMMARY OF THE INVENTION
[0005] Several embodiments of the present invention answer the above and other needs by providing an Impact Marking Vest (IMV) system for use in indicating the position and angle of an impact on a ballistic vest.
[0006] In one embodiment, the invention may be characterized as an impact marking vest comprising: a backing layer comprising a flexible material for forming a three-dimensional (3D) target surface; a substrate layer bonded to the backing layer such that the substrate layer covers at least a portion of an exterior surface of the backing layer, wherein the substrate layer comprises a first color; a coating layer disposed on the substrate layer and covering substantially an entire exterior surface of the substrate layer, wherein the coating layer is a second color different from the first color of the substrate layer; and an attachment device connected to the backing layer and configured for attachment to a ballistic vest.
[0007] In another embodiment, the invention may be characterized as a method of forming a ballistic impact marking vest comprising the steps of: forming a backing layer comprising a flexible material into a three-dimensional (3D) target surface; bonding a substrate layer to the backing layer such that the substrate layer covers at least a portion of an exterior surface of the backing layer, wherein the substrate layer comprises a first color; disposing a coating layer on the substrate layer such that the coating layer substantially covers an exterior surface area of the substrate layer, wherein the coating layer is a second color, different from the first color of the substrate layer; and fixing an attachment device to the backing layer, wherein the attachment device is configured for attachment to a ballistic vest.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of an impact marking vest cooperated together with a ballistic vest according to one embodiment of the present invention;
[0009] FIG. 2 is a perspective view of the impact marking vest of FIG. 1 ;
[0010] FIG. 3 is a schematic view of a back panel used in forming the impact marking vest comprised of a backing layer, a substrate layer and a target surface formed from the substrate layer;
[0011] FIG. 4 depicts the back panel of FIG. 3 , together with the backing layer, the substrate layer, a target surface, an adhesive coating and a coating layer;
[0012] FIG. 5 depicts a schematic view of side panels used in forming the impact marking vest comprising a backing layer, a substrate layer and a target surface formed from the substrate layer;
[0013] FIG. 6 depicts a schematic view of the side panels of FIG. 5 , together with the backing layer, the substrate layer, the target surface formed from the substrate layer and a coating layer;
[0014] FIG. 7 depicts a two-dimensional schematic view of the complete panel used in forming the impact marking vest;
[0015] FIG. 8 depicts a cross-sectional view of the layers composing the impact marking vest, including the coating layer, substrate layer and backing layer; and
[0016] FIG. 9 depicts a coating layer patch comprising an adhesive patch coating and a coating patch layer.
DETAILED DESCRIPTION
[0017] The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims.
[0018] Widely acknowledged drawbacks to marking cartridge systems include the high per-round unit cost of marking cartridge ammunition as well as the increased need for enhanced safety protocols. For example, modified firearms pose the risk that some participants may convert live firearms to function with marking cartridge ammunition, increasing the probability that live ammunition and fully functioning firearms will be introduced into the training environment. Although, the use of Airsoft guns and plastic BBs serves to mitigate the cost of simulation training, plastic BBs fail to provide the marking indications necessary for the verification of impact or impact angles on a role player.
[0019] Referring now to FIG. 1 , which depicts a ballistic vest 110 together with the impact marking vest (IMV) 120 comprising attachment device 130 , coating layer 140 and a target surface formed from a substrate layer 150 .
[0020] In one embodiment, the ballistic vest 110 is a protective vest system that may function as a ballistic vest, overlying the body of a user. In a preferred embodiment, the ballistic vest 110 is configured to overlay the upper body or torso region of a user and will contain holes for the user's arms, neck and torso. However, in alternative embodiments, the ballistic vest 110 may be shaped or configured to cover essentially any portion of a user's body. To facilitate cooperation with a user's body, the ballistic vest 110 may include one or more fastening devices. By way of example, the ballistic vest 110 may include fastening means such as, but not limited to: straps, elastic straps, fasteners, zippers, buttons, magnetic means, adhesive means or a hook and loop type fastening device, such as VELCRO or a functional equivalent, etc. The ballistic vest 110 may also be constructed of one or more layers; however, in preferred embodiments, the ballistic vest 110 will be comprised of a flexible and impact resistant material. By way of example, the ballistic vest 110 may be comprised of free-floating layers of plastic or Kevlar, nylon or cotton fabric.
[0021] In one preferred embodiment, the impact marking vest (IMV) 120 is mechanically cooperated with ballistic vest 110 via attachment device 130 such that the IMV 120 substantially covers the entire outside surface of the ballistic vest 110 . In this configuration, the torso of a user wearing the ballistic vest 110 together with the IMV 120 will be covered by the IMV 120 over substantially the same areas as if the ballistic vest 110 were to be worn alone. In one preferred embodiment, the attachment device 130 used to fasten the IMV 120 to the ballistic vest 110 comprises a hook and loop type fastening device, such as VELCRO or a functional equivalent. However, cooperation between the IMV 120 and ballistic vest 110 can be accomplished using virtually any suitable fastening means, including but not limited to: straps, elastic straps, fasteners, zippers, buttons, magnetic means, adhesive means or a hook and loop type fastening device, such as VELCRO or a functional equivalent, etc.
[0022] In an alternative embodiment, the IMV 120 may be mechanically cooperated with the ballistic vest 110 via a carrying device (not shown) such as a wire frame or a ballistic nylon holder. In this embodiment, the IMV 120 may cooperate with the carrying device such that at least a portion of the IMV 120 is exposed on the outer surface. Regardless of whether the IMV 120 is worn together with the ballistic vest 110 or worn alone, the outer surface of the IMV 120 effectively forms a three-dimensional (3D) target face.
[0023] In yet another embodiment, the IMV 120 may be worn without the use of the ballistic vest 110 altogether. For example, the IMV 120 may be worn alone or may be worn over the user's clothing. In some embodiments, the attachment device 130 may be configured to cooperate with, or adhere to an article of the user's clothing. In other embodiments, the attachment device 130 may be configured to cooperate with a portion of the user's body such that mechanical cooperation with clothing or the ballistic vest 110 is unnecessary for effective use of the IMV 120 .
[0024] As will be described in further detail below, the IMV 120 is comprised of a coating layer 140 disposed on top of an underlying substrate layer 150 such that a target design is formed by the regions of the substrate layer 150 not obscured by coating layer 140 (by exposed regions of the substrate layer 150 ). In one embodiment, the substrate layer 150 may be comprised of a paper or plastic material. In alternative embodiments the substrate layer may be comprised of a plastic film; however, the substrate layer may be comprised of essentially any material suitable for indicating a contrast between the substrate layer 150 and the coating layer 140 .
[0025] In some embodiments, the coating layer 140 may completely cover the substrate layer 150 such that the underlying substrate layer 150 is not immediately visible and no target pattern is discernable. Alternatively, the target design may be in or on the coating layer 140 , or in or on the substrate layer 150 (and either obscured by the coating layer 140 or aligned with regions of the substrate layer 150 not obscured by the coating layer 140 ). The target pattern may include a concentric circle pattern (i.e., a target design) or may indicate more highly valuable target locations, such as regions where a target may be more exposed, and not protected by his/her ballistic vest, such as at the armpits.
[0026] In operation, a user wearing the cooperated ballistic vest 110 and IMV 120 combination will be effectively covered by the IMV 120 outer surface. Accordingly, when used in conjunction with simulated training firearms, the coating layer 140 disposed on the outer surface of IMV 120 will flake away upon ballistic impact, exposing the underlying substrate layer 150 . In a preferred embodiment, the coating layer 140 will be of a dark color or pigment in order to contrast with a brightly colored substrate layer 150 such that the direction and point of impact on the IMV 120 will be easily ascertainable by an observer. In some embodiments, the coating layer 140 may be of a black, matte-black, matte-olive drab or earth tone color and substrate layer 150 may be a bright orange, yellow or green color. However, the coloration of coating layer 140 and substrate layer 150 may be of any combination that provides a visible contrast between the substrate layer 150 and coating layer 140 . Alternatively, this contrast may be invisible in the visible spectrum, but detectable in, e.g., the infrared spectrum, or under a source of irradiation selected to cause, e.g., fluorescence, e.g., of the exposed substrate layer 150 , and not of the coating layer 140 .
[0027] In a preferred embodiment, the IMV 120 will be used in conjunction with a non-lethal marking firearm or replica firearm (e.g., an “Airsoft” gun) that fires 6 mm or 8 mm plastic BBs. However, the IMV 120 may conceivably be used with any firearm/firearm replica or projectile suitable to cause the removal of the coating layer 140 on the outer surface of the IMV 120 .
[0028] Referring now to FIG. 2 , which depicts a more detailed perspective view of the IMV 120 comprising attachment device 130 , a coating layer 140 , a backing layer 210 and a target surface 220 formed from the substrate layer 150 .
[0029] In one preferred embodiment, the backing layer 210 is configured in a three-dimensional vest shape and forms the inner surface of IMV 120 . For example, the backing layer 210 may be comprised of thin-film high density foam for conforming to the curvature of a user's body. In alternative embodiments the backing layer may comprise substantially any suitably flexible and/or rigid material. However, in preferred embodiments, the backing layer 210 will be constructed of a semi-penetrable material that will facilitate the flaking away of the coating layer 140 , as will be further discussed below.
[0030] In operation, the substrate layer 150 is disposed on the backing layer 210 , using an adhesive coating (as will be described in further detail below), such that the substrate layer 150 covers either all or a portion of the outer surface of the backing layer 210 . The outer surface of the substrate layer 150 is then covered with the coating layer 140 such that a target surface 220 is defined by the visible (or, as noted above, otherwise distinguishable) portion of the substrate layer 150 that is revealed by the absence of the coating layer 140 . In alternative embodiments, the coating layer 140 may cover the entire outer surface of substrate layer 150 or may cover any fractional portion thereof to form substantially any desired pattern or design. The attachment device 130 is then fixed to the backing layer 210 and configured for attachment to a ballistic vest 110 such as that shown in FIG. 1 , above.
[0031] Referring now to FIG. 3 , which depicts a 2D schematic view of a back panel 310 of the IMV 120 together with the substrate layer 150 forming the target surface 220 . In one preferred embodiment, the substrate layer 150 is configured such that the resulting target surface 220 only covers a portion of the back panel 310 . However, in alternative embodiments, the substrate layer 150 may be sized such that the resulting target surface 220 covers substantially any desired portion of the surface area of back panel 310 .
[0032] Referring now to FIG. 4 , which depicts a 2D cut-away view of the back panel 310 of the IMV 120 . The back panel 310 comprising the backing layer 210 , the substrate layer 150 , the adhesive coating 410 and coating layer 140 . In a preferred embodiment the adhesive coating 410 is comprised of a pressure-sensitive adhesive. In some embodiments, the adhesive coating 410 is disposed on the surface of the substrate layer opposite the coating layer 140 such that the substrate layer 150 can be removably attached to the backing layer 210 . In an alternative embodiment, the adhesive coating 410 can be disposed on the outer surface of the backing layer 210 to achieve the similar purpose of removably attaching the substrate layer 150 .
[0033] In practice, the adhesive coating 410 enables the convenient replacement of portions of the substrate layer 150 attached to the backing layer 210 . This feature allows a user to readily change/replace the outer surface of the IMV 120 such that used or worn portions of the substrate layer 150 may be easily exchanged with the new substrate layer 150 portions containing the newer coating layer 140 .
[0034] Referring now to FIG. 5 , which depicts a schematic view of the side panels 510 together with a target surface 520 defined by the substrate layer 150 . The side panels 510 form the side and front segments of the IMV 120 .
[0035] In one preferred embodiment, when the IMV 120 is cooperated with the ballistic vest 110 the target surface 520 depicted in FIG. 5 will be configured to wrap around the user's torso covering the underarm and chest portions of the ballistic vest 110 . This particular positioning of target surface 520 may facilitate in instructing a FOF participant to avoid exposure of the underarm and chest regions when engaged in a real or simulated firefight. In alternative embodiments, the substrate layer 150 may be configured to create a target surface 520 in essentially any desired position or arrangement with respect to the outer surface of the IMV 120 .
[0036] Referring now to FIG. 6 , which depicts the side panels of FIG. 5 together with coating layer 140 , backing layer 210 and substrate layer 150 for forming target surface 520 . In a preferred embodiment, the coating layer 140 covers only a portion of the substrate layer 150 such that a strip of the underling substrate layer 150 is revealed by the region wherein the coating layer 140 is absent. This revealed portion of the substrate layer 150 defines the border of the target surface 520 that can be visibly identified on the outer surface of IMV 120 . However, although the border of the target surface 520 may be visually identifiable, the majority of the target surface 520 remains obscured by the coating layer 140 . In alternative embodiments, the coating layer 140 may cover substantially the entire surface of the substrate layer 150 such that the underlying target surface 520 is wholly obscured.
[0037] In practice, the side panels 510 are configured to form the side portions of IMV 120 . In such a configuration, the target surface 520 will form a three-dimensional (3D) surface spanning a region from beneath the participant's arms to the center chest portion of the IMV 120 . In alternative embodiments, the target surface may be located on substantially any portion of the IMV 120 and may cover the entire outer surface area of the IMV 120 , or any portion thereof.
[0038] Referring now to FIG. 7 , which depicts a schematic (2D) view of a complete panel 710 comprising the backing layer 210 . In practice, the backing layer 210 of the complete panel 710 is molded into a three-dimensional vest shape for use in forming the IMV 120 , as described above with respect to FIGS. 1 and 2 . However, in alternative embodiments the backing layer 210 may be configured to form essentially any shape to produce a 2D or 3D target surface for use in registering an impact event.
[0039] Referring now to FIG. 8 , which depicts a cross-sectional view of the IMV 120 comprising the coating layer 140 , the substrate layer 150 , the adhesive coating 410 and the backing layer 210 . In one embodiment, the structure of the IMV 120 is formed by the bonded coating layer 140 , the substrate layer 150 and the backing layer 210 as shown in FIG. 8 . In one preferred embodiment, the adhesive coating 410 is permanently fixed to the backing layer 210 such that an adhesive surface is formed on the outer surface of the backing layer 210 . In this configuration, the substrate layer 150 can be removably bonded with the backing layer 210 via the adhesive surface of the adhesive coating 410 . In an alternative embodiment, the adhesive coating 410 can be permanently disposed on the underside of the substrate layer 150 , opposite the coating layer 140 .
[0040] In practice, the coating layer 140 is configured to flake away upon ballistic impact, exposing the underlying substrate layer 150 . In one preferred embodiment, the substrate layer 150 is composed of a bright color (e.g. a bright orange or yellow color) that can be easily contrasted with a darker color of the coating layer (e.g. a black, matte-black, matte-olive drab or earth tone color). However, the coating layer 140 and the substrate layer 150 may be comprised of virtually any materials that are distinguishable from one another (visibly or otherwise). With this contrasting color scheme, a user may visually identify a point or angle of ballistic impact by identifying the location on the IMV 120 surface where the coating layer 140 has flaked away to expose the underlying substrate layer 150 .
[0041] After a ballistic impact has been incurred by the IMV 120 , it may be desirable to renew the coating layer 140 on the outer surface of the IMV 120 . In a preferred embodiment, the new coating layer 140 may be added to the IMV 120 by simply replacing the underlying substrate layer 150 with a new substrate layer containing the new coating layer 140 . In one embodiment, the substrate layer 150 comprises the adhesive coating 410 disposed on the side opposite of the coating layer 140 . In this configuration, the substrate layer 150 may be removably attached to the backing layer 210 such that a user may peel away the used substrate layer 150 and the adhesive coating 410 for easy replacement.
[0042] Referring now to FIG. 9 , which depicts a cut-away view of a coating layer patch 910 comprising coating patch layer 930 and adhesive patch coating 920 . The coating patch layer 930 of the coating layer patch 910 is similar to the coating layer 140 discussed above with respect to the IMV 120 . The coating layer patch 910 comprises the coating patch layer 930 on one surface and an adhesive patch coating 920 on the opposite surface. In a preferred embodiment, the coating layer patch will be of a circular shape measuring approximately one-inch in diameter; however, in alternative embodiments the coating layer patch may be of substantially any shape or size.
[0043] In practice, the coating layer patch 910 may be used to touch-up the coating layer 140 of the IMV 120 . For example, the coating layer patch 910 may be used to cover portions of the coating layer 140 on the IMV 120 that have flaked away due to ballistic impact. As such, the coating layer patch 910 offers a quick and inexpensive way to repair the outer surface of the IMV 120 without the need for replacing the entire the substrate layer 150 .
[0044] While the above is a complete description of the preferred embodiment of the present invention, it is possible to use various alternatives, modifications and equivalents. Therefore, the scope of the present invention should be determined not with reference to the above description but should, instead be determined with reference to the appended claims, along with their full scope of equivalents. Any feature described herein, whether preferred or not, may be combined with any other feature described herein, whether preferred or not.
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A method and apparatus for use in facilitating force-on-force (FOF) training. Specifically, an impact marking vest (IMV) for use in registering a ballistic impact event upon a three-dimensional target surface.
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FIELD OF THE INVENTION
This invention relates to an ultraviolet radiation exposure apparatus for the decontamination of fluids using a high intensity, directed light source and a fluid container having a protected window.
BACKGROUND OF THE INVENTION
The combination of ultraviolet radiation and oxidant, or the use of ultraviolet radiation alone, is a powerful tool for the removal of organic and microbial contaminants from fluids, particularly water. Both hydrogen peroxide and ozone are suitable oxidants for use in ultraviolet radiation/oxidation systems, but ozone is more economical and therefore more often used.
Ozone alone is a strong oxidizing agent that can react with all oxidizable contaminants in the fluid; however, the rate of oxidation can be enhanced by the simultaneous application of ultraviolet radiation. According to equation 1, ultraviolet radiation accelerates the decay of ozone dissolved in water to the hydroxyl radical (.OH), one of the most powerful oxidants known. ##STR1##
Oxidation of organic contaminants by ultraviolet radiation and ozone ultimately yields non-harmful products consisting of carbon dioxide, water and oxygen according to equation 2. The application of ultraviolet radiation and ozone for control of microbial contamination is also a very efficient process because the cell wall of the microorganism is ruptured, killing the organism. ##STR2##
Known ultraviolet radiation/oxidation systems suffer a serious disadvantage, however. Typically, a germicidal ultraviolet lamp is enclosed in a sleeve which is immersed in the fluid to be treated so that the ultraviolet radiation propagates through the fluid. In prior art systems, these sleeves have been made of quartz, one of the few materials that is transparent to the high energy, short wavelength ultraviolet light that promotes the reactions described above.
Quartz sleeves often require cleaning due to water caused fouling. A film tends to accumulate on the quartz sleeve which decreases transmission of the ultraviolet radiation to the fluid. The frequent mechanical or chemical cleaning which is required to remove the film is extremely inefficient since it requires shutting down the fluid decontamination system and draining the fluid to reach the surfaces needing cleaning. Furthermore, quartz which is subjected to ultraviolet light is solarized, producing a slightly tan color in the quartz, which also reduces transmission. Most importantly, quartz sleeves are fragile and expensive.
Immersion of the quartz sleeve in the fluid to be treated disrupts the straight forward flow of the fluid through the reaction vessel and creates eddies and subcurrents such that all the fluid is not irradiated or exposed to the oxidant to an equal extent. Therefore, the contaminants are inefficiently treated.
SUMMARY OF THE INVENTION
According to this invention, an ultraviolet radiation exposure apparatus is provided which minimizes the disadvantages associated with quartz and immersion of a quartz sleeve into the fluid to be treated. In addition, the ultraviolet radiation exposure apparatus of this invention allows fluid treatment at high or low pressures and it tolerates sudden pressure changes.
One embodiment of this invention provides a high tensile strength alloy or steel container with a reflective interior surface that is lined with an inert, non-sticking material which is transparent to ultraviolet radiation, such as fluorinated ethylene propylene (FEP). The non-stick nature of FEP prevents fouling of the container's interior which simplifies cleaning and maintenance of the ultraviolet radiation exposure apparatus. Optionally, an oxidant is injected into the fluid which is irradiated with ultraviolet light while in the container.
A high intensity, directed beam of ultraviolet radiation enters the container through an ultraviolet-transparent window, and because the beam is directed, the window can be relatively small. The window is preferably quartz. The quartz window is lined with, or otherwise protected by, a layer of FEP to prevent fouling of the window, further simplifying maintenance of the apparatus. The FEP protective layer is held in place within the container by any suitable surface feature formed inside the container.
The use of a directed, high intensity light source rather than a diffuse light source, such as the germicidal lamps used in the prior art, eliminates the need for reflectors or some other system of collecting and directing the diffuse light. The use of high intensity light according to this invention directs more lumens per unit time through the fluid, and thus promotes the desired oxidation more efficiently, leading to shorter reaction times.
The reflective interior surface of the container repeatedly reflects the ultraviolet radiation, thereby irradiating a substantial portion of the container's volume. The ultraviolet transparent lining which covers the reflective interior surface allows this reflection.
The high tensile strength material forming the container allows the treatment of fluids at high or low pressures and tolerates sudden pressure changes.
By avoiding immersion of an ultraviolet lamp and its quartz sleeve into the fluid, the apparatus according to this invention allows straightforward flow of the fluid, and therefore avoids the generation of eddies and subcurrents that can cause some portions of the fluid to be inefficiently treated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of one embodiment of an ultraviolet radiation exposure apparatus according to this invention.
FIG. 2 is a side view of the assembled apparatus shown in FIG. 1.
FIG. 3 shows a typical mated flange for joining the sections of the apparatus in FIG. 2.
FIG. 4 is a schematic view of a laser system for producing a directed beam of ultraviolet light.
FIG. 5 is a magnified view of the non-linear inner surface of the container for securing the fluorinated ethylene propylene (FEP) coating in place.
FIG. 6 is a magnified view of the window area in the apparatus of FIG. 1 showing the FEP protective layer being held in place by the same ridges holding the window in place.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, fluid enters a high tensile strength alloy or steel container 1 from inflow source 2. Fluid exits the container 1 through an out-flow chamber 3 having one or more dispersing pipes, shown here as pipes 3a and 3b, also made of a high tensile strength material. Out-flow chamber 3 and container 1, which may form a Y-shape, are joined as described below. At the base of the converging pipes 3a and 3b, a window 6 is seated in an opening which is sealed like a port-hole with an ozone impervious gasket 5 and any suitable plates (not shown). The light source 7 produces a high intensity ultraviolet light beam directed toward window 6, where window 6 is made of a material transparent to ultraviolet radiation, such as quartz.
The interior of container 1 is formed with a surface 9 that is highly reflective to ultraviolet radiation, such as polished aluminum. The light beam from light source 7 passes through window 6 and is repeatedly reflected by the interior of container 1 so that a substantial portion of the volume of container 1 is irradiated. Window 6 can be formed so that the light beam from light source 7 is flared by passing through window 6, thereby irradiating a substantial portion of the container's volume. The light may also be scattered throughout container 1 by ridges (shown in FIG. 5) formed by routing the interior of container 1. Reflective inner surface 9 covers the entire interior of container 1, both the ridged and routed areas.
The interiors of container 1 and out-flow chamber 3 are lined with a lining 10 and 4, respectively, where the lining 4, 10 material is substantially chemically inert under conditions encountered by the apparatus during oxidation of organic contaminants. The lining 10 should also be transparent to ultraviolet radiation so that the lining 10 does not prevent reflection of ultraviolet radiation by surface 9. The lining 10 will protect container 1 and inflow source 2, and lining 4 will protect out-flow chamber 3, from corrosion and fouling caused by the contaminants in the fluids to be treated. Window 6 is similarly protected by protective lining 8, which can be integrally formed with lining 4 or 10, or formed as a separate piece. The cone shape of lining 8 will facilitate fluid flow and aid in the prevention of eddies and subcurrents by directing the fluid flow to pipes 3a and 3b; however, the preferred shape of lining 8 in an actual embodiment will depend on the particular shape of the apparatus and other factors. The linings 10, 4 and 8 may be attached to the reaction vessel by any suitable, fluid-tight means as described below.
Fluoridated ethylene propylene (FEP) can provide the non wetting, non-sticking, but ultraviolet transparent linings 10, 4 and 8 required. This chemically inert material prevents film accumulation on the interior walls of container 1, on window 6, and on the walls of out-flow chamber 3 caused by contaminants in the fluid being treated, thereby simplifying cleaning and maintenance of the apparatus. Prevention or removal of film accumulated on the interior of container 1 and window 6 is important because the film would decrease the reflectivity of reflective surface 9 and decrease the transparency of window 6, and therefore would decrease the efficiency of ultraviolet light transfer throughout container 1. FEP will not deteriorate under long exposure to ultraviolet light.
The base of inflow source 2 has an optional injection port 11 for injecting an oxidant such as hydrogen peroxide or ozone. Ozone can be produced as needed with an ozone generator according to well known methods. A plurality of injection ports may be used to increase the quantity and the rate of oxidant addition.
FIG. 2 illustrates a side view of the apparatus described above. Container 1 and inflow source 2 are assembled from two half shells, upper half 12 and lower half 13, both of which have flanged edges 15 which are mated and securely fastened with bolts 16. Out-flow chamber 3 is a solid, one piece unit also having a flange 15 which mates with a flange of assembled container 1 and is fastened to container 1 with bolts 16. A typical mated flange 15 is shown in FIG. 3. Gasket 17 is made of a material which is impervious to ozone, such as teflon, and is positioned to form a fluid-tight seal between the joined, bolted sections. The bolt 16 is inserted through bolt hole 18.
Because the apparatus can be disassembled and the interior is easily accessible, this construction simplifies cleaning and maintenance of the interior, including replacement of the linings 10, 4, and 8 and of the window 6. The lining 10 can be formed in 2 pieces which fit halves 12 and 13 so that each half will be lined by one continuous segment of fluorinated ethylene propylene material. The lining 4 may, in one embodiment, be integrally formed with cone shaped lining 8, and the resulting lining can be formed as a one piece unit which conforms to the one-piece out-flow chamber 3. The linings 10 and 4 may extend to a position between mated flanges 15 so that the linings act as a gasket. This configuration also insures secure attachment of the linings 10 and 4 to the container 1 and the out-flow chamber 3, respectively.
Ridges formed by routing the interior of container 1 will also stabilize placement of the lining 10 in container 1. FIG. 5 shows a magnified view of the ridges formed in container 1. The ridges are preferably arranged in a criss-cross, diamond pattern. Lining 10 is pressed or molded to fill the routed areas and covers the ridges so that the interior of container 1 presents a smooth, lined surface. Consequently, lining 10 is formed with a varying thickness having indentations corresponding to the ridges of container 1. The coupling of these ridges and indentations prohibits any movement of lining 10 relative to container 1 by locking the lining 10 in place. The smooth surface of lining 10 facilitates direct fluid flow, as is necessary to prevent the generation of eddies and subcurrents in the reaction vessel.
The light source 7 may be a laser or a configuration of lasers according to FIG. 4. High pulse energy Nd:YAG laser 20 produces a beam with a wavelength of 355 nm which acts as a pump source for the pulsed dye laser 21. The dye for pulsed dye laser 21 is chosen to allow the laser configuration according to FIG. 4 to ultimately produce an output beam in the ultraviolet range. The frequency of the beam from pulsed dye laser 21 is doubled using a barium-borate crystal 22 to achieve the desired wavelength spectrum. A microprocessor scan control unit 23 is connected to both the pulsed dye laser 21 and the barium-borate crystal 22 to control the final wavelength of light produced.
With this configuration of lasers, a beam with a wavelength of 254 nm can be produced and directed through window 6 into container 1. This wavelength, which is diffusely produced by germicidal lamps, is known to be effective for promoting the oxidation of organic contaminates in the presence of an oxidant.
In another embodiment, light source 7 may be an electron-beam-pumped excimer laser or other suitable laser which outputs UV radiation at, for example, 193 nm. In one embodiment, the laser outputs 150 watts, or more, continuous power and provides 10 nm pulses of radiation energy.
FIG. 6 is a more detailed illustration of window 6 and lining 8 secured within container 1. Window 6 is held in place with respect to container 1 by ridges 30 and 32 formed in container 1. Gasket 5 forms a tight seal between container 1 and window 6. Since lining 8 is formed of a substantially non-stick material, such as FEP, lining 8 will not adhere directly to the smooth quartz window 6. Therefore, lining 8, formed as a separate lining piece, is formed in FIG. 6 so as to use ridges 30 and 32 as anchors to container 1. Alternatively, any non-linear surface, such as protruberances, can be formed on the inner surface of container 1 to provide an anchor for lining 8 to be secured to.
Although in FIG. 1, lining 8 is shown as having a triangular or cone shape, FIG. 6 illustrates that lining 8 may also be a flat piece.
In the preferred embodiment, the FEP lining 8 is approximately 10 mm thick or less and is partially supported by window 6 for stabilization against the fluid and vacuum forces within container 1. Also, in the preferred embodiment, lining 8 is made easily removable and replaceable to maintain the high transparency of lining 8.
The size and shape of window 6 and lining 8 will depend upon the light source used and the container 1 size and shape. In one embodiment, window 6 may be 8×8 inches, with a corresponding size of lining 8.
The apparatus of FIG. 1 can be operated with a continuous flow of fluid. Alternatively, longer reaction times may be achieved by recirculating the fluid from the dispersing pipes 3a and 3b to the inflow source 2 or by holding the fluid in container 1 while continuing oxidant injection and ultraviolet irradiation.
The flow rate of the fluid, the rate of oxidant injection and the wavelength of the laser output beam can be adjusted to achieve optimum results, meaning minimum residual contamination in practically short reaction times. The optimum conditions will depend on the degree of initial contamination, the desired level of purification, the nature of the contaminants, and the amount of fluid to be treated.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made within departing from this invention in its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as fall within the true spirit and scope of this invention.
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An ultraviolet radiation exposure fluid decontamination apparatus is provided which includes a container made of high tensile strength material through which the fluid to be treated flows, a high intensity, directed beam light source, and an ultraviolet transparent window through which the directed beam propagates. The container interior has a reflective surface which distributes the light throughout the container. A non-stick material lines the container interior which prevents fouling of the container. The window is also protected by a similar non-stick material. Organic contaminates are oxidized to carbon dioxide, water and other nonharmful products during the fluid treatment carried out by this apparatus.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to tubing that is used to produce hydrocarbons in a subterranean environment and specifically to an improved tubing having an insert with electrical wiring.
BACKGROUND OF THE INVENTION
[0002] Basic artificial lift methods to produce oil and water from a well have improved and changed in recent years. Nearly all methods of artificial lift still employ the connection of a plurality of pipes to form a conduit within a well that has been drilled and cased to allow oil and water to be pumped from the bottom of the well to production tanks at the surface. The production string usually has a pumping device at its lower end that is positioned near the bottom of the well bore that has been prepared for production. Pumping mechanisms such as electrical submersible pumps (ESP) and progressive cavity pumps (PCP) provide the energy needed to bring fluids to the surface through a string of jointed tubing. These pumps normally require an electric motor in order to make them work. Although a multitude of improvements have been made to these pumps over the years, there has been little done to reposition the wires that provide power to the pump from the outside of the tubing to the inside of the tubing.
[0003] For various reasons, those who are skilled in the science of producing fluids from a well have sought out a reliable method of supplying power to the bottom of a well bore. The previously proposed solutions to this problem have been unreliable, expensive, and complicated to install and remove. For example, the currently preferred method of power transmission to the bottom of the well bore is to secure a cable, that contains one or more wires by means of bands that secure the cable to the outside of the production string of tubing. The bands keep the wire adjacent to the tubing so that it does not snag on the production casing or on any objects which might be in the well bore. The bands also support the weight of the cable by securing the cable to the tubing. However, this method is problematic because it exposes the cable and bands to the corrosive elements of the well bore. Furthermore, installing (running) or removing (pulling) the tubing string creates opportunities to separate the cable from the tubing because inclined well bores (the most common type of well bores) increase the chance of the band to hanging up and failing at the gap where two joints of casing have been screwed together. Failure of one or more bands can prevent the removal of the pump or tubing because the annular space between the outside of the production tubing and the inside of the production casing is small and the cable, if not secured to the tubing, can wedge between the casing and the tubing causing the tubing to become stuck. Even if the cable does not break, the insulation on the wire inside the cable can be damaged which can create a short circuit in the electrical circuit, rendering the wire essentially useless. The tubing string then has to be pulled back up to the surface, and the short found and repaired, before the pump can be run back to bottom of the well bore. The problems created by banded external cables are costly and time consuming. Therefore, a need exists for an alternative method of power transmission from the surface to the bottom of the well bore that is both reliable and cost effective.
[0004] One solution to the above stated problem is to employ a plurality of tubing with multiple wires attached to the inside of the tubing instead of the outside of the drill pipe. While this solution alleviates the problem of snagging the wire, it does not solve the problem of exposing the wire to the harsh environment of the produced fluids that are contained within the production tubing. Simply hanging the cable on the inside of the tubing is also problematic because there is no way to support the weight of the cable and the pressure requirements of the pump will be higher due to the added friction between the fluid that is being pumped and the rough exterior of the cable.
[0005] Another solution to the above stated problem is to concentrically position the wires on the exterior of a tube that is inserted and attached to the actual production tubing itself. This solution avoids the problems presented by simply attaching the wire to either the interior or the exterior of the tubing. An example of this technique can be found in U.S. Pat. No. 4,683,944 (the '944 patent) entitled “Drill Pipes and Casings Utilizing Multi-Conduit Tubulars.” The '944 patent discloses a drill pipe with electrical wires positioned inside conduits in the drill pipe wall. However, positioning the wire inside the drill pipe wall significantly decreases the overall pipe wall thickness. In order to overcome the decreased wall thickness, significantly thicker drill pipes will have to be used. Furthermore, the multiple conduits create weak points in the drill pipe in between the conduits. The high rotational stress which the drill pipe encounters in the drilling operations can cause stress fractures in the pipe wall between the multiple conduit tubulars. In an extreme case, high rotational stress can lead to an internal fracture in the drill pipe that disengages the interior wall of the drill pipe from the exterior wall of the drill pipe.
[0006] Furthermore, the manufacture of the multiple conduit drill pipe is a complicated process which is unlike the manufacturing process for conventional drill pipe. Conventional drill pipe is manufactured by attaching male and female pipe connections to opposite ends of a conventional piece of pipe. The two connections are usually welded to the pipe. Multiple conduit pipes must be either extruded with the multiple conduits in place, or the multiple conduits must be drilled or cut out of a conventional drill pipe. In either case, the costs associated with manufacture of multiple conduit drill pipe are high.
[0007] Another problem encountered in the addition of wires to drill pipe, which is not unique to multiple conduits, is the problem associated with creating reliable, secure electrical connections. In conventional drill pipe the individual pipe segments screw together, creating a problem for connecting the wires during the screwing or unscrewing process. This problem can be overcome by using drill pipe that plugs together and that is secured with a threaded coupler. This type of connection is known in the art. The '944 patent discloses a similar type of coupling connection, but requires a planer conduit seal in between the individual pipe segments in order to assure the integrity of the conduit connection. The removable conduit seal is crucial to the method in the '944 patent because a permanently installed conduit seal would be susceptible to damage during manufacture, transportation, storage, and installation of the multiple conduit drill pipe during drilling operations. Installing these conduit seals during the drilling process is also a cumbersome and a time consuming process. Therefore, a need exists for a method of transmitting electrical power to the bottom of a well bore in which the electrical connections are adequately protected from damage and the process of connecting the individual pipe segments is relatively simple and fast.
[0008] The needs identified above exist for production tubing, drill pipe, casing, and/or for any cylindrical pipe used to produce hydrocarbons in a subterranean environment. Therefore, as used herein, the term “tubing” shall mean production tubing, drill pipe, casing, and/or any other cylindrical pipe that is used to produce hydrocarbons in a subterranean environment.
[0009] Since, the previous solutions to the power transmission problem are lacking, a need still exists for an apparatus and method of transmitting power to a well bore in which the wire is not exposed to either the interior or the exterior of the tubing and is operable with any conventional tubing, including without limitation production, casing or drill pipe. Furthermore, a need exists for an apparatus and method for connecting the individual tubing segments together in which the electrical connections are well protected and the connection process is quick and easy.
SUMMARY OF THE INVENTION
[0010] The present invention, which meets the needs stated above, is an improved tubing which overcomes the problems presented by earlier inventions involving tubing and electrical wiring combinations. The invention comprises a section of tubing with coupled end connectors and an insert containing at least one electrical wire. The insert has an outside diameter that is approximately equal to the inside diameter of the improved tubing. The insert also has projections at each end such that when two inserts are placed end to end, the projections will mate up. The insert has at least one groove cut into its side and running the length of the insert. The groove is for the placement of a wire for transmission of power to the well bore or for the placement of a wire for transmission of data from the well bore. The groove is installed down the length of the insert. The groove is deep enough so that when a wire is placed inside the groove, the wire does not project beyond the outside diameter of the insert. The insert may contain as many groove and wire combinations as are necessary for the particular application. The wire has an electrical connection at each end of the insert. When the inserts are placed end to end, the insert projections line up the electrical connectors and correct mating of the insert projections will result in correct mating of the electrical connectors.
[0011] The inserts are the same length as the tubing and are installed inside the tubing such that the insert is flush with the first end of the tubing. The inserts are then welded to the tubing or secured to the tubing by some other method. A threaded coupler is then installed on the second end of the tubing to protect the exposed insert and electrical connector. The coupler will also be used to secure the improved tubing together.
[0012] Individual pieces of improved tubing are connected together in a three step process. First the coupler is threaded onto the second end of the tubing. Next, the first end of one tubing member is positioned above the second end of another tubing member. Next, the insert projections are properly aligned so that they will mate together. Then, the two pieces of tubing are plugged together so that the electrical connections engage each other. Finally, the coupler is screwed onto the first end of the tubing so that the two pieces of tubing are secured together. The process may be repeated as necessary to create an elongated string of improved tubing.
BRIEF DESCRIPTION OF DRAWINGS
[0013] [0013]FIG. 1 is an illustration of the improved tubing without the insert or the coupler.
[0014] [0014]FIG. 2 is an illustration of the insert.
[0015] [0015]FIG. 3 is an illustration of the insert installed in the improved tubing.
[0016] [0016]FIG. 4A is a cross-sectional illustration of the two wire embodiment of the insert taken along line 4 - 4 in FIG. 2.
[0017] [0017]FIG. 4B is a cross-sectional illustration of the three wire embodiment of the insert similar to the two wire embodiment in FIG. 4A.
[0018] [0018]FIG. 5 is an exploded illustration of the connection between the first end of the improved drill pipe and the second end of the improved tubing.
[0019] [0019]FIG. 6 is a cross-section of the two wire embodiment of the insert installed in the improved tubing taken along line 6 - 6 in FIG. 5.
[0020] [0020]FIG. 7 is a cross-section of the two wire embodiment of the insert installed in the improved tubing taken along line 7 - 7 in FIG. 5.
[0021] [0021]FIG. 8 is an illustration of the positioning and alignments steps for the two wire embodiment of the improved tubing.
[0022] [0022]FIG. 9A is an illustration of the plugging step for the two wire embodiment of the improved tubing.
[0023] [0023]FIG. 9B is an illustration of the securing step for the two wire embodiment of the improved tubing.
[0024] [0024]FIG. 10 is an illustration of the positioning and alignment step for the three wire embodiment of the improved tubing. The dashed line indicates the alignment of the wire connectors in the three wire insert embodiment.
[0025] [0025]FIG. 11 is a cross-sectional illustration of the three wire embodiment of the insert taken along line 11 - 11 in FIG. 10.
[0026] [0026]FIG. 12 is an illustration of the plugging step for the three wire embodiment of the improved tubing.
[0027] [0027]FIG. 13 is an illustration of the securing step for the three wire embodiment of the improved tubing.
[0028] [0028]FIG. 14 is a cross-sectional illustration of the three wire embodiment of the insert taken along line 14 - 14 in FIG. 13.
[0029] [0029]FIG. 15 is a detail view of the geometry between the insert, the wire, and the improved tubing around the area indicated by circle 15 in FIG. 14.
[0030] [0030]FIG. 16 is an illustration of a submerged pump in a production situation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] As used herein, the term “improved tubing” means tubing that is adapted to receive a coupler and that has an insert. FIG. 1 is an illustration of improved tubing 100 without insert 200 (see FIG. 2) or coupler 300 (see FIG. 5). Improved tubing 100 is comprised of three sections: first end 120 , midsection 140 , and second end 160 . First end 120 comprises coarse threads 122 , first end weld joint 124 , and wrench grip 126 . Midsection 140 comprises pipe 142 , pipe first end 144 , and pipe second end 146 . Second end 160 comprises fine threads 162 , second end weld joint 164 , and coupler stop flange 166 . First end 120 and second end 160 may be like those found in U.S. Pat. No. 5,950,744 (the '744 patent) entitled “Method and Apparatus for Aligning Pipe and Tubing.” Typically, first end 120 and second end 160 are manufactured by either casting or forging and pipe 142 is manufactured by some other method (i.e. electric resistance welding or extrusion). The manufacture of improved tubing 100 involves the threading of first end 120 and second end 160 to pipe 142 . While the preferred method of manufacturing first end 120 and second end 160 is threading the two ends of improved tubing 100 , those skilled in the art will be aware of other methods of manufacturing first end 120 and second end 160 . Regardless of the method of manufacture, the inside diameter of first end 120 , midsection 140 , and second end 160 are substantially the same so that when insert 200 engages improved tubing 100 , the outside surface area of insert 200 contacts the inside surface area of improved tubing 100 .
[0032] [0032]FIG. 2 is an illustration of inset 200 . Insert 200 is comprised of insert first end 220 , insert midsection 240 , and insert second end 260 . Insert first end 220 comprises insert first end projection 222 and insert first end electrical connection 224 . Insert midsection 240 comprises insert body 242 and insert groove 244 . Insert second end 260 comprises insert second end projection 262 and insert second end electrical connection 264 . The depressions in insert second end 260 in between insert second end projections 262 match up with the insert first end projections 222 . Likewise, the depressions in insert first end 220 in between insert first end projections 222 match up with the insert second end projections 262 . Thus, when two inserts 200 are coaxially aligned with insert first end 220 facing insert second end 260 , insert first end 220 will mate up with insert second end 260 . Insert 200 also contains insert groove 244 which is a groove cut down the long axis of insert 200 . Insert groove 244 is sufficiently large to accommodate at least one wire 246 . Wire 246 is electrically coupled to insert first end electrical connection 224 and insert second end electrical connection 264 and is used as a medium to transfer electricity from the surface to the bottom of the well bore. Insert first end electrical connection 224 and insert first end electrical connection 264 are single plug connectors similar to the K-25 series electrical connectors produced by Kemlon Products and Development Co. of Pearland, Tex. The K-25 series of single plug electrical connections are able to withstand temperatures up to 500° F. and pressures up to 25,000 psi.
[0033] [0033]FIG. 4A is a cross-section of the two wire embodiment of insert 200 taken along line 44 in FIG. 2. Inset 200 may contain only one wire 246 or may contain a plurality of wires 246 . For simplicity of illustration of the invention, FIGS. 1 through 9B (excluding 4 B) depict the invention with only two wires. In alternative embodiments, wire 246 can be a fiber optic in which case the two electrical connections on insert 200 would be optical connections and the embodiment, the invention could employ a mixture of fiber optics and electrical wires. In the preferred embodiment the invention incorporates three wires such that the three wires each carry the appropriate load of a three phase, 440-volt electrical system, as illustrated in FIGS. 4 B and 10 through 15 . However, the number and type of wires is not meant to be a limitation on the invention as those skilled in the art will be aware of how best to configure the invention with fiber optics, electrical wiring, or other connections within insert groove 244 of improved drill pipe 100 .
[0034] [0034]FIG. 3 is an illustration of improved tubing 100 with insert 200 installed. Insert 200 is sized lengthwise so that when insert 200 is inserted into improved tubing 100 , insert first end projection 222 is flush with first end 120 and insert second end projection 262 is the only portion of insert 200 that is projecting beyond second end 160 . As seen in FIG. 6, insert 200 is circumferentially sized such that the outer diameter of insert 200 is sufficiently equal to the inside diameter of improved tubing 100 . Insert groove 244 is sufficiently deep in insert body 242 so that wire 246 does not extend beyond the outer diameter of insert 200 , yet is not deep enough to affect the structural integrity of insert 200 . Insert 200 is coaxially positioned inside improved tubing 100 and secured in place. In the preferred embodiment, insert 200 is the same material as improved tubing 100 and is secured in place by welding. However, insert 200 can be made of any material suitable for drilling operations including various metal alloys, fiberglass, plastic PVC, polymer, or any other material as determined by those of skill in the art. Likewise, insert 200 can be secured in place by welding, glue, heat shrinking, expanding, set screws, or any other method as determined by those skilled in the art. Heat shrinking is defined as a process in which the outer pipe is heated so that the outer pipe expands, the insert is positioned inside the pipe, and the pipe is allowed to cool so that it contracts and secures the insert in place. Expanding is a process in which a tool (expander), having a slightly larger outside diameter than the inside diameter of the insert, is pulled forcibly through the insert causing the outside surface of the insert to expand and grip the inside of the improved tubing. Set screws is a process in which the improved tubing and insert are tapped and threaded and a screw is inserted through the improved tubing and insert to secure the insert in place relative to the pipe.
[0035] [0035]FIG. 5 is an exploded illustration of the connection between two separate pieces of improved tubing 100 with insert 200 installed and coupler 300 positioned for installation on first end 120 and drill pipe second end 160 . Coupler 300 is annular in shape and contains coupler fine threads 302 and coupler coarse threads 304 . Coupler fine threads 302 are configured for screwing engagement with drill pipe fine threads 162 . Coupler coarse threads 304 are configured for screwing engagement with drill pipe coarse threads 122 . The pitch of drill pipe coarse threads 122 and drill pipe fine threads 162 are different pitch so that coupler 300 can only mate up with improved tubing 100 in one orientation. Similarly, when coupler fine threads 302 and coupler coarse threads 304 engage pipe coarse threads 122 and drill pipe fine threads 162 , the coarse threads and the fine threads do not interfere with the threading process of each other. As seen in FIG. 7, coupler stop flange 166 has a larger cross-sectional area than fine threads 162 and acts as a stop for coupler 300 so that coupler 300 does not go past second end 160 . The outside diameter of coupler 300 is sufficiently similar to pipe wrench grip 126 so that when the user is attaching the individual pieces of improved drill pipe 100 together, a pipe wrench will fit onto both pipe wrench grip 126 and coupler 300 without undue adjustment of the pipe wrench. Coarse threads 122 and coupler coarse threads 304 are tapered so that they may be completely engaged with a minimal amount of rotations after first end 120 and second end 160 have been plugged together. Coupler 300 is also sufficiently long so that when coupler 300 is completely screwed onto second end 160 and abuts coupler stop flange 166 , coupler 300 extends past insert second end projection 262 . It is important that coupler 300 extend past insert second end projection 262 because improved tubing 100 will typically be stored, transported, and handled with coupler 300 installed on second end 160 and coupler 300 will protect insert second end 260 and specifically insert second end electrical connection 264 from damage.
[0036] [0036]FIG. 8 is an illustration of coupler 300 installed on second end 160 just prior to connection of two pieces of improved tubing 100 . FIG. 8 is representative of how improved tubing 100 will be stored, transported, and handled. In FIG. 8, coupler 300 extends past insert second end projection 262 and insert second end electrical connection 264 .
[0037] [0037]FIGS. 8, 9A, and 9 B illustrate the process of attaching two sections of improved tubing 100 together. In attaching the two sections of improved tubing 100 together, as far as the scope of this invention is concerned, it does not matter whether the second end 160 of one section of improved tubing 100 is above the first end 120 of the other section of improved tubing 100 or vice-versa. The improved tubing 100 may also be connected in the horizontal. However, the preferred embodiment and industry standard is to place the second end 160 above the first end 120 . The attachment process comprises four steps: positioning, aligning, plugging, and securing. First, in the positioning step the two sections of improved tubing 100 are positioned over one another with a second end 160 of one improved tubing 100 facing the first end 120 of the other improved tubing 100 . As seen in FIG. 8, the aligning step consists of rotating one or both sections of improved tubing 100 such that the insert second end projection 262 in one section of improved tubing 100 will properly mate with the insert first end projection 222 in the other section of improved tubing 100 .
[0038] When the two sections of improved tubing 100 are properly aligned, the two sections of improved tubing 100 may be plugged together. FIG. 9A is an illustration of the plugging step in which two sections of improved tubing 100 are plugged together. In the plugging step, the second end 160 of one section of improved tubing 100 is lowered onto the first end 120 of the other section of improved tubing 100 until the two sections of improved tubing 100 contact each other and/or the two inserts 200 fully mate with each other. To properly mate, insert second end projections 262 will fill the depression between insert first end projections 222 and insert first end projections 222 will fill the depression between insert second end projections 262 . When insert first end projection 222 and insert second end projection 262 properly mate, insert first end electrical connection 224 and insert second end electrical connection 264 will electrically couple and provide an electrical connection which will tolerate the harsh environment of the well bore. After the two improved tubing 100 are plugged together, they are secured by screwing coupler 300 onto first end 120 .
[0039] [0039]FIG. 9B is an illustration of two sections of improved tubing 100 secured together by coupler 300 . Coupler 300 is secured to first end 120 by pipe wrenches (not shown) which grip coupler 300 and pipe wrench grip 126 and torque coupler 300 until coupler 300 is firmly screwed onto drill pipe first end 120 . The two sections of improved tubings 100 may then be used in the production process.
[0040] [0040]FIGS. 10 through 14 illustrate a three wire embodiment. The manufacture of the three wire improved drill pipe is similar to the manufacture of the two wire improved tubing. Likewise, the assembly of a plurality of three wire improved tubing is similar to the assembly of a plurality of two wire improved tubing. FIG. 10 is an illustration of the alignment step for a three wire embodiment of the insert in which coupler 300 is installed on second end 160 . The dashed line in FIG. 10 indicates the alignment of inset first end electrical connection 224 and insert second end electrical connection 264 . When the two electrical connectors are properly aligned, insert first end projection 222 and insert second end projection 262 are also properly aligned. FIG. 11 is a cross-sectional illustration of the three wire embodiment of insert 200 and improved tubing 100 taken along line 11 - 11 in FIG. 10. FIG. 12 is an illustration of the plugging step for the three wire embodiment of insert 200 taken along line 11 - 11 in FIG. 10. FIG. 13 is an illustration of the securing step of two pieces of improved tubing 100 with the three wire embodiment of insert 200 and the coupler disengaged from the first end of the tubing.
[0041] [0041]FIG. 14 is a cross-section of the three wire embodiment of the insert taken along line 14 - 14 in FIG. 13. Insert 200 in the three wire embodiment is similar to insert 200 in the two wire embodiment in that the inside diameter of pipe 142 is substantially the same as the outside diameter of inset body 242 . FIG. 15 is a detail view of the geometry between insert 200 , wire 246 , and improved tubing 100 around the area indicated by circle 15 in FIG. 14. FIG. 15 illustrates the point that insert groove 244 is cut into insert body 242 so that wire 246 does not project above the outer surface of insert body 242 .
[0042] [0042]FIG. 16 is an illustration of a submerged pump in a production situation. FIG. 16 shows multiple pieces of improved tubing 100 with the inserts installed (not shown). Power comes from an external source 402 and is stepped down in transformer 404 , is routed through vent box 406 , and goes to wellhead 408 . Power is transmitted down tubing pump 412 and or motor 414 . Well bore 418 is typically cased with casing 416 .
[0043] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
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The invention comprises a section of improved tubing with coupled end connectors and an insert containing at least one electrical wire. The insert has an outside diameter that is approximately equal to the inside diameter of the improved tubing. The insert also has projections at each end such that when two inserts are placed end to end, the projections will mate up. The insert has at least one groove cut into its side and running the length of the insert. The groove is for the placement of a wire for transmission of power to the well bore or for the placement of a wire for transmission of data from the well bore. When a plurality of the inventions are placed end to end, the insert projections line up the electrical connectors and correct mating of the insert projections will result in correct mating of the electrical connectors.
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This application is a continuation of Ser. No. 610,711, May 16, 1984, now abandoned, which is a continuation-in-part of my co-pending application Ser. No. 297,388, filed Aug. 28, 1981, entitled "Composition and Method for Improving the Quality of Human Skin and Skin Aging Retardant", now abandoned.
FIELD OF THE INVENTION
This invention relates to methods using vitamin A acid to retard the effects of aging of the skin and generally improve the quality of the skin, particularly human facial skin.
BACKGROUND OF THE INVENTION
Caucasians who have had a good deal of sun exposure in childhood will show the following gross cutaneous alterations in adult life: wrinkling, leatheriness, yellowing, looseness, roughness, dryness, mottling (hyperpigmentation) and various premalignant growths (often subclinical). These changes are most prominent in light-skinned persons who burn easily and tan poorly. The baleful effects of sunlight are cumulative, increasing with time. Although the anatomic degradation of the skin is most advanced in the elderly, the destructive effects of excessive sun exposure are already evident by the second decade. Serious microscopic alterations of the epidermis and dermis occur decades before these become clinically visible. Wrinkling, yellowing, leatheriness, loss of elasticity are very late changes.
It is known to use vitamin A acid for the treatment of acne as set forth in my U.S. Pat. No. 3,729,568. Other known uses of vitamin A acid which were reviewed by Thomas and Doyle in Journal of American Academy of Dermatology (May, 1981) Volume 4, No. 5, subsequent to completion of the present invention, include, in addition to acne treatment, treatment of senile comedones, nevus comedonicus, linear verrucous nevus, plantar warts, pseudofolliculitis, keratoacanthoma, solar keratosis of extremities, callosities, keratosis palmaris et plantaris, Darier's disease, ichthyosis, psoriasis, acanthosis nigricans, lichen planus, molluscum contagiosum, reactive perforating collagenosis, melasma, corneal epithelial peeling, geographic tongue, Fox-Fordyce disease, cutaneous metastatic melanoma and keloids or hypertrophic scars. Vitamin A acid derivatives (retinoids) are known to have prophylactic and therapeutic effects on a great variety of tumors and are being increasingly used as anti-tumor drugs.
In view of the foregoing, it is believed that vitamin A acid influences ultrastructural and proliferative properties of epidermal cells. However, these prior art uses of vitamin A acid have generally involved short term treatments in which relatively large doses of the acid are applied (i.e. sufficient to cause significant irritation and often peeling) in order to obtain a quick cure or treatment of the particular condition, such as removal of comedones, as opposed to persistent treatment of normal aging skin.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to the use of low strength vitamin A acid (retinoic acid), known clinically as tretinoin, in moderating and preventing the aging changes of the exposed areas of the skin, especially the face. In particular, the methods of the present invention retard the effects of normal aging of the skin due to impairment of the differentiation of epidermal epithelial cells and due to loss of collagen fibers, abnormal changes in the elastic fibers and deterioration of small blood vessels of the dermis of the skin. The methods comprise applying topically to the epidermis of the skin effective amounts of vitamin A acid in a program of maintenance therapy, whereby epithelial growths are substantially reduced and prevented and the skin substantially regains and maintains its firmness, turgor and elasticity during the therapy. Generally, the maintenance therapy is begun in middle age when epithelial growths and other aging changes being to appear clinically.
The vitamin A acid may be applied to the skin in any suitable non-toxic, dermatologically acceptable vehicle, preferably a non-volatine, emollient or lubricating vehicle, in an amount and at a frequency which are insufficient to cause excessive irration of the skin. Generally, concentrations in the range of about 0.005 to 0.05% by weight of the vehicle are preferred.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The purpose of this invention is to moderate and retard the aging changes in the skin by topical application of tretinoin beginning in middle age when aging changes first become evident clinically. Certain of the anatomic alterations can be corrected and at least partially reversed, accompanied by improvement in the appearance of the skin.
The invention accomplishes two goals. First, a prophylactic effect in preventing progression and worsening of the damage with the passage of time. Secondly, various abnormalities are corrected and modified to the extent that the structure and function of the skin acquires the characteristics of younger skin.
AGE ASSOCIATED STRUCTURAL CHANGES
Although many of the effects of the aging of the human skin are the result of underlying structural changes which build up over a period of years and can only be detected histologically prior to middle age, these changes and effects being to appear clinically about middle age, namely between about 35 and 45 years of age, and become more and more evident and pronounced thereafter. The more apparent effects of aging have already been referred to above, and each is associated with one or more underlying structural changes in the skin. For example, blotchiness or mottling (hyperpigmentation) is due to changes in the melanocytes in the population of epidermal cells. These pigment producing cells which, unlike the keratinocytes remain at the base of the epidermis lose their normal regulation process with aging and produce excess pigment which cause the blotchiness and mottling.
However, aside from such obvious cosmetic changes in the skin, there are a number of other changes which are more important though less apparent, including loss of sensory acuity and ability to heal wounds, decreased blood flow and decrease in the thickness of the skin. Older people have less sensitivity to pain and a longer response time. Thus, pain due to irritation or injury is not felt as soon or to the same extent as in young people with the result that superficialy minor but potentially serious injuries may be sustained without the individual being aware of the injury until serious damage has occured.
The surface temperature of the skin in older people is somewhat lower than the skin temperature in younger people, so that they often feel cold. This is due to a decrease in the blood supply to the skin due to loss of small blood vessels and decreased proliferation of new capillaries and small blood vessels in the skin. This is at least one of the causes of the loss of sensory acuity and response to pain. Furthermore, the decreased blood supply decreases the rate at which irritants and toxins are cleared from the skin tissue.
Still further, the skin of older people is more easily torn than that of younger people, since both the epidermis and dermis become thinner with age. As a result, there is less bulk to protect underlying organs and therefore more risk of serious injury. Moreover, when wounds or injuries are sustained, healing of the wounds is much slower in older people and may take as much as twice as long to heal as in younger persons.
The underlying causes of the above gross skin effects may be understood more readily from the following discussion of the specific changes in the epidermis and dermis as aging progresses.
1. Epidermis
With increasing age and exposure of a human to sun and other environmental traumas, cells divide at a slower rate (decreased capacity to renew themselves). They show marked irregularities in size, shape and staining properties; orderliness (polarity) from below to above is lost. The thickness of the epidermis decreases (atrophy). The horny layer which comprises the barrier against water loss and penetration of chemicals becomes abnormal due to the shedding (exfoliation) of cells in large group or clusters instead of as individual cells, resulting in roughness, scaling and dryness. There is loss of the orderly transformation of living epithelial cells into cornified dead cells which are shed at the surface, that is, differentiation is impaired. Aberrant differentiation results in numerous foci of abnormal epithelial growths or tumors, the most frequent and important of which are actinic keratoses. After many years these can transform into frank skin cancers called basal cell and squamous cell cancers. Pigment producing cells (melanocytes) can also become altered forming flat, dark growths (lentigo melanoma) which may progress to malignant melanoma. The cells which make up these premalignant growths are destroyed by topical tretinoin.
2. Dermis
The cells which make the fibers of the dermis become smaller and sparser with increasing age, usually in sundamaged facial skin. There is a great loss of collagen fibers resulting in looseness and easy stretchability of the skin; elastic fibers become abnormal so that the skin does not promptly snap back after being stretched. Since the fibrous components comprise more than 90% of the bulk of skin of which 95% is collagen, the degradation of these fibers, especially collagen, is mainly responsible for wrinkling, laxness and loss of elasticity.
Small blood vessels become thin walled, dilated and often ruptured. Vascular supply thereby becomes compromised.
BENEFICIAL EFFECTS OF TRETINOIN IN ACCORDANCE WITH THE PRESENT INVENTION
(a) Increases proliferative activity of epidermal cells
This results in thickening of the epidermis with correction of atrophy. Cell renewal is quickened so that cells divide at a rate typical of younger skin. Treatment with vitamin A acid in accordance with the invention can double the skin thickness. The stimulation of cell growth also results in faster wound healing. Experiments have been performed wherein blisters have been raised and cut off on skins of individuals of various ages. Healing takes place in 2 or 3 weeks in young people, but takes much longer in older persons. Application of tretinoin before raising the blister results in healing twice as fast in the older subjects.
(b) Corrects abnormalities of differentiation
Vitamin A acid regulates and controls the physiologic behavior of epithelial tissue, assuring its stability and integrity. It corrects and normalizes abnormalities of differentiation. In sundamaged skin, the numerous foci of abnormal growths and segments of atypical, abnormal epidermis are corrected, reversed or eliminated. Fewer growths appear and progression to cancer is halted. Normalizing of the epidermis results in a smoother, less dry and rough skin, since cells are not only produced more rapidly but exfoliation occurs by individual cells rather than clusters or scales, thus improving the topography of the skin. Moreover, hyperpigmentation resulting in blotches and splotches is reduced by tretinoin stopping excessive production of pigment by the melanocytes, although it cannot eliminate depigmentation.
(c) The metabolism of fibroblasts is increased
Fibroblasts synthesize the fibers of the dermis; new collagen is laid down, strengthening the physical foundation of the skin. Fibroblasts also make the ground substance which exists between the fibers, allowing these to glide past each other. The ground substance, known as acid mucopolysaccharides, is also responsible for the turgor and bounce of the skin. Tretinoin stimulates the formation of new acid mucopolysaccharides.
Accordingly vitamin A acid promotes the formation of a more normal dermis. Because of this activity, it has been found to promote and accelerate the healing of wounds in compromised tissue, of which regressed, aged dermis is an example. Further, the production of a new collagen layer not only repairs damaged skin but results in the effacement and prevention of fine wrinkles and lines.
(d) Vascularity is increased
Tretinoin stimulates blood flow and promotes the formation of new vessels. Blood flow is greatly reduced in aged, sundamaged skin. A brisker blood supply improves the physiologic competence of the skin and imparts a livelier, glowing appearance. Patients often say their skin feels "more alive".
Several of the prior art treatments using vitamin A acid as referred to above have claimed there is an increase in the blood flow in the skin. However, the increased blood flow from such short term treatments could result simply from vasodilation caused by the irritating effects of high concentrations of vitamin A acid. In contrast, the low sub-irritating concentrations of vitamin A acid according to the present invention do not cause significant vasodilation, but it has been found that over the long term there is not only a proliferation of new blood vessels, but also an increase in lymphocytes and other blood cells. As a result, there are more cells to fight infection, and the increased blood supply allows the skin to clear irritants and toxins more quickly from the skin.
Still further, treatment with vitamin A acid according to the present invention raises the surface temperature of the skin by about 1/2 degree centigrade due to the greater basodermal flow of blood. The increased blood flow also increases acuity to pain and irritation, and the skin becomes more reactive to chemical insults. For example, experiments with highly drying and irritating cosmetics, soaps, perfumes, etc. have shown that young people will experience severe irritation within 3 or 4 days whereas it may take 2 or 3 weeks for an older person to feel the same irritation. The increased sensitivity of the skin treated with vitamin A acid provides an early warning system to older people so that too much damage is not done before the pain or irritation is felt.
Tretinoin may be formulated in bland, moisterizing bases, such as creams or ointments, usually in the concentration range of about 0.005% to 0.05% and preferably about 0.01% to 0.025% by weight of base, although higher concentrations may be used for darker skins. Other non-toxic, dermatologically acceptable vehicles or carriers in which tretinoin is stable will be evident to those of ordinary skill in the art. In general, emollient or lubricating vehicles, such as oleaginous substances, which help hydrate the skin are preferred. Volatile vehicles which dry or otherwise harm the skin, such as alcohol and acetone, should be avoided.
An ointment base (without water) is preferred in the winter and in subjects with very dry skin. Examples of suitable ointment bases are petrolatum, petrolatum plus volatile silicones, and lanolin.
In warm weather and often for younger persons, emulsion (cream) bases, which are mixtures of oils and water are preferred. Examples of suitable cream bases are Eucerin (Beiersdorf), cold cream (USP), Purpose Cream (J & J), and hydrophilic ointment (USP).
Tretinoin is a mild irritant and may cause redness and scaling, which may be accompanied by some tenderness and tightness. These reactions quickly disappear when the applications are stopped. However, even when applied excessively to produce an intense dermatitis, the reaction fades quickly leaving no permanent sequellae. Systemic side reactions are unknown. Selection of an appropriate emollient vehicle will more readily allow the use of a highly effective but sub-irritating dose of the vitamin A acid.
The extent or length of treatment according to the present invention may best be described as persistent or indefinite. That is, compared to the short term prior art treatments of various conditions with vitamin A acid in which the treatments are terminated as soon as the condition disappears or subsides, the treatment according to the present invention is intended to continue indefinitely, otherwise the effects of aging will reappear after treatment is terminated. That is, the treatments of the present invention may be considered to be intervention therapy in decelerating the aging process. If the intervention is stopped, there is regression to the original state.
Usually, there is little point in beginning the treatments of the present invention until middle age when the effects of aging begin to appear. The particular program of maintenance therapy according to the present invention will vary depending upon the individual being treated. Generally, depending upon the age and state of the skin when treatments begin, it has been found that once a day applications of vitamin A acid for up to 6 months may be necessary to reduce and control the effects of aging which have already occurred. Once a stabilized skin control has been obtained, the frequency of application of vitamin A acid may be reduced, for example to two or three times a week, and in some cases only once a week for the rest of the person's life. That is, once the aging process has been controlled, a maintenance dose on the order of two applications per week is generally sufficient to maintain that state.
The invention will be illustrated in more detail by reference to the following specific, non-limiting examples:
EXPERIMENTAL EXAMPLE 1
There has been applied 0.01% to 0.025% by weight concentrations of tretinoin in a base to the faces of middle-aged and elderly women. At least 500 persons have used typical tretinoin experimentally for periods ranging from three months to five years. These women were studied as follows:
About two hundred were inmates of the Philadelphia Home for the Indigent at Riverview. They ranged in age from 45 to 75. The creams or ointments were applied once daily before bedtime in an amount sufficient to achieve a continuous sustaining film. Clinical assessments were made once monthly. Beneficial effects were obtained in about 80% after about three months. Most of those who improved continued to use tretinoin daily for one to two years. Improvement was maximal at about six months and persisted as long as the drug was used. Withdrawal of the drug resulted in a slow loss of improvement with a return to the original state in about four to five months. Maintenance therapy was required to prevent relapse.
The beneficial effects included effacement of small wrinkles, smoother surface, greater turgor, elimination of actinic keratoes, elimination of senile comedones, less conspicuous pores and less mottling (fading of pigmented spots).
EXPERIMENTAL EXAMPLE 2
Histologic studies were conducted on twenty six residents of Riverview as follows. Tretinoin was applied to one side of the face once daily as in Experimental Example 1 for four to six months. The other side received the cream or ointment base alone.
Biopsies were taken from both sides at the end of the study and processed for histologic examination using a variety of histochemical stains. The tretinoin treated side was easily recognized in 24 of 26 subjects. The chief effects of tretinoin, as demonstrated by the indicated tissue staining techniques, were:
(a) Routine H & E stain: epidermis thicker, polarity restored, cells were regular size and shape, loss of atypia, no epidermal irregularities or pre-malignant growths, density of fibroblasts increased, more vessels.
(b) Fontanas stain for melanin: dispersion of pigment granules and far less pigment in epidermal cells.
(c) Reticulin stain: increase in young collagen fibers indicating deposition of new collegen.
(d) Orcein stain for elastin: moderate removal of degenerated elastic tissue, allowing intact fibers to be visualized more clearly.
(e) Hale's stain for ground substance: definite increase in acid mucopolysaccharides, especially in deeper dermis.
EXPERIMENTAL EXAMPLE 3
There have been treated at least another two hundred subjects in the aging skin clinic at the Hospital of the University of Pennsylvania. These are middle-class white women, ages 35 to 60. Tretinoin was applied as in Experimental Example 1 for at least six months.
Beneficial effects were clinically evident in about 80% of these persons. With this more sophisticated group we took note of subjective reactions as well. These women uniformly thought that their skin was livelier, smoother, fresher, and tighter. Again, we noted more turgor, effacement of fine lines, less hyperpigmentation, more youthful appearance, less roughness, less wrinkling.
EXPERIMENTAL EXAMPLE 4
About one hundred pain volunteers recruited at Ivy Research Laboratories have been studied in a variety of ways including biopsies, physiologic tests, etc. The importance of this series is that the tests were conducted according to the double-blind format and hence were strictly controlled. Tretinoin was applied once daily as in Experimental Example 1 for six to twelve months to one side of the face; the other side received the unmedicated vehicle. The applications were made five days a week by a trained monitor who did not know which of the two preparations contained the active agent. The clinical observations were made without knowledge of the drug treated side.
When the code was broken, some improvement was noted in about 15% of cases treated with the vehicle alone. Distinctly beneficial effects were secured in about 85% on the tretinoin treated side. Histologic study in thirteen cases confirmed the clinical results of restoration to a more normal pattern on the tretinoin side. The epidermal and dermal changes were those described above.
Fluorescein injected into both sides was removed in about half the time on the tretinoin side. This indicates improved vascularity resulting in faster clearance of drugs from the skin. Moreover, a series of clinical stimuli indicate that tretinoin treated skin is more reactive, showing behaviors more typical of young skin. It responds more rapidly and intensely to irritant chemicals such as croton oil and dimethylsulfoxide; it blushes more readily after application of nicotinate; blisters raised by ammonium hydroxide heal more quickly (greater wound healing, a known effect of tretinoin); and contact allergic rections (poison ivy) also heal more quickly.
EXPERIMENTAL EXAMPLE 5
The rhino mouse is a hairless species with abnormally wrinkled skin. Topical application of tretinoin in 0.01% to 0.025% concentration virtually eliminates wrinkling in three to four weeks. The skin becomes fuller and more turgid.
The improvement is largely a result of increased ground substance and greater water content. The epidermis thickens and certain epithelial abnormalities regress. These beneficial effects are surprisingly similar to those in human skin suggesting that this is an appropriate model, especially in regard to wrinkling and looseness of skin.
From the foregoing, it will be seen that the invention has the following advantages inter alia:
A. Clinical
Effacement of fine wrinkles
Smoother surface
Lightens pigmented blotches
Skin has more turgor
Large pores less noticeable
Skin feels livelier
B. Histologic
Thicker epidermis
Normalizes atypia and pre-malignant changes.
Atrophy and dysplasia corrected.
Stimulates blood flow; new vessels formed
Stimulates fibroblasts with new collagen formation
Increases ground substance
Melanin within keratinocytes is decreased
It will be recognized by those skilled in the art that changes may be made to the above-described embodiments of the invention without departing from the broad inventive concepts thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover all modifications which are within the scope and spirit of the invention as defined by the appended claims.
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Various effects of aging of skin due to impairment of differentiation of epidermal epithelial cells and loss of collagen fibers, abnormal changes in elastic fibers and deterioration of small blood vessels in the dermis of the skin are retarded by applying topically to the epidermis in a maintenance therapy program effective amounts of vitamin A acid (tretinoin) such that epithelial growths are substantially reduced and prevented and the skin substantially regains and maintains its firmness, turgor and elasticity. Moreover, with persistent treatment dermal blood cells and vessels increase and the epidermis and dermis thicken, resulting in improved ability of the skin to sense, resist and recover from irritation or injury. Further, hyperpigmentation, lines and wrinkles due to aging are reduced and prevented. The treatment is particularly useful for human facial skin and preferably applied in amounts insufficient to cause excessive irritation.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a recording apparatus for effecting a recording operation by a relative movement of a recording head with respect to a recording medium.
2. Related Background Art
In conventional recording apparatus equipped with plural recording heads, for example a color printer equipped with three recording heads for cyan (C), magenta (M) and yellow (Y), the positional registration among these recording heads is achieved by electrical or mechanical adjustments based on a printed test pattern.
However the mechanical adjustment of registration requires delicate operations which take a long time, except for an expert. Also the registration of the recording heads has to be adjusted each time a recording head is replaced.
An incomplete adjustment results in a positional aberration of images of different colors, thus significantly deteriorating the image quality.
SUMMARY OF THE INVENTION
In consideration of the foregoing, an object of the present invention is to provide a recording apparatus not associated with the drawbacks of the prior technology.
Another object of the present invention is to provide a recording apparatus allowing easy detection of the errors in registration of plural recording heads.
Still another object of the present invention is to provide a recording apparatus capable of compensating the detected errors in registration of plural recording heads, thereby enabling to an image of a high quality to be obtained.
Still another object of the present invention is to provide a recording apparatus provided with detection means for detecting a mark provided on each recording head and a reference mark provided on a carriage supporting said recording heads, operation means for calculating the distance of each recording head from said reference mark based on the output of said detection means, and control means for controlling the timing of recording of each recording head according to the output of said operation means.
The foregoing and still other objects of the present invention will become fully apparent from the following description, which is to be taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a principal part of a color printer embodying the present invention;
FIG. 2 is a view showing the relationship between a head carriage with recording heads mounted thereon and the output of a linear sensor;
FIG. 3 is a block diagram of an electric circuit of an embodiment of the present invention;
FIG. 4A is a flow chart showing an initializing operation; and
FIG. 4B is a flow chart showing a recording operation of a line.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective view of a color printer embodying the present invention, wherein a head carriage 1 carries a cyan head 2C, a magenta head 3M and a yellow head 4Y in predetermined positions. Each head is provided with ink orifices of a predetermined number arranged in a vertical direction and an ink tank, which is replaced when the ink in the ink tank is exhausted. There are also shown a pair of pulleys 5, a driving motor 6 linked to one of the pulleys, and a belt 7 mounted around the pulleys 5 and fixed to the head carriage 1.
A linear sensor 8, composed for example of a CCD, is fixed at a position opposite to the head carriage 1 in a standby state, and detects a reference mark on the head carriage 1 and the positions of the recording heads as will be explained later. There are further shown a platen 9 and a recording sheet 10.
FIG. 2 shows the relationship between the head carriage with the recording heads mounted thereon and the output of said linear sensor. Corresponding to a reading position 11 of the linear sensor 8, the head carriage 1 bears reference marks 12 on both ends of a face opposed to said linear sensor 8, and the recording heads bear registration adjustment marks 13 (head 4Y), 14 (head 3M), 15 (head 2C) and vertical position detecting marks 16 (head 4Y), 17 (head 3M), 18 (head 2C) corresponding to the reading position 11 of the linear sensor 8. The marks 13, 14, 15 indicate the positions of ink orifices on the recording heads. Said marks 13, 14, 15 are orthogonal to the line of reading position 11, while the marks 16, 17, 18 are diagonal to said line. Consequently, for example at initialization, the linear sensor 8 can detect distances a, b, c of the marks 13, 14, 15 of the recording heads from the reference mark, or the amounts of registration in the moving direction of the head carriage. The symbols a, b and c respectively indicate the amounts of registration of the heads 4Y, 3M and 2C in the lateral direction.
FIG. 3 is a block diagram of the present embodiment, wherein a CPU 31, a RAM 32 and a ROM 33 store a program of a control sequence as shown in FIG. 4. A data selector 34 separates image data signal into respective color signals Y, M and C, and supplies each of thus separated color signals to a head control circuit of a corresponding color. It is to be noted that FIG. 3 only shows the details of a control circuit 51 for the yellow head, but does not show the details of the control circuits 52, 53 for other two colors since they are identical to the circuit 51. The yellow head control circuit 51 is composed of components 36-41 to be explained in the following.
A head print data buffer 35 stores image data of a corresponding color (Y) supplied from the data selector 34. A read-out address counter 36 selects a position of data read-out from the head print data buffer 35, in response to a control signal from the CPU 31. The head print data buffer 35 supplies, in parallel manner, the data of a position designated by the read-out address counter 36 to a parallel/serial (P/S) converter 37.
Serial data signal obtained from the P/S converter 37 is serially supplied to a shift register 38, then supplied in parallel manner to a selector 39 controlled by a control signal from the CPU 31, then serially supplied to a serial/parallel (S/P) converter 40, and supplied to a driver circuit 41 functioning in response to an output enable signal from the CPU 31.
In response to each output enable signal, the driver circuit 41 activates recording elements of the yellow head 4Y corresponding to the signal from the driver circuit 41, thus achieving a yellow print on the recording sheet.
The CPU 31 drives the head carriage 1 by means of the driving motor 6, which supplies the CPU 31 with a movement pulse for each movement, corresponding to a dot, of the head carriage in the scanning direction. The CPU 31 also receives the signal from the linear sensor 8, calculates the aforementioned values a, b, c in the form of numbers of movement pulses in an initializing step and stores said values in the RAM 32.
In the following there will be explained, as examples of the functions of the above-explained embodiment, an initializing operation in relation to FIG. 4A and a printing operation of a line in relation to FIG. 4B. Programs corresponding to the flow charts shown in FIGS. 4A and 4B are stored in the ROM 33 shown in FIG. 3.
The initializing operation is conducted in the following manner. A step T1 initializes a counter CNT and the aforementioned values corresponding to head distances to zero. Then steps T2, T3 activate the linear sensor 8 and read the output thereof.
The counter CNT remains inactive until an output corresponding to the reference mark is obtained from the linear sensor 8. When said output is obtained (step T4), the value of the counter CNT is increased until there is obtained an output corresponding to the mark of the yellow head (steps T5, T6). When said output is obtained, a step T7 effects a calculation CNT x α in order to correlate the value of the counter CNT with the number of dots between the recording heads, and stores the result of said calculation, which is equal to the aforementioned value a, in the RAM 32.
Then the values b and c are determined respectively in steps T8 to T10 and T11 to T13 in a similar manner.
FIG. 4B shows a control sequence for effecting a recording operation, with compensations of the head distances, based on the values a, b and c determined in the above-explained manner.
After the initialization, a step S1 sets the number of movement pulses required for the reference mark of the head carriage 1 in the standby position to move to the printing position, as a print start delay, in the RAM 32. Then a step S2 starts the movement of the head carriage 1. A step S3 discriminates the entry of a moving pulse corresponding to a dot. If said pulse has not been entered, the program awaits its entry. If the pulse has been entered, it reduces the value of print start delay by a count and the program proceeds to a step S5.
The step S5 discriminates whether the value of the print start delay has reached zero. If not zero, the program returns to the step S3. If zero, the program proceeds to a step S6, whereupon the reference mark of the head carriage 1 moves to the print position.
The step S6 sets, in the RAM 36, a number of moving pulses corresponding to the distance a from the reference mark of the head carriage 1 to the ink orifice of the yellow head as the Y-head delay. It also sets, in said RAM 36, the number of moving pulses corresponding to the distance b as the M-head delay and that corresponding to the distance c as the C-head delay. Then a step S7 resets the pointers of the read-out address counters for the Y, M and C-heads to zero. Then a step S8 turns off the output enable signals for the Y, M and C heads.
A step S9 then discriminates the entry of a moving pulse. If not entered, the program awaits its entry. If a moving pulse has been entered, the program proceeds to a step S10 to discriminate whether the value of the Y-head delay has reached zero. If not, the program proceeds to a step S11 to decrease said value by one, and then proceeds to a step S12. If the value of the Y head delay is identified as zero in the step S10, the program proceeds to a step S13.
The step S13 discriminates whether the pointer of the read-out address counter for the Y-head has reached a value corresponding to the end of a line. If said value has been reached, a step S14 turns off the output enable signal for the Y head and the program proceeds to the step S12. On the other hand, if said value has not been reached, the program proceeds to a step S15 to turn on the output enable signal for the Y head, then to a step S16 to increase the pointer of the read-out address counter for the Y head by one, and to the step S12.
The step S12 executes a procedure for the M head similar to the steps S10, S11, S13, S14, S15 and S16. Then the program proceeds to a step S17 which executes a procedure for the C head similar to the steps S10, S11, S13, S14, S15 and S16.
A step S18 discriminates whether all the Y, M and C heads have completed the printing of a line, and, if not, the program returns to the step S9. On the other hand, if completed, the program is terminated.
As explained in the foregoing, the linear sensor 8 detects the distances a, b and c of the marks 13, 14 and 15 of the recording heads from the reference mark, and, after the reference mark of the head carriage 1 reaches the print position, the printing operation of each head is started upon receiving a number of moving pulses corresponding to thus detected value a, b or c. Consequently the head registration can be automatically adjusted, and can be easily achieved even when the recording head is replaced.
The above-explained embodiment allows automatic compensation of the errors in the registration of the recording heads by detecting the marks respectively provided on the recording heads and the reference mark provided on the head carriage and determining the distances of said marks from said reference mark, thereby improving the image quality.
In case of simply correcting the errors in mutual registration of the recording heads, it is only required to determine the mutual distances of the recording heads.
The present invention is not limited to the foregoing embodiment but is subject to various modifications and variations within the scope and spirit of the appended claims.
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A recording apparatus, such as an ink jet printer, with plural recording heads is described. Each recording head has a mark which is read by a detector to generate a corresponding signal. The signals from plural recording heads are utilized for registering these heads.
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STATE OF THE ART
The invention is based on a sensor element for an oxygen limiting current probe of the type including a pumping cell where oxygen supply is provided by a short-circuit cell disposed upstream of the pumping cell. Such sensor elements, which operate according to the diffusion limiting current principle, measure the diffusion limiting current at a constant voltage applied to the two electrodes of the sensor element. In an oxygen containing measuring gas, this current is a linear function of the oxygen partial pressure as long as the diffusion of the gas to the pumping electrode determines the speed of the reaction taking place. It is known to construct such sensor elements so that the anode as well as the cathode are exposed to the gas to be measured, with the cathode including a diffusion barrier so as to ensure operation within the diffusion limiting current range.
The prior art oxygen limiting current probes generally serve to determine the λ value of exhaust gas mixtures from internal-combustion engines. This λ value represents the ratio of "total oxygen to the oxygen required for a complete combustion of the fuel" for the air-fuel mixture being combusted in a cylinder.
Due to a simplified and economical manner of manufacturing, the production of sensor elements that can be produced in ceramic sheet and screen-printing technology has become popular in practice in recent years.
Planar sensor elements can be produced in a simple and economical manner from plate or sheet shaped oxygen conducting solid electrolytes, for example of stabilized zirconium dioxide. These sensor elements are coated on both sides with electrodes and leads, namely with an inner pumping electrode on the one side and an outer pumping electrode on the other side. The inner pumping electrode is here advantageously disposed at the end of a diffusion gap or diffusion channel through which measuring gas is able to diffuse in and which serves as a gas diffusion resistance or diffusion barrier.
In addition, German Unexamined Published Patent DE-OS 3,543,759 and EP-A 0,142,992, 0,142,993, 0,188,900 and 0,194,082 disclose sensor elements and detectors which have in common that they each include a pumping cell and a sensing cell composed of plate or sheet shaped oxygen conducting solid electrolytes and two electrodes disposed thereon, and they have a common diffusion gap or diffusion channel.
Finally, DE-OS 3,728,618 discloses a sensor element for polarographic probes for a determination of the λ value of gas mixtures. This sensor element includes a plate or sheet shaped solid electrolyte that is conductive for O 2- ions and is equipped with outer and inner pumping electrodes, with the inner pumping electrode on the plate or sheet shaped solid electrolyte being disposed in a diffusion channel for the measuring gas. The sensor element further includes conductor paths for the pumping electrodes. At least one second inner pumping electrode is disposed in the diffusion channel on the side facing the inner pumping electrode and this second inner pumping electrode is short-circuited with the first inner pumping electrode.
A lecture by B.Y. Liaw and W. Weppner of the Max-Planck-Institut fur Festkorperforschung [Max Planck Institute For Solid State Research] in Stuttgart, held on the occasion of the "7th International Conference on Solid State Ionics," Nov. 5-11, 1989, in Hakone, Japan, disclosed an oxygen limiting current probe based on tetragonal ZrO 2 in which a short-circuit cell and an oxidic mixed conductor are attached upstream of an inner pumping electrode (Cathode) for measuring the limiting current. The authors represent the opinion that the upstream connected short-circuit cell and the oxidic mixed conductor simultaneously constitute a diffusion barrier and they expect the oxygen permeation to obey the diffusion laws so that, consequently, it is a linear function of the external oxygen partial pressure and thus generates a limiting current at the subsequently connected pumping cell. However, in fact this is only the case if electrode effects (polarizations) of the short-circuit cell can be neglected and have no influence on the oxygen permeation. Otherwise, no linear relationship is obtained between oxygen partial pressure and measuring signal (pumping current).
The drawbacks of the prior art sensor elements for oxygen current limiting probes, particularly those produced by laminating together a plurality of solid electrolyte sheets, particularly by laminating together sheets based on stabilized ZrO 2 , are that with increasing pump voltage they exhibit transverse sensitivity to CO 2 and H 2 O. In that case, not only O 2 is converted at the inner pumping electrode (cathode), but also CO 2 and H 2 O. The measuring current is considerably greater and no longer a linear function of the oxygen partial pressure.
SUMMARY AND ADVANTAGES
The sensor element according to the invention, which is suitable for a determination of the λ value of gas mixtures, particularly of exhaust gases in internal-combustion engines, and which includes a pumping cell where oxygen supply is provided by a short-circuit cell disposed upstream of the pumping cell and a separate diffusion barrier disposed between the short-circuit cell and the pumping cell, has significant advantages compared to the prior art planar sensor elements.
Due to the fact that the sensor element does not receive the oxygen to be measured directly, but by way of an upstream connected short-circuit cell, it is possible, when the sensor element is operated in the exhaust gas of internal-combustion engines, to avoid transverse sensitivity to the other components of the exhaust gas, CO 2 and H 2 O, as it occurs at higher temperatures and higher pump voltages. Additionally, the accumulation of solid particles from the exhaust gas in the diffusion barrier of the probe is prevented so that they are unable to change the diffusion resistance.
Compared to the sensor element presented at the "7th International Conference on Solid State Ionics", the sensor element according to the invention has the advantage that due to the arrangement of a separate diffusion barrier between the pumping cell and the short-circuit cell, the short-circuit cell does not perform the function of a diffusion barrier but merely takes care that the same oxygen partial pressure as in the measuring gas exists upstream of the installed diffusion barrier. The short-circuit cell therefore does not adversely affect the oxygen supply.
The operation of a sensor element according to the invention can be explained as follows:
If in an oxygen concentration cell O 2 , Pt/ZrO 2 /Pt, O 2 , the two Pt electrodes are short-circuited, a short-circuit current will flow until the O 2 partial pressure is the same on both sides. If, the gas chamber is limited at least on one side of the cell and is relatively small and the polarizations and ohmic resistances which determine the short-circuit current are correspondingly low, this compensation can take place relatively quickly. In this way, it is possible to transport oxygen from the measuring gas to the actual measuring cell (pumping cell) in a limiting current probe without annoying or damaging exhaust gas components coming in contact with the measuring cell. If, according to the invention, a short-circuit cell is connected upstream of the diffusion barrier and the pumping cell, the short-circuit causes the same O 2 partial pressure to be set in the gas chamber upstream of the diffusion barrier as in the exhaust gas.
In the case of the sensor element according to the invention, the pumping cell is thus supplied with oxygen by way of a short-circuit cell disposed upstream of a separate diffusion barrier. A sufficiently large diffusion barrier must then be present between the short-circuit cell and the pumping cell.
According to a first advantageous embodiment of the invention, the sensor element is configured in such a way that the anode of the pumping cell lies within the measuring gas. In this embodiment, the short-circuit cell must replenish all of the oxygen consumed by the measuring current. This oxygen is returned to the measuring gas by way of the anode.
According to a second advantageous embodiment of the invention, the sensor element is configured in such a way that the anode of the pumping cell together with the diffusion barrier and the cathode are disposed in the interior gas chamber of the short-circuit cell. In that case, the oxygen that is generated at the anode of the pumping cell and is consumed at the cathode, is conducted in a gas circuit including the diffusion barrier. The short-circuit cell acts on this gas circuit in a regulating manner only if the O 2 partial pressure in the measuring gas changes. It is thus required only to match the O 2 partial pressure to the external oxygen partial pressure and not replenish all of the oxygen consumed at the cathode of the pumping cell. In this second embodiment, the adjustment times are generally shorter than in the first embodiment.
Preferably, the sensor elements according to the invention are produced on the basis of plate or sheet shaped ceramic materials which are imprinted, laminated together and sintered according to conventional, known methods, for example screen printing, with the short-circuit cells as well as the pumping cells being obtained in a simple manner by imprinting a plate or sheet shaped solid electrolyte as it is customary for the production of oxygen limiting current probes with a metal belonging to the platinum group.
The diffusion barrier of a sensor element according to the invention is composed of a zone or section of a coarsely porous sintered ceramic material that is permeable to gas to a certain degree and is based, for example, on Al 2 O 3 or ZrO 2 , or of a diffusion gap or diffusion channel which, if required, may be filled partially with roughly pre-sintered ceramic material.
BRIEF DESCRIPTION OF THE DRAWINGS
Two advantageous exemplary embodiments of a sensor element according to the invention are shown in the drawing figures in a simplified manner.
FIG. 1 is a schematic longitudinal sectional view of the front portion of a first embodiment of the sensor element according to the invention; and
FIG. 2 is a schematic cross-sectional view of a second embodiment of the sensor element according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The first embodiment of the sensor element according to the invention shown schematically in FIG. 1 is composed of a carrier or substrate 1 in the form of a small plate on whose one side is disposed an insulation layer 2 and a heater 3 and on whose other side a diffusion barrier 4 as well as a short-circuit cell 5 composed of electrodes 6 and 7 as well as a solid electrolyte layer 8 and a pumping cell 9 composed of an anode 10, a cathode 11 and a solid electrolyte layer 8.
The carrier or substrate 1 of the sensor element according to the invention is composed of a ceramic material as it is customarily employed for the production of sensor elements, for example on the basis of ZrO 2 or Al 2 O 3 . It has been found to be advantageous to produce the sensor element of sheets made of an unsintered ceramic material having a layer thickness of 0.3 to 2.0 mm, particularly of about 0.6 to 1.0 mm.
Insulation layer 2 is composed of a conventional insulating layer, for example based on Al 2 O 3 . It may have a thickness of, for example, 15 to 20 μm. The heater 3 may be, for example, a heater based on Pt/Al 2 O 3 which can be obtained by printing on an appropriate cermet paste.
The diffusion barrier 4 is composed of a coarsely porous sintering ceramic material, for example based on Al 2 O 3 or ZrO 2 , that can be obtained by imprinting a corresponding paste or laminating on a porously sintering sheet. Its layer thickness is advantageously about 20 to 50 μm. As shown in FIG. 1, it need not fill the entire area. It is sufficient if parts of the oxygen diffusion path between the short-circuit cell anode and the pumping cell cathode are constricted by a barrier.
The porosity of the diffusion barrier may be varied, if required, by the addition of pore formers which combust during the sintering process, decompose or evaporate. Typical pore formers that can be employed are, for example, thermal soot powder, graphite carbon; plastics, for example based on polyurethane; salts, for example ammonium carbonate; and further organic substances such as, for example, theobromine and indanthrone. Such pore formers may be added to the porously sintering starting material in various quantities.
The electrodes of short-circuit cell 5 and of pumping cell 9 are preferably composed of a metal of the platinum group, particularly platinum, or of alloys of metals of the platinum group or alloys of metals of the platinum group with other metals. If required, they contain a ceramic supporting frame material, for example in the form of a YSZ powder, at a volume percentage of preferably about 40 volume percent. They are porous and as thin as possible. Preferably they have a thickness of 8 to 15 μm. The conductor paths belonging to the electrodes are preferably also composed of platinum or a platinum alloy of the described type. Moreover, they may likewise be produced from a paste based on a noble metal cermet.
Solid electrolyte layer 8 is composed of one of the known oxides of four-valent metals employed for the production of O 2- ion conducting solid electrolyte sheets, such as, in particular, ZrO 2 , CeO 2 , HfO 2 and ThO 2 containing two-valent earth alkali oxides and/or preferably three-valent oxides of the rare earths. Typically, the layer may be composed of approximately 50 to 97 mole percent ZrO 2 , CeO 2 , HfO 2 or ThO 2 and 50 to 3 mole percent CaO, MgO or SrO and/or oxides of the rare earths and particularly Y 2 O 3 . Advantageously, the layer is composed of ZrO 2 that is stabilized with Y 2 O 3 The thickness of the layer may advantageously lie at 10 to 200 μm, particularly 15 to 50 μm.
In the case of this first embodiment, anode 10 lies in the measuring gas and the short-circuit cell replenishes all of the oxygen consumed by the measuring current. Thus the oxygen of the measuring gas penetrates electrolyte layer 8 in the form of ionized oxygen which is developed at the second electrode (anode of the short-circuit cell) 7 back into oxygen (O 2 ). This oxygen penetrates the diffusion barrier and is pumped off by the cathode 11 of pumping cell 9 and discharged to the measuring gas by way of pumping cell anode 10.
In the case of the second advantageous embodiment of the sensor element according to the invention, shown schematically in FIG. 2, the anode 10 of pumping cell 9 is disposed in the interior gas chamber of short-circuit cell 5.
The sensor element is composed of the carrier or substrate 1 of ceramic material, for example, a ZrO 2 ceramic, and includes a heater 3 that is embedded in an insulating layer, a diffusion gap 12, which in the case of this second embodiment forms the diffusion barrier, an annular pumping cell 9 equipped with an anode 10 and a cathode 11 as well as a solid electrolyte layer 8, a sealing frame 13, glass fittings 14 and a short-circuit cell 5 composed of a solid electrolyte sheet or a small solid electrolyte plate 15, for example of a ZrO 2 ceramic, which is covered all around by electrodes 16.
Glass fittings 14 which determine the distance of short-circuit cell 5 from pumping cell 9 may be composed, for example, of a high melting point glass and may have such dimensions that the distance of the electrode of short-circuit cell 5 facing pumping cell 9 from the anode 10 of pumping cell 9 is about 20 to 500 μm.
The element may be produced by printing, laminating together and sintering of appropriate sheets, with the diffusion gap possibly being produced, for example, by imprinting a coating substance which decomposes, evaporates or combusts without residue at the pre-sintering or sintering temperature. If required, however, diffusion gap 12 may also be filled with a coarsely porous sintering ceramic material, for example based on Al 2 O 3 or ZrO 2 . In this process, short-circuit cell 5 and pumping cell 9 and its carrier 1 are sintered separately and then connected by fittings 14.
In the case of this sensor element 1 with a fixed-on short-circuit cell 5, the oxygen developed at anode 10 of pumping cell 9 and consumed at cathode 11 is conducted in a gas circuit over the diffusion barrier, and the short-circuit cell enters the gas circuit only in a regulating manner if the O 2 partial pressure in the measuring gas changes.
The production of a sensor element according to the invention may be effected by machine in a multiple access process. The elements may be inserted in a housing of a customary, known type and may be employed to determine the λ value of gas mixtures. The short-circuit cell connected upstream then avoids CO 2 and H 2 O transverse sensitivity as it is customary in comparable sensor elements. The upstream connected short-circuit cell additionally prevents solid particles from the exhaust gas from being deposited in the diffusion barrier of the probe to thus change the diffusion resistance.
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A sensor element is proposed for an oxygen limiting current probe for the determination of the λ value of gas mixtures, particularly the exhaust gases of internal-combustion engines, whose oxygen supply is provided by a short-circuit cell disposed upstream of the pumping cell of the sensor element. In this way the CO 2 and H 2 O transverse sensitivity of the sensor element is made ineffective. In order to obtain at the pumping cell a limiting current that is a linear function of the O 2 partial pressure, a diffusion barrier must additionally be disposed between the short-circuit cell and the pumping cell.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of corrosion inhibition. More particularly, the invention relates to the inhibition of corrosion of metals commonly used in the fuel distribution and handling systems for internal combustion engines, especially where the fuel is alcohol and the engine is used to power motor vehicles.
Alcohols have, in the past, been used as extenders and replacements for petroleum fuels in internal combustion engines. Thus, "gasohol" fuel is becoming increasing familar as an engine fuel in the United States. If oil supplies become less available in future years, it is anticipated that alcohols may gradually replace petroleum fuels in internal combustion engines. In Brazil, for example, ethanol is widely used as fuel for internal combustion engines. In the United States, both methanol and ethanol have been considered for supplementation or replacement of petroleum fuels.
The use of alcohols, such as ethanol, as a replacement fuel for petroleum in internal combustion engines presents corrosion problems not heretofore encountered in petroleum fueled internal combustion engines. Thus, alcohol fuels present corrosion problems throughout their storage and distribution systems. The corrosion problem, for example with ethanol, is mainly due to the presence of a small amount, i.e., 3 to 9%, of water in the alcohol which is not removed during normal distillation processes. Although it is possible to remove this residual amount of water by a final distillation step, the cost is inordinately high. Accordingly, some processors do not normally remove the last amounts of water in the alcohol and the presence of such water enhances corrosion of metals with which the alcohol comes in contact. Further, impurities in the alcohol, such as chloride ions and acetic acid, also contribute to the corrosive effects of alcohol on metals it contacts during its transportation in the field and its use in the fuel systems of internal combustion engines.
Since alcohols come into contact with a variety of metals during their preparation, storage, distribution and transportation and within the fuel system of an internal combustion engine, corrosion scientists are faced with complex problems in the effort to inhibit corrosion in a system composed of various metals.
2. Prior Art
The most common metals encountered in the fuel systems of vehicles powered by internal combustion engines are alloys of zinc, copper, iron, tin, steel and aluminum. Most commonly, alloys such as ternplate, brass, steel and Zamak (an alloy of zinc, copper and aluminum) are encountered.
A variety of chemical corrosion inhibitors have been used to inhibit corrosion in metals such as zinc, steel, copper, etc. Such inhibitors include aliphatic and aromatic amines, amine salts of acids such as benzoic acid, hetercyclic amines such as pyridines, alkenyl succinic acids, triazoles such as benzotriazole and the like. Such inhibitors have been used in such media as salt water, acids and alkali. Other inhibitors which have been used include hydrogen sulfide, metal salts such as sodium chromate, sodium silicate, ferrous nitrate, ammonium phosphate, potassium dichromate, sodium borate, sodium phosphate, sodium nitrate, and sodium chlorate, glucose, borax, formamide, rosin amine, propargyl ether, propionic acid, valeric acid, quaternary amine salts, alkanolamines, aminophenols, alkyl and aryl mercaptans and the like. A comprehensive summary of corrosion inhibitors is set forth by M. Brooke, "Chemical Engineering", Feb. 5, 1982, pages 134 through 140 and by C. C. Nathan, Corrosion Inhibitors, (NACE), 1973.
SUMMARY OF THE INVENTION
In accordance with the present invention, it has been found that a particular combination of inhibitors greatly retards the corrosion of metals used in the fuel systems of vehicles which utilize alcohol as a fuel and retards corrosion of metals in the associated alcohol storage and distribution system. Thus, it has been found that a composition comprising an amine salt of an acid, together with a triazole, inhibits corrosion by alcohols. Accordingly, the present invention provides a composition for the inhibition of corrosion of metals by alcohols and the process of using same and a corrosion inhibited alcohol fuel.
DETAILED DESCRIPTION OF THE INVENTION
The corrosion inhibitor composition of the invention comprises (1) an amine salt of an acid and (2) a triazole.
Acids which are used to form salts with amines may be any acid which is capable of forming a salt with an amine. Examples of suitable acids include the saturated aliphatic monocarboxylic acids such as formic, acetic, propionic, butyric, caproic, caprylic, capric, lauric, myristic, palmitic, stearic and the like; saturated aliphatic dicarboxylic acids such as oxalic, malonic, succinic, glutaric, adipic, pimelic, suberic, azelaic, sebacic and the like, cycloaliphatic acids such as cyclohexane monocarboxylic acid and cyclohexane dicarboxylic acid; unsaturated aliphatic monocarboxylic acids such as acrylic, crotonic decenoic, decendioic, undecenoic, tridecenoic, pentadecenoic, pentadecendienoic, heptadeceneoic, oleic, linoleic, linolenic and the like; unsaturated aliphatic dicarboxylic acids such as fumaric and maleic; cyclic unsaturated carboxylic acids such as hydnocarpic and chaulmoorgric; aldehydic acids such as glyoxalic and ketonic acids such as pyruvic and acetoacetic; and aromatic acids such as benzoic, toluic, aminobenzoic, phenylacetic, naphthoic, phthalic, cinnamic, gallic and the like.
Preferred acids are the alkenyl dicarboxylic acids such as alkenylmalonic, alkenylsuccinic, alkenylglutaric, alkenyladipic, alkenylpimelic, alkenylsuberic, alkenylazelaic, alkenylsebacic and the like.
Especially preferred acids are the alkenylsuccinic acids and hydrolyzed alkenylsuccinic anhydrides. Exemplary alkenylsuccinic acids which may be used in accordance with the present invention are ethenylsuccinic, propenylsuccinic, tetrapropenylsuccinic, sulfurized-propenylsuccinic, butenylsuccinic, 2-methylbutenylsuccinic, 1,2-dichloropentenylsuccinic, hexenylsuccinic, 2,3-dimethylbutenylsuccinic, 3,3-dimethylbutenylsuccinic, 1,2-dibromo-2-ethylbutenylsuccinic, heptenylsuccinic, octenylsuccinic, 4-ethyhexenylsuccinic, nonenylsuccinic, decenylsuccinic, 1,2-dibromo-2-ethyloctenylsuccinic, undecenylsuccinic, dodecenylsuccinic, 2-propylnonenylsuccinic, tridecenylsuccinic, tetradecenylsuccinic, hexadecenylsuccinic, octadecenylsuccinic, eicosenylsuccinic, tetracosenylsuccinic, hexacosenylsuccinic, hentriacontenylsuccinic acid and the like.
The acids described hereinabove are well known and their various methods of preparation are also well known to those skilled in the art. For example, preparation of alkenylsuccinic acids is by the known reaction of an olefin with maleic acid. Alkenylsuccinic acids may be prepared as mixtures thereof by reacting a mixture of olefins with maleic acid. Such mixtures, as well as the pure acids, are utilizable herein.
Any acid, as exemplified by the above classes of acids, may be used herein to form a salt with an amine as one component of the corrosion inhibitor of the present invention. Accordingly, any acid may be used in accordance with the present invention so long as its salt with an amine is sufficiently soluble in alcohols to afford corrosion inhibition.
Similarly, any amine which will form an acid salt which is soluble in an alcohol and inhibits corrosion may be used in the present invention. Exemplary classes of amines which may be utilized herein include the primary, secondary and tertiary alkyl, aryl, alkaryl, aralkyl, alicylyl, and heterocyclyl amines and the like. Accordingly, typical amines include alkyl amines such as the mono-, di- and tri-alkylamines, e.g., methylamine, dimethylamine, trimethylamine, propylamine, tripropylamine, laurylamine, stearylamine, alkanolamines such as ethanolamine, triethanolamine; cyclohexylamines; phenylamines, morpholinylamines; pyridylamines; ethoxylated amines such as ethoxylated rosin amines; morpholines, pyridines; phenanthridines; amideimidazolines; rosin amines; fatty acid amines such as cocoanut fatty acid amines; alkylsulfonamides; alkylbenzensulfonamines; anilines; alkylenepolyamines, such as ethylenediamine; polyalkyleneimines such as polyethyleneimine and the like.
The above-described acids and amines are merely illustrative of the wide variety of acids and amines which may be used to form salts of the present invention. Obviously, one skilled in the art will readily determine other acids and amines which may be utilized in a functionally equivalent manner. The only limiting factors in determining the acid/amine salts which may be used herein is the solubility of the salt in alcohols, especially ethanol, and its corrosion inhibition characteristics. Determination of the appropriate amine salt to be used to afford corrosion inhibition of a particular metal may require a modicum of experimentation which is well within the scope of one skilled in the art. More than one acid/amine salt may be present in the composition of the invention.
The second component of the corrosion inhibitor of the invention is a triazole. Suitable triazoles which may be used in the present invention include substituted triazoles such as heterocyclic, aromatic and sulfur-substituted triazoles such as pyrrodiazole, benzotriazole, diphenyltriazole, tolyltriazole, mercaptobenzotriazole and similar triazoles.
The corrosion inhibitor is normally added to the alcohol at bulk storage facilities, usually in the form of a solution of the inhibitor in an appropriate solvent such as trimethylbenzene, isopropanol or other carrier for ease of handling and treating.
The acid/amine salt is prepared, in general, as follows:
The acid and amine numbers are determined for each of the reactants and combined in the correct proportions depending on the product desired. The reaction is exothermic and cooling may be desired. There is no water of reaction formed.
The ratio of amine to acid, based on amine and acid number determinations, is generally from about 1:0.5 to about 1:2, preferably from about 1:0.75 to about 1:1.25, especially about 1:1.05.
The ratio, on a weight basis, of the salt component to the triazole component is generally from about 5:1 to about 140:1, preferably from about 20:1 to about 100:1, especially about 70:1.
The inhibitor is normally added to alcohol in a minor but effective corrosion inhibiting amount. Generally, the concentration of inhibitor in alcohol is from about 0.001 to about 1.00%, preferably from about 0.03 to about 0.50%, especially about 0.25% on a volume basis.
In the following illustrative examples, a corrosion test was used to measure the corrosion effects of hydrated ethanol on coupled, dissimilar metals. The corrosion test is specified in paragraph 3.31 on "Anti-corrosive Additive for Hydrated Ethylalcohols" Volkswagen do Brasil, SA Provisory Norm CT VW 580 83 BR.
SUMMARY
A set of metal coupons (Zamak, brass and steel) is immersed in hydrated ethanol for 6 days at 50° C. At the end of 6 days the coupons are visually inspected and weight changes are recorded.
DESCRIPTION OF TEST CONDITIONS
A coupon set consists of one Zamak, one brass, and one steel coupon, each having a 5 mm diameter centered hole. The coupons set is assembled on a 4 mm diameter threaded brass stud with a 1 mm thick brass washer placed between the Zamak and brass coupons, the brass coupon in direct contact with the steel coupon and brass nuts isolated from the coupons with Teflon washers.
The coupon dimension and compositions are listed below:
______________________________________Zamak 40 × 20 × 3 mm DIN-1743couponBrass 23 × 15 × 2.5 mm DIN-17660 (ABNT P-TB-50)couponSteel 24 × 10 × 2 mm DIN-1651 (ABNT 12L 14)couponBrass 1 mm thick, DIN-17660 (ABNT P-TB-50)washer 12 mm diameter______________________________________
PROCEDURE
A. The plane faces of the coupons, brass washer, and nuts are prepared by wet polishing with No. 320 aluminum oxide polishing paper. The Zamak and brass coupons are wet polished with water while the steel coupon is polished using anhydrous ethanol.
B. After polishing the coupons, washers and nuts are cleaned with a soft brush under tap water, rinsed in anhydrous ethanol and then rinsed in acetone. The coupons are stored in a desiccator under vaccum for 45 minutes and then weighed to the nearest 0.1 mg.
C. The coupon unit is assembled as described above using gloves and taking care not to touch the parts with bare hands. One hundred fifty (150) milliliters of hydrated ethanol are measured into a 250 ml wide-mouth Erlenmeyer flask. The coupon assembly is placed in the alcohol so that the stud is at a 45° angle to the horizontal. The flask is closed with polyethylene film. The flask is placed in an oven maintained at 50° C. for six days.
D. At the end of the six day test period, the samples are removed from the oven and allowed to cool. The coupon set is then removed and disassembled. The three coupons are cleaned, dried and weighed as in Paragraph B above. Weight changes are determined and visual observations recorded.
EXAMPLES 1 THROUGH 3
In these examples, Zamak, brass and steel coupons were tested in the static corrosion test, described above, singly and coupled in a unit. The results are shown in Table I.
TABLE I__________________________________________________________________________STATIC CORROSION TESTProcedure using Brazilian Ethanol WEIGHTEX. COUPON TYPE* ADDITIVE VISUAL OBSERVATIONS @ 6 DAYS CHANGE (mg.)__________________________________________________________________________1A Zamak 5 No add. slight corrosion; a few gray spots on +0.1ace1B Brass No add. discolored; dark gray in color -0.22 Steel No add. small rust spots over much of surface -0.53 All coupons No add. very heavy corrosion - Zamak 5 -5.4 coupled as slight discoloration - brass +0.3 a unit a few small rust spots - steel -0.2__________________________________________________________________________ *Zamak 5 Zinc alloy ZN.sub.95 AL.sub.4 CU.sub.1 Brass Cartridge brass (70 Cu/30 Zn) Steel Mild, 1010 carbon steel
The data indicate severe corrosion of Zamak alloy and only slight corrosion of other metals when coupled as a unit. Only slight corrosion is evident on uncoupled coupons.
EXAMPLES 4 THROUGH 7
In these examples, a coupon of cartridge brass was tested in the static corrosion test and the results, comparing the use of benzotriazole to a control are shown in Table II.
TABLE II__________________________________________________________________________STATIC CORROSION TESTPROCEDURE USING BRAZILIAN ETHANOL*Metal Coupon: Cartridge brass (70 Cu/30 Zn) VISUAL OBSERVATIONSEX ADDITIVE CONC. (ppm) 2 days 6 days__________________________________________________________________________4 No additive -- very tarnished & discolored discolored & corrode5 Composition A 10 one edge tarnished-otherwise ≈25% of surface (Benzotriazole) bright slightly tarnished6 Composition A 50 bright and shiny bright and shiny (Benzotriazole)7 Composition A 100 bright and shiny bright and shiny (Benzotriazole)__________________________________________________________________________ *Ethanol adjusted for water and acetic acid content
The data indicate that the benzotriazole, used alone, is effective in controlling corrosion of brass in the ethanol test fuel.
EXAMPLES 8 AND 9
In these examples, static corrosion tests were performed on coupled Zamak, brass and steel coupons showing the results of using an inhibitor system consisting of the salt of an amideimidazoline with tetrapropenylsuccinic acid and benzotrizole. The results are shown in Table III.
TABLE III__________________________________________________________________________Procedure using Brazilian Ethanol CONC. WEIGHTEX ADDITIVE (ppm) COUPON TYPE VISUAL OBSERVATION @ 6 CHANGES__________________________________________________________________________ (mg)8 Composition B 500 Zamak 5* slight corrosion on top; bottom -0.7n (Benzotriazole Brass slight discloration +0.2 TPSA/Amideimidazoline Salt) Steel slight rusting on bottom -0.8ace9 Composition B 1000 Zamak 5* same appearance for each type -0.7 (Benzotriazole Brass coupon as at 500 ppm rate +0.1 TPSA/Amideimidazoline Salt) Steel -0.6__________________________________________________________________________ {}* coupons coupled on glass rod TPSA = tetrapropenylsuccinic acid
The data indicate that a composition comprising benzotriazole and the salt of amideimidazoline with tetrapropenylsuccinic acid is effective in controlling corrosion of the Zamak alloy when compared to the results of Table I.
EXAMPLES 10 THROUGH 23
In these examples, coupled Zamak, brass and steel coupons were static corrosion tested using various inhibitor systems as compared to a control. The results are shown in Table IV.
TABLE IV__________________________________________________________________________STATIC CORROSION TESTVolkswagon Test ProcedureUsing Brazilian EthanolMetal coupons coupled with brass rod, washers,and nuts. Complete assembly tested as a unit.__________________________________________________________________________ AMIDEIMID- *** AMINEEX ADDITIVE TPSA* n-DDSA** AZOLINE n-DECYLAMINE t-ALKYLAMINES COCOAMINE SALT.sup.±__________________________________________________________________________10 none -- -- -- -- -- -- --11 Comp. A X -- X -- -- -- --12 Comp. B X -- X -- -- -- --13 Comp. C X -- X -- -- -- --14 Comp. D X -- X -- -- -- --15 Comp. E X -- X -- -- -- --16 Comp. F X -- X -- -- -- --17 Comp. G -- X X -- -- -- --18 Comp. H X -- X -- -- -- --19 Comp. I -- X -- -- X -- --20 Comp. J X -- -- X -- -- --21 Comp. K X -- -- -- X -- --22 Comp. L X -- -- -- -- X --23 Comp. M -- -- X -- -- -- X__________________________________________________________________________ ADDITIVE APPROXIMATE TOLYL- TREATING RATIO OF COUPON WT. CHANGE (mg.)EX ADDITIVE BENZOTRIAZOLE TRIAZOLE RATE (ppm) SALT:TRIAZOLE STEEL BRASS ZAMAK__________________________________________________________________________ 510 none -- -- -- -- +0.1 +0.6 -8.311 Comp. A -- X 540 17:1 +0.3, 0 -0.8, -1.5, -1.612 Comp. B -- X 560 10:1 0 +0.5 -1.913 Comp. C -- X 610 5:1 0 +0.3 -3.414 Comp. D -- X 1030 102:1 - 0.3 +0.1 -2.115 Comp. E -- X 1300 51:1 -0.1 +0.2 -1.816 Comp. F -- X 1350 17:1 0 +0.3 -2.017 Comp. G -- X 1210 120:1 0 +0.2 -3.218 Comp. H X -- 610 5:1 -0.1 +0.4 -2.519 Comp. I -- X 700 6:1 -0.2 +0.2 -2.420 Comp. J -- X 240 7:1 -0.2 -0.1 -2.721 Comp. K -- X 443 17:1 -0.2 0 -1.322 Comp. L -- X 456 17:1 -0.1 +0.2 -2.123 Comp. M -- X 625 24:1 0 +0.7 -2.1__________________________________________________________________________ *Tetrapropenylsuccinic acid **n-Dodecenylsuccinic acid ***Mixture of talkylamines .sup.± Tetrapropenyl succinic acid/alkanolamine reaction product
The data indicate that mixtures of acid/amine salts and a triazole are effective in reducing the corrosive effects of ethanol test fuel on various metal alloys.
EXAMPLES 24 THROUGH 29
In these examples, Zamak, brass and steel coupons were coupled and static corrosion tested with various inhibitor systems. The results are shown in Table V.
TABLE V__________________________________________________________________________STATIC CORROSION TESTFuel: Ethyl Alcohol obtained from Brazil with alcoholcontent reduced to 92.6% and acetic acid content raised to 3.0 mg/100__________________________________________________________________________ml TREATING RATE COMPONENTS (ppm) VOL/VOL* APPROX. RATIOEX ADDITIVE TPSA t-ALKYLAMINE TOLYLTRIAZOLE 1000 2500 SALT:TRIAZOLE__________________________________________________________________________24 None -- -- -- -- -- --25 Comp. N X X X X -- 17:126 Comp. O X X X -- X 42:127 Comp. P X X X -- X 69:128 Comp. Q X X X -- X 71:129 Comp. R X X X -- X 67:1__________________________________________________________________________EX ADDITIVE COUPON TYPE WT. Δ in mg. WT. Δ in g/m.sup.2 AVERAGE Wt. Δ in__________________________________________________________________________ g/m.sup.224 None Zamak 5 -6.6, -6.8, -6.9 -3.17, -3.27, 3.3 -3.25 Brass +0.3, +0.2, +0.2 +0.33, +0.22, +0.22 +0.26 Steel -0.2, 0, 0 -0.34, 0, 0 -0.1125 Comp. N Zamak 5 -2.2, -2.5, -2.6 -1.06, -1.20, -1.25 -1.17 Brass +0.3, +0.3, +0.2 +0.33, +0.33, +0.22 +0.29 Steel 0, 0, 0 0, 0, 0 0.0026 Comp. O Zamak 5 -1.4, -1.7, -1.2 -0.67, -0.82, -0.58 -0.69 Brass +0.1, 0, 0 +0.11, 0, 0 +0.04 Steel 0, -0.1, 0 0, -0.17, 0 -0.0627 Comp. P Zamak 5 -0.9, -0.9, -1.1 -0.43, -0.43, -0.53 -0.46 Brass 0, +0.1, +0.1 0, +0.12, +0.12 +0.08 Steel 0, +0.1, -0.1 0, +0.17, -0.17 0.0028 Comp. Q Zamak 5 -0.8 -0.38 -- Brass +0.2 +0.22 -- Steel +0.1 +0.17 --29 Comp. R Zamak -0.9 -0.43 -- Brass +0.1 +0.11 -- Steel +0.1 +0.17 --__________________________________________________________________________ *Added volumetrically
EXAMPLE 30
In addition to static corrosion tests, an electrochemical technique was used to measure the corrosion rate of Brazilian hydrated ethanol on mild steel (1018) in the presence and absence of the corrosion inhibitor composition of the present invention. The electrochemical technique used was the Polarization Admittance Instantaneous Rate (PAIR) technique. In this example, the test fluid was Brazilian hydrated ethanol with water and acetic acid content adjusted to 7.4% and 30 ppm, respectively.
The procedure involved placing mild steel elctrodes (connected to a Petrolite Instruments Model M-1010 PAIR brand polarization rate meter) in a 1000 ml tall-form beaker containing 900 ml of the test fluid. The alcohol was stirred, open to the atmosphere, at ambient temperature for the test duration (i.e., 18 hours). The results are shown in Table VI. The Table reports the corrosion rate in MPY (mils/yr) which are average of the anodic and cathodic readings for the test fuel. The higher corrosion rate measured initially in the sample containing additive is due to the increased conductivity of the alcohol due to the presence of the acid/amine salt. The calculated percent protection at 18 hours is 88%.
TABLE VI______________________________________ELAPSED CORROSION RATE, MPYTIME, NO ADDITIVE COMPOSITION EXAMPLEHOURS ADDED NO. 29 ADDED AT 2500 ppm______________________________________1 0.104 0.1752 0.106 0.1123 -- 0.0784 -- 0.0605 -- 0.0486 -- 0.04018 0.110 0.013______________________________________
While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention.
Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and description set forth herein, but rather than the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skill in the art to which the invention pertains.
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There is provided a corrosion inhibitor for use in the storage, distribution and use of alcohol as a fuel for internal combustion engines. The inhibitor comprises a triazole and an amine salt of an acid. There is further provided a corrosion-inhibited alcohol fuel and a method of inhibiting corrosion in metals.
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BACKGROUND OF THE INVENTION
The present invention is directed to infinitely variable transmissions and methods and apparatus for control of infinitely variable transmissions. More particularly, the present invention is directed to an infinitely variable transmission using a walking beam with a variable fulcrum and to methods and apparatuses for controlling infinitely variable transmissions in response to predetermined parameters of an internal combustion engine, such as manifold pressure.
For nearly every application where a prime mover or power source is coupled to an output device, a transmission device is required therebetween to convert the output motion of the prime mover to a form usable by the driven device. For some applications, a fixed, single speed transmission is suitable. However, for most applications, particularly for applications involving motor vehicles, multiple discrete transmission ratios are provided in order to enhance the efficiency of the prime mover while providing optimum torque or fuel economy over a wide range of speeds. However, the use of multiple discrete gear ratios in a transmission has several well known drawbacks, including a loss of power and efficiency while shifting between gear ratios. Furthermore, discretely variable transmissions, while more efficient than single speed transmissions, are still limited in their ability to efficiently couple a prime mover with a driven device.
For this reason, many continuously or infinitely variable transmissions have been designed in the past in order to overcome the disadvantages of discretely variable transmissions. These devices have taken various forms including belt driven transmissions, gear driven transmissions, and walking beams having variable fulcrums. While many continuously variable transmissions of the belt-type have been offered commercially in the past, such devices have had limited commercial success in the past, due partially to a loss of efficiency resulting from belt slippage, the cost, weight and space requirements of such tranmissions, and the slow responsiveness of such transmissions to changing conditions.
An example of a power transmission device of the variable fulcrum walking beam type is disclosed in U.S. Pat. No. 982,666, to Girin. Girin teaches a change speed gear having a driving and a driven shaft, a lever connected to the driving shaft and a clutch mechanism engaging the driven shaft and connected to the other end of the lever. A movable fulcrum is provided intermediate the two ends of the lever. The fulcrum is displaced to vary the ratio between the rotational speed of the drive shaft to the driven shaft. Girin, however, uses a complicated and space consuming series of cranks to transfer power to and from the lever. Furthermore, Girin nowhere provides for an automatic means controlling the position of the fulcrum. Additionally, the device in Girin is intended to permit selection of the output speed by movement of the fulcrum point, while permitting the motor to run at any predetermined speed. Thus, no effort is made in Girin to optimize fuel efficiency or torque. Girin nowhere suggests that a walking beam and movable fulcrum arrangement may be advantageously used to control output characteristics in a cooperative manner with a prime mover supplying a controllably varied output. Instead, the device is only used to directly control output speed independent of the functioning of the prime mover.
It has occurred to the Applicant in the present application that a variable fulcrum walking beam may be advantageously used to achieve improvements in fuel efficiency in fossil fuel combustion engines. This is particularly true if appropriate controls are provided to optimize the transmission ratio in response to conditions in the prime mover, and possibly in response to additional input supplied by other devices used in conjunction with the internal combustion engine and from the human operator of the internal combustion engine. Such a device would be particularly useful in a motor vehicle in order to improve the fuel efficiency of the internal combustion engine of the motor vehicle. However, in order to be satisfactory for use in a motor vehicle, such a device must be made in a compact, lightweight and inexpensive form and must be capable of smoothly and efficiently delivering power from an internal combustion engine to the wheels of a motor vehicle.
The need for a fuel efficient transmission for motor vehicles has increased recently as a result of the dramatic increase which has occurred in the cost of fuel, as well as the imminent shortage of fuel which is being predicted by many independent sources. Thus, an efficient and lightweight infinitely variable transmission is needed. Furthermore, as a result of the need to conserve fuel, the internal combustion engines in motor vehicles have become smaller and smaller and, accordingly, the output of internal combustion engines in typical vehicles has decreased. While various modifications to the internal combustion engine itself have been made to permit an increase in the amount of torque and power available from a particular engine, many of the vehicles still have undesirably sluggish performance as a result of the downsized engines. The dual problems of increased fuel prices and sluggish performance have resulted in a reversal of the previous trend away from manual transmissions to automatic transmissions.
Accordingly, it is highly desirable to provide an automatic infinintely variable transmission which provides sufficient torque to overcome the sluggishness problem of current motor vehicles using discrete automatic transmissions. What is also needed is a method and apparatus for directly controlling an infinitely or continuously variable transmission for a motor vehicle in response to vehicle and, possibly, operator inputs so as to optimize the operation of the internal combustion engine of the vehicle under varying conditions.
SUMMARY OF THE PRESENT INVENTION
The present invention provides an infinitely variable transmission overcoming many of the above described shortcomings of prior transmissions. Furthermore, the present invention provides a method and apparatus for controlling continuously variable transmissions in response to predetermined parameters of a prime mover, such as the manifold pressure of an internal combustion engine, to optimize fuel efficiency yet provide improved responsiveness of the driven device to sudden demands for increased output.
The infinitely variable transmission of the present invention includes a driving shaft having at least one cam mounted thereto and a driven shaft having at least one one-way clutch mounted thereto and a gear mounted to the one-way clutch. A lever having a movable fulcrum is provided between the driving and driven shafts and includes a cam follower at one end engaging the cam and a rack at the other end engaging the gear so as to deliver power from the driving shaft to the driven shaft. The position of the fulcrum is varied in order to change the transmission ratio.
In a preferred embodiment, the lever consists of a beam having an elongated portion and a pair of spaced apart flanges extending therefrom. The cam and a movable fulcrum block are each provided between the flanges. The movable fulcrum block is movable between a position in alignment with a pivoting point of the rack to positions intermediate the pivoting point and the driving shaft so as to vary the transmission ratio. Furthermore, in the preferred embodiment, a plurality of cams, one-way clutches, gears, levers, and racks are used. Preferably, each lever is provided with two racks, each of the two racks cooperating with one of a pair of gears mounted on oppositely oriented one-way clutches so that the lever will drive the driven shaft in each direction of oscillation.
The method and apparatus for controlling an infinitely variable transmission, according to the present invention, provides for varying the transmission ratio of an infinitely variable transmission in response to preselected parameters of an internal combustion operation, preferably the intake manifold pressure. Thus, the operator of the motor vehicle would control the fuel/air mixture delivered to the internal combustion engine in a conventional manner and the transmission would select an appropriate gear ratio in response to engine parameters to optimize either fuel efficiency or torque. In the preferred embodiment, the method and apparatus for controlling an infinitely variable transmission according to the present invention includes a cylinder and piston driven by pressure supplied, for example, by the oil pump, to displace the fulcrum. A valve is provided responsive to a vacuum gage measuring the intake manifold pressure, the valve regulating the supply of pressurized fluid to the cylinder. The valve may be mechanically linked to the vacuum gage. Alternatively, a microprocessor control may be provided between the vacuum gage and the valve so as to selectively permit reprogramming the control assembly to respond to other parameters of operation of the internal combustion engine or to various inputs supplied by the driver.
It is, accordingly, a primary object of the present invention to provide an infinitely variable transmission for efficiently transferring power from a prime mover to a driven device. This is accomplished by the present invention by providing a compact and lightweight infinitely variable transmission which positively links a driving shaft with a driven shaft. This object is further achieved by providing an efficient and effective automatic control apparatus for controlling the transmission ratio. It is further achieved by providing a variable fulcrum walking beam transmission having the walking beam, or lever, disposed generally between the driving shaft and the driven shaft, rather than displaced therefrom. The efficiency of this device is enhanced by the use of multiple levers and multiple racks per lever and by varying the fulcrum location in response to intake manifold pressure.
Another object of the present invention is to provide a method and apparatus for controlling any infinitely variable transmission and, particularly, for controlling the novel infinitely variable transmission disclosed herein using a variable fulcrum walking beam.
Still another object of the present invention is to provide a control apparatus for an infinitely variable transmission which permits reprogramming of the response of the movable fulcrum to exhaust manifold pressure in response to other preselected parameters, including driver input. This object is accomplished by the use of a microprocessor control between the intake manifold vacuum gage and the apparatus for moving the fulcrum point.
These and many other objects, features, and advantages of the present invention will become apparent to those skilled in the art when the following detailed description of the preferred embodiment is read in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings appended hereto:
FIG. 1 is a perspective view of an example of structure of an infinitely variable transmission according to the present invention;
FIG. 2 is a top plan view thereof illustrating the lever pivot subassembly in a neutral position in solid line and in a power transmitting position in phantom line;
FIG. 3 is a sectional view taked along lines 3--3 of FIG. 2;
FIG. 4 is a side elevational view thereof;
FIGS. 5 and 6 are schematic side views similar to portions of FIG. 4 but illustrating the infinitely variable transmission thereof with the fulcrum point in the neutral position and a power transmitting position, respectively;
FIG. 7 is a partial top view similar to FIG. 2 but illustrating a modified infinitely variable transmission according to the present invention;
FIG. 8 is a side view of the modified infinitely variable transmission of FIG. 7;
FIG. 9 is a schematic view of an electromagnetic servo mechanism for controlling an infinitely variable transmission according to the present invention;
FIG. 10 is a schematic view of a direct acting governor for controlling an infinitely variable transmission according to the present invention; and
FIG. 11 is a graphical representation illustrating theoretical performance predicted for an infinitely variable transmission constructed according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there are illustrated examples of structure for an infinitely variable transmission 10, FIGS. 1 through 6, or 10', FIGS. 7 and 8, and examples of structure for a control apparatus 12, FIG. 9, and 12', FIG. 10. It will be appreciated by those skilled in the art that many modifications and variations may be made from the structure illustrated therein without departing from the spirit of the present invention.
Referring particularly to FIGS. 1 through 6, a single acting infinitely variable transmission 10 is illustrated. A driving shaft 14 is provided with rotary motion by a prime mover, such as an internal combustion engine. The driving shaft 14 may be, for example, the crankshaft of a motor vehicle or may be coupled thereto by appropriate means. A plurality of cams 16 are mounted to the driving shaft 14 and are rotated thereby. In the preferred embodiment, the cams 16 consist of eccentrically mounted discs. A driven shaft 18 is provided parallel to the driving shaft 14 and spaced away therefrom. A plurality of one-way clutches 20, FIGS. 1 and 2, are mounted to the driven shaft 18. A gear 22 is mounted to each of the one-way clutches 20 such as to permit the gear 22 to drive the driven shaft 18 in one angular direction.
An intermediate shaft 24 is disposed parallel to and between the driving shaft 14 and the driven shaft 18. A plurality of racks 26 are pivotally mounted to the intermediate shaft 24 and extend therefrom into engagement with the gear 22. In the example of structure illustrated in FIGS. 1 through 6, the racks 26 each consist of a segment of a circular gear. Each rack 26 also has of an arm 28 extending radially outwardly from the intermediate shaft 24 opposite the teeth 30 of the rack.
A walking beam or lever 32 is pivotally mounted to the arm 28 of each of the racks 26 by means of a pivot pin assembly 33, shown in FIGS. 4 through 6. As will be appreciated by those skilled in the art, the pivot pin assembly 33 preferably consists of a pin 34 movably disposed in a slot 35, as shown in FIG. 5, to faciliate the smooth pivoting motion of the rack 26 and the lever 32 about different pivot points. Furthermore, an elongated sliding member, not illustrated, may be provided between the pin 34 and the slot 35 to provide an increased surface area of contact therebetween, the sliding member being slidingly engaged with the slot while the pin is pivotally mounted to the sliding member.
In the single acting infinitely variable transmission 10 illustrated, the lever 32 consists of an elongated member having generally the shape of an "I" beam. That is, each lever 32 has an elongated portion 38 and a pair of parallel flanges 40 and 42 extending therefrom, FIG. 4. Cam follower means 36 are provided at the end of the lever 32 opposite the pivot pin 34. Each cam follower means engages one of the cams 16. The cam follower means 36 illustrated consists of a pair of oppositely disposed plates 44 and 46, each mounted by appropriate means to one of the flanges 40 and 42 so as to surround the cam 16. If desired, the cam follower means may be formed integrally with the lever and may consist of extensions of the flanges 40 and 42. Alternately, the plates 44 and 46 may be formed from a single U-shaped stamping, not illustrated, fitted over the lever 32 and closing the end 43 thereof.
A lever pivot subassembly 48 is provided between the driving shaft 14 and the driven shaft 18. In the example illustrated, the lever pivot subassembly 48 consists of a plurality of blocks 50 each slidingly disposed between the flanges 40 and 42 of one of the levers 32. As shown in FIG. 3, two blocks 50a and 50b may be used on opposite sides of the elongated portion 38 of each lever 32. Each block 50, or 50a and 50b, is pivotally mounted to a standard 52 by means of a pin 54. Each of the pins 54 are axially aligned so as to cooperate together to define a pivot axis for the lever 32. A bracket 51 secures the standards 52 and the levers 32 together such as to permit sliding movement therebetween. Each of the standards 52 extends away from the plane defined by the driving shaft 14 and the driven shaft 18 and are rigidly interconnected by means of a link 56, shown in FIGS. 1, 2 and 4. A guide subassembly 58 is provided to permit selective displacement of the lever pivot subassembly 48 towards and away from the driving shaft 14.
From the above description, the operation of the single acting infinitely variable transmission will now be apparent to those skilled in the art. The pins 54 define a pivoting axis for each of the levers 32. The levers 32 are driven to pivot about that axis by the driving shaft 14 due to the cooperation of the cam follower means 36 with the cam 16. Preferably, each of the individual cams 16 are oriented at a different angular position relative to the driving shaft 14 so as to vary the phase angle between the various levers 32. The oscillatory pivoting motion of the lever 32 about the pins 54 causes a pivoting motion of the pivot pin 34 interconnecting the lever with the rack 26, thereby causing a similar oscillatory motion of the rack 26. The oscillatory motion of the rack 26 drives the driven shaft 18 to rotate in a predetermined angular direction due to the one-way clutch 20. Together, the levers 32 drive the driven shaft to rotate at an even speed, due to the differing phase angles of the cams 16. Accordingly, power may be taken off the driven shaft 18, as desired. A flywheel 60 may optionally be provided to further smooth out high frequency oscillations in the angular rotational speed of the driven shaft 18.
The lever pivot subassembly 48 may be selectively displaced in a direction parallel to the plane defined by the driving shaft 14 and the driven shaft 18, as indicated by the arrow 62 in FIG. 4, to vary the fulcrum point defined by the pin 54. Varying the fulcrum point will vary the speed ratio between the driving shaft 14 and the driven shaft 18. Thus, if the infinitely variable transmission 10 is to be used as a speed control device taking power off a motor running at full throttle, for example, a manual speed control may be obtained by manually displacing the lever pivot subassembly 48.
As best shown in FIGS. 3 and 5, the levers 32 and the lever pivot subassembly 48 may be designed so as to permit displacement of the pins 54 to a point where they become aligned with the pivot pins 34. In this neutral position, no power is transferred from the driving shaft 14 to the driven shaft 18. Thus, an idling condition may be obtained without disengaging the racks 26 from the gears 22. The transition, therefore, between a driving condition, as illustrated in FIG. 6, and an idling condition, as illustrated in FIG. 5, requires no clutching operation.
A double acting infinitely variable transmission 10' is illustrated in FIGS. 7 and 8. The double acting infinitely variable transmission is identical to the single acting infinitely variable transmission except as described below.
The double acting infinitely variable transmission 10' is provided with two one-way clutches 20a' and 20b' for each lever 32. The one-way clutches 20a' and 20b', associated with a single lever 32, are oppositely oriented so as to drive the driven shaft 18 in opposite directions. Each of the one-way clutches 20a' and 20b' is coupled to a gear 22a' and 22b', respectively. Each of the racks 26' is provided with a first set of teeth 30a' disposed between the driven shaft 18 and intermediate shaft 24 and engaging one of the gears 22a'. Each of the racks 26' is also provided with a second set of teeth 30b disposed on the opposite side of the driven shaft 18 from the intermediate shaft 24 and engaging the other gear 22b'. Thus, as a result of the oppositely oriented one-way clutches 20a' and 20b', the rack 26' will drive the driven shaft 18 through one of the gears 22a' in one direction of motion and will drive the driven shaft 18 through the other gear 22b' in the other direction of motion. Thus, the double acting infinitely variable transmission 10' further reduces the high frequency oscillation which occurs in the rotational speed of the driven shaft 18.
Referring now to FIG. 9, a control apparatus 12 for an infinitely variable transmission according to the present invention is illustrated. The control apparatus 12 includes a cylinder 64 having a piston 66 disposed therein. The piston is interconnected by means of a rod 68 with the lever subassembly 48 such that displacement of the piston 66 results in similar displacement of the fulcrum point for each of the levers 32. A chamber 76 on one side of the piston 66 is pressurized to a pressure P1 by means of a supply line 70 interconnected with a pump 72. The pump 72 may be an existing pump, such as the oil pump of a motor vehicle, supplying pressurized fluid to other components of the motor vehicle. A normally opened valve 74 is provided along the supply line 70. An outlet line 78 vents the chamber 76 and is provided with a normally closed valve 80.
A chamber 82 on the side of the piston opposite the chamber 76 is similarly pressurized to a pressure P2 provided with a supply line 84 leading to the pump 72 and with a normally closed valve 86. Another outlet line 88 vents the chamber 82 through a normally closed valve 90.
A vacuum gage 92 measures the intake manifold pressure and sends one or more signals corresponding thereto to a microprocessor 94 which selectively directs the opening and closing of the valves 74, 80, 86 and 90 so as to regulate the pressures P1 and P2. The pressure differential between the chambers 76 and 82 thereby causes a preselected displacement of the piston, which drives the lever pivot subassembly 48 to move. As described above, the position of the lever pivot subassembly 48 determines the location of the fulcrum point for the levers 32 and, thus, the microprocessor 94 controls the transmission ratio.
It will be readily appreciated by those skilled in the art that the microprocessors 94 may receive and respond to various types of signals. For example, and as illustrated schematically in FIG. 9, the microprocessor may respond to two different signals, one corresponding to exhaust manifold pressure in excess of a first predetermined amount and the other corresponding to exhaust manifold pressure being less than a second predetermined amount, the second predetermined amount being smaller than the first predetermined amount. Alternatively, the microprocessor could respond to the actual value of the intake manifold pressure, converted to digital form by any convenient method, rather than merely the two above described discrete values. Additionally, the microprocessor could be designed so as to respond to additional input variables, such as oil temperature, air temperature, the length of time the vehicle has been running, and specific signals from the driver.
Referring now to FIG. 10, an alternate control apparatus 12' is illustrated. The control apparatus 12' is a direct acting governor having a cylinder 64' and piston 66' responsive to the differential in force between a pressure chamber 76' on one side of the piston 66' and a spring 96 on the other side of the piston. The pressure chamber 76' is pressurized by a line 98 leading from the pump 72'. A bleed line 100 extends from the line 98 to vent pressure in the line 98 through a normally open valve 104. The valve 104 is selectively closed in response to a vacuum pressure gage 92' which detects a drop in the intake manifold vacuum pressure beyond a predetermined amount, such as one inch of mercury (1 in. Hg).
Thus, when the intake manifold pressure decreases by the predetermined amount, the valve 104 closes such as to increase the pressure in the chamber 76' and, accordingly, to displace the piston 66' to adjust the fulcrum point of the lever 32.
FIG. 11 illustrates the predicted performance of an infinitely variable transmission 10 or 10' according to the present invention. A curve 114 represents the road load horsepower required for a typical motor vehicle while curves 116 and 118 represent predicted fuel consumption of a vehicle based on the road load horsepower and the specific fuel chosen.
It will be appreciated by those skilled in the art that many modifications and variations may be made from the structures described above within the spirit of the present invention. For example, the oscillatory motion of the levers 32 may be provided by means other than the driving shaft 14 and the cam 16. More particularly, the levers 32 may each be interconnected with one of the cylinders of an internal combustion engine, for example, through a suitable crank arrangement. The transmission may, therefore, be provided within the engine block of the vehicle and the crankshaft and, if needed, could be substantially reduced in weight and size. A second similar transmission may be provided to drive a second output shaft at a substantially constant speed independent of engine and vehicle speeds, the second output shaft being used to drive accessories.
Similarly, more or fewer levers 32 may be used, depending on the need. For example, the use of three levers may be required for a single acting infinitely variable transmission, each having a phase angle of one hundred and twenty degrees (120°) away from the other levers. On the other hand, in a double acting infinitely variable transmission, two levers 32 having phase angles differing by ninety degrees (90°) may be sufficient since each lever works in both directions.
It will be further appreciated by those skilled in the art that the present invention may be combined with existing fuel economy and pollution regulation apparatus to further enhance the function of a motor vehicle. For example, if a microprocessor 94 is used to control the transmission ratio, the same microprocessor may be used to measure a variety of motor vehicle parameters and regulate a variety of motor vehicle functions so as to optimize each of the controllable parameters. For example, the microprocessor could receive information relating to various temperature and pressure levels as well as driver inputs and control the selection of the transmission ratio, fuel metering, engine timing and cooling systems. It will further be appreciated by those skilled in the art that vehicle accessories may be driven by the crankshaft or the transmission output shaft, depending on their speed, through an overrunning clutch mechanism. The transmission of the present invention may be used on a single shaft gas turbine engine. In this event, the control of the pivot point may be regulated in response to the turbine temperature and turbine speed and no power turbine is required. Alternatively, the transmission of the present invention may be used in conjunction with a flywheel drive assembly. In this event, the transmission ratio will be controlled in response to the current speed of the flywheel to maintain constant vehicle speed.
The above description and the appended drawings are offered by way of example and illustrate the best mode contemplated by the inventor for carrying out the present invention at the time of filing. Many additional modifications and variations will be apparent to those skilled in the art after having the benefit of reading the disclosure of the present invention. These modifications and variations are included within the intended scope of the claims appended hereto.
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An infinitely variable transmission, method of controlling an infinitely variable transmission, and an apparatus utilizing the method. The infinitely variable transmission provides a lever or walking beam having a variable fulcrum point. Power is supplied to one end of the lever, for example by cams on a driving shaft. Power is taken from the other end of the lever by use of a rack cooperating with a gear mounted to a one-way clutch on a driven shaft. The method controlling the infinitely variable transmission includes measuring the intake manifold pressure of the internal combustion engine driving the transmission and displacing the fulcrum point of the lever in response to the measurement obtained to vary the transmission ratio. The apparatus disclosed for accomplishing this method includes a cylinder and piston assembly, the piston being interconnected with the movable fulcrum, a vacuum gage measuring intake manifold pressure and a source of pressurized fluid, and a valve selectively operable in response to the vacuum gage to pressurize the cylinder on one side of the piston.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an implantable medical device that delivers sufficient electrical energy to cardiac tissue to terminate (cardiovert) tachycardias and thus restore normal sinus rhythm. An improved DC-DC converter control circuit provides the cardioversion energy.
2. Description of the Prior Art
Implantable medical devices for the therapeutic stimulation of the heart are well known in the art from U.S. Pat. No. 3,478,746 issued to Wilson Greatbatch, which discloses a demand pacemaker. The demand pacemaker delivers electrical energy (5-25 microjoules) to the heart to initiate the depolarization of cardiac tissue. This stimulating regime is used to treat heart block by providing electrical stimulation in the absence of naturally occurring spontaneous cardiac depolarizations.
Another form of implantable medical device for the therapeutic stimulation of the heart is the automatic implantable defibrillator (AID) described in U.S. Pat. Nos. Re. 27,652 and Re. 27,757 to Mirowski, et al and the later U.S. Pat. No. 4,030,509 to Heilman et al. These AID devices deliver energy (40 joules) to the heart to interrupt ventricular fibrillation of the heart. In operation, the AID device detects the ventricular fibrillation and delivers a nonsynchronous high-voltage pulse to the heart through widely spaced electrodes located outside of the heart, thus mimicking transthoracic defibrillation. The Heilman et al technique requires both a limited thoracotomy to implant an electrode near the apical tip of the heart and a pervenous electrode system located in the superior vena cava of the heart. In practice, these devices have received limited usage due to the complexity of their implantation, their relatively large size and short operating life, and to the small numbers of patients who might benefit from it.
Another example of a prior art implantable cardioverter includes the device taught by U.S. patent application Ser. No. 58,847 to Engle, et al. This device detects the onset of tachyarrhythmia and includes means to monitor or detect the progression of the tachyarrhythmia so that progressively greater energy levels may be applied to the heart to interrupt the arrhythmia.
A further example is that of an external synchronized cardioverter, described in Clinical Application of Cardioversion in Cardiovascular Clinics, 1970,2, pp. 239-260 by Douglas P. Zipes. This external device is described in synchronism with ventricular depolarization to ensure that the cardioverting energy is not delivered during the vulnerable T-wave portion of the cardiac cycle.
Still another example of a prior art implantable cardioverter includes the device disclosed in U.S. Pat. No. 4,384,585 to Douglas P. Zipes. This device includes circuitry to detect the intrinsic depolarizations of cardiac tissue and includes pulse generator circuitry to deliver moderate energy level stimuli (in the range of 0.1-10 joule) to the heart in synchrony with the detected cardiac activity.
The functional objective of this stimulating regime is to depolarize areas of the myocardium involved in the genesis and maintenance of re-entrant or automatic tachyarrhythmias at lower energy levels and with greater safety than is possible with nonsynchronous cardioversion. Nonsynchronous cardioversion always incurs the risk of precipitating ventricular fibrillation and sudden death. Synchronous cardioversion delivers the shock at a time when the bulk of cardiac tissue is already depolarized and is in a refractory state.
It is expected that the safety inherent in the use of lower energy levels, the reduced trauma to the myocardium, and the smaller size of the implanted device will expand the indications for use for this device beyond the patient base of prior art automatic implantable defibrillators. Since many episodes of ventricular fibrillation are preceded by ventricular (and in some cases, supraventricular) tachycardias, prompt termination of the tachycardia may prevent ventricular fibrillation.
Typically, the electrical energy to power an implantable cardiac pacemaker is supplied by a low voltage, low current, long-lived power source, such as a lithium iodine pacemaker battery of the types manufactured by Wilson Greatbatch Ltd. and Medtronic, Inc. While the energy density of these power sources is relatively high, they are not designed to be rapidly discharged at high current drains, as would be necessary to directly cardiovert the heart with cardioversion energies in the range of 0.1-10 joules. Higher energy density battery systems are known which can be more rapidly discharged, such as lithium thionyl chloride power sources. However, none of the available implantable, hermetically sealed power sources have the capacity to directly provide the cardioversion energy necessary to deliver an impulse of the aforesaid magnitude to the heart following the onset of tachyarrhythmia.
Generally speaking, it is necessary to employ a DC--DC converter to convert electrical energy from a low voltage, low current power supply to a high voltage energy level stored in a high energy storage capacitor. A typical form of DC--DC converter is commonly referred to as a flyback converter which employs a transformer having a primary winding in series with the primary power supply and a secondary winding in series with the high energy capacitor. An interrupting circuit or switch is placed in series with the primary coil and battery. Charging of the high energy capacitor is accomplished by inducing a voltage in the primary winding of the transformer creating a magnetic field in the secondary winding. When the current in the primary winding is interrupted, the collapsing field develops a current in the secondary winding which is applied to the high energy capacitor to charge it. The repeated interruption of the supply current charges the high energy capacitor to a desired level over time.
SUMMARY OF THE INVENTION
The implantable synchronous intracardiac cardioverter of the present invention employs sensing means responsive to cardiac depolarizations for producing a sense signal indicative of naturally occurring cardiac activity, such as ventricular R-waves; detection means responsive to the sensing means for detecting cardiac tachyarrhythmias, such as ventricular tachyarrhythmia, for producing a trigger signal; pulse generator means responsive to the detection of a tachyarrhythmia for delivering a cardioverting pulse to cardiac tissue in response thereto; and voltage conversion means for providing a high energy power supply to said pulse generator means, said voltage conversion means including regulating circuit means for controlling the voltage converter.
Additional circuitry may be included to provide a demand-pacing function in addition to the previous described carioverting output. It is also anticipated that the amount of energy delivered can be controlled (programmed) by an external unit to reduce the joules delivered or increase the amount to a value that will be capable of terminating ventricular fibrillation. Finally, the device may be programmed to deliver the energy automatically after sensing particular parameters of a tachycardia or it can be programmed to deliver the energy only when an external magnet is held in place over the pulse generator.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will become apparent from the following description of the invention and the drawings wherein:
FIG. 1 is a block diagram showing the functional organization of the synchronous intracardiac cardioverter;
FIGS. 2A and 2B are alternative timing diagrams illustrating the tachycardia detection criteria;
FIG. 3 is a timing diagram of the delivery of a high energy cardioversion pulse to the heart; and
FIG. 4 is a circuit diagram of the DC--DC converter of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As described hereinbefore, implantable cardioverters designed to treat ventricular tachyarrhythmias are generally known as described in the aforementioned U.S. Pat. No. 4,384,585. The present invention is embodied in a form of an implantable cardioversion system including a pulse generator and a lead, preferably a transvenous lead. The pulse generator preferably includes the components necessary to accomplish at least ventricular demand pacing at ordinary pacing energies and rates and circuitry for providing the cardioversion function. The lead preferably includes ring and tip electrodes located near one another in the distal portion of the lead adapted to be placed in the apex of the right ventricle and large surface area ring electrodes located more proximally along the lead body to be positioned in or near the superior vena cava. Such a lead is disclosed in U.S. Pat. No. 4,355,646. Very generally speaking, demand pacing is accomplished through the ventricular ring and tip electrodes, and cardioversion is accomplished between the ring and tip electrodes as a single indifferent or cathode electrode, and the superior vena cava electrode acting as the anode electrode.
The sense amplifier is connected between the ring and tip electrodes and, with appropriate logic, is capable of detecting normal R-waves to inhibit the operation of the pacing pulse generator and with appropriate detection logic, is capable of detecting abnormally high rate R-waves and operating the high energy cardioverter.
Referring now to FIG. 1, there is shown a block diagram similar to FIG. 2 of U.S. Pat. No. 4,384,585 in which the present invention may be practiced. In FIG. 1, the patient's heart 10 is coupled to the synchronous intracardiac cardioverter 12 through an appropriate lead 14 of the type described above and lead interface 16. The lead interface 16 includes circuitry to isolate the QRS detector 18 from the high voltage present during the delivery of a cardioverting pulse. Very generally, the ring and tip electrodes are coupled together by lead interface 16 during delivery of a cardioverting pulse.
Depolarization signals from the heart are communicated to the sensing amplifier or QRS detector 18 where they are detected. Such sense amplifiers are known in the art from U.S. Pat. No. 4,379,459 which is incorporated herein by reference. A subsequent tachyarrhythmia detector section 20 is coupled to the QRS detector through connection 19 to detect tachyarrhythmia based upon the electrogram information producing a tachy detect signal.
The synchrony detecter 24 receives the tachy detect signal through connection 26. The output 27 of the synchrony detector is communicated to an appropriate logic section 31 which controls the cardioversion pulse generator circuitry 32 and triggers the delivery of the cardioverting pulse in response to the detected tachyarrhythmia. The synchrony detector 24 insures that the cardioverting pulse is delivered to the cardiac tissue concurrent with a detected ventricular depolarization of cardiac tissue. Circuit 32 includes a high energy converter 36 which converts low battery voltage into current and charges a capacitor in the high energy cardioversion energy storage circuit 38.
In operation, the electrogram information from the heart 10 is processed by the device which detects depolarizations of cardiac tissue and produces a sense signal indicative of this fact. This sense amplifier output is processed by a tachyarrhythmia detector 20 to determine the presence or absence of a tachyarrhythmia in a manner described hereafter.
If a tachyarrhythmia is detected, the logic section 30 will initiate a discharge of the energy storage section 38 to produce a cardioverting output. The synchrony detector 24 will insure that the energy is delivered to the heart 10 concurrently with a detected ventricular depolarization. The synchrony detector 24 may comprise combinatorial logic to activate the cardioverting pulse generator circuitry 32 only when a tachy detect signal has been produced by the tachyarrhythmia detection circuitry. After the delivery of the cardioverting energy, the device will monitor the heart activity to determine if the arrhythmia has been terminated. If the arrhythmia is continuing, then additional cardioverting pulses will be delivered to the heart. These may be of the same or greater energy.
The synchronous intracardiac cardioverter is shown combined with demand pacing energy pulse generator circuitry 34 coupled to the lead interface 16. This pulse generator comprises a low energy converter 37 for charging the pacing energy storage circuitry 39 from the battery 35. In operation, logic 31 receives the signal from the QRS detector 18 and resets an escape interval timing system. If no cardiac depolarization is detected within the escape interval, a pacing pulse will be delivered to the heart. The integrated demand pacer with the synchronous cardioverter permits the device to initiate a cardiac depolarization if a previously delivered cardioverting pulse has prevented or slowed the re-establishment of a normal sinus rhythm.
The power source 35 preferably consists of two lithium thionyl chloride cells, connected in series which produce an open circuit voltage of 7.33 volts to supply the cardioversion power circuit 32 and the backup pacing circuit 34 and one lithium iodine cell to provide the power for the remaining sensing and control circuits.
In addition, the preferred embodiment would be programmable and possess telemetry as shown, for example, in U.S. Pat. Nos. 4,401,120 and 4,324,382, respectively, each incorporated herein by reference. Among the programmable characteristics would be the mode (VOO, VVI and VVI with cardioversion), pacing rate, sensitivity, pulse width, tachy trigger interval, number of intervals to trigger, detection of interval change threshold, cardioversion pulse energy, patient therapy record and inhibit function. The receiving antenna 43, receiver logic 44 and decode logic 45 operate to effect programming of memory registers within program memory and logic 31 in the manner described in U.S. Pat. No. 4,401,120.
Among the telemetry functions, digital data, such as the device model identification, programmed parameter settings, cardioverter battery status, programming confirmation, the electrogram from the bipolar/ventricular lead, the marker channel exhibiting the amplifier sense after refractory period, the amplifier sense within tachy trigger interval, the ventricular pace pulse and the cardioversion pulse would all be transmitted out on command. The marker channel telemetry would be similar to that shown in U.S. Pat. No. 4,374,382 and is depicted as including market channel logic 40, telemetry logic 41 and transmitting antenna 42. (In practice, the transmitting antenna 42 and receiving antenna 43 may be a single antenna.) The pacing components, with the telemetry and marker channel features, preferably employ circuits disclosed in the aforementioned prior Medtronic patents and used in the prior Medtronic Spectrax-SXT ventricular pulse generator. In addition, it is contemplated that the DDD pacing components described in U.S. Pat. No. 4,390,020 could be incorporated into the cardioversion system to effect atrial and/or ventricular multimode pacing and/or cardioversion.
The additional programmable features of the preferred embodiment of the present invention, that differ from the prior patents and device mentioned above, comprises the additional cardioversion operating mode and the additional tachyarrhythmia recognition and cardioversion pulse energy parameters. These modes and parameters are stored in program memory and logic circuit 31 and directed to the tachy detector 20, and the cardioversion circuit 32.
The cardioversion output circuit 32 can only be activated when a tachycardia has been detected. Tachycardia recognition can be based on a sudden increase in heart rate combined with high rate or on high rate alone. The first method is called "the acceleration plus interval mode", and the second is called "interval mode". The "tachy trigger interval" (TTI) is an interval programmed into the pulse generator which recognizes sensed intervals between consecutive R-waves as indicative of a tachycardia if the sense intervals are shorter than this programmed tachy trigger interval. The "number of intervals to trigger" (NIT) is defined as that number of consecutive intervals shorter than the tachy trigger interval which will initiate a cardioversion. The "interval change threshold" (ICT) is defined as the number of milliseconds by which an interval has to be shorter than its predecessor in order to activate the tachy trigger interval and number of intervals to trigger criteria for tachycardia recognition. In order to detect such changes, the pulse generator continuously measures the difference between the last and second to last interval. If the interval change threshold is programmed equal to zero, the tachycardia recognition depends on the tachy trigger interval and number of intervals to trigger alone. Each of these factors, the TTI, NIT and ICT are programmable and are stored in memory and logic circuit 31.
In the acceleration plus interval mode, tachycardia is recognized if the interval change exceeds the interval change threshold while the succeeding intervals are also shorter than the selected tachy trigger interval for the selected number of consecutive intervals to trigger. In interval mode, tachycardia is recognized if the detected intervals are shorter than the selected tachy trigger interval for the selected consecutive number of intervals to trigger.
Thus the tachy detector 20 comprises a logic circuit having counters for timing out the intervals between the successive R-waves and comparing them to the programmed tachy trigger interval, interval change threshold, and number of intervals to trigger according to the acceleration and interval mode or the interval mode alone.
FIG. 2A depicts the timing of a sequence of R-waves where the tachy trigger interval is selected to be 400 milliseconds, the number of consecutive intervals to trigger equals 4 and the interval change threshold is programmed to zero. Thus, very simply, if four consecutive R-waves are sensed, each having an R--R interval less than 400 milliseconds, the tachyarrhythmia detection criteria are satisfied and a tachy detected signal is applied through logic 31 to the energy converter 36.
FIG. 2B depicts the acceleration plus interval mode tachyarrhythmia detection operation wherein the interval change threshold is programmed to 100 milliseconds. Thus, if the sensed R--R interval decreases by more than 100 milliseconds and the subsequent four R--R intervals are less than 400 milliseconds, the tachy detection criteria are satisfied and a tachy detected signal is again applied by logic 31 to the energy converter 36.
When the selected tachycardia criteria has been fulfilled, the charging cycle for the cardioversion output stage 32 is initiated and controlled by the high energy charging circuit of FIG. 4.
FIG. 3 depicts a timing sequence of the detection and delivery of a cardioversion pulse in synchrony with a sensed R-wave. The refractory intervals and the cardioversion sense period are depicted as they occur following the delivery of a cardioversion impulse.
After charging to the programmed energy level, the cardioversion sense period is initiated during which a cardioversion pulse will be delivered in synchrony with a detected depolarization as described more specifically in U.S. Pat. No. 4,384,585. If sensing does not occur within the cardioversion sense period (1,000 milliseconds) following completion of capacitor charge period, the cardioversion pulse is aborted and the device reverts to VVI pacing. The VVI mode and tachycardia detection circuitry are also activated for 150 milliseconds after delivery of a cardioversion pulse. The amplifier refractory period will be 195 milliseconds in VVI mode and tachycardia detection, but 320 milliseconds after the charge period because of the switch on time. If an R-wave follows within the 320 milliseconds refractory period after charge completion, refractory is extended an additional 200 milliseconds. The cardioversion pulse is delivered 7.8 milliseconds delayed on the next sensed event still within the cardioversion sense period. If cardioversion remains unsuccessful after five attempts, the cardioversion will remain inactive until one of the tachy detection criteria is not met or a back up pacing pulse is delivered.
Referring our attention now to the charging circuit 34 of FIG. 4, the two series connected lithium thionyl chloride batteries 50 and 52 are shown connected to the primary coil 54 of transformer 56 and to the power FET transistor switch 60. The secondary coil 58 is connected through diode 62 to the cardioversion energy storage capacitor 64. Very generally, the flyback converter works as follows: When switch 60 is closed, current I p passing through the primary winding 54 increases linearly as a function of the formula V=L p dI/dt. When FET 60 is opened, the flux in the core of the transformer 56 cannot change instantaneously so a complimentary current I s which is proportional to the number of windings of the primary and secondary coils 54 and 58 respectively starts to flow in the secondary winding 58 according to the formula (N P /N S )I p . Simultaneously, voltage in the secondary winding is developed according to the function V s =L s dI s /dt. The cardioversion energy storage capacitor 64 is charged thereby to the programmed voltage.
To simplify the drawings, optional connections have been omitted from FIG. 4 which would be included to correct the power source 50, 52 and the oscillator 66 to the circuit 32 upon command of the program memory and logic 31. Such switching circuits could be at the output of oscillator 66 and in the line between capacitor 55 and resistor 132 in FIG. 4. In addition, the circuitry for sensing the voltage on the capacitor 64, comparing it to the programmed value and disconnecting the power source means 50, 52 and oscillator 66 is not shown. In general, the voltage on capacitor 64 is reflected back through the transformer 56 and can be detected by comparison circuits coupled to the input winding 54 and the program memory and logic 31 to disconnect the power source 50, 52 and oscillator 66.
Each time the power FET 60 is switched into conduction, the current in the primary winding 54 starts to increase according to the preceding formula. At the moment that the power FET 60 is switched off, the field of the transformer 56 collapses and the secondary current starts to charge the capacitor 64. If the power FET 60 is switched on again before the secondary current has decreased to zero, the primary current starts to increase from a certain value (referred to as the pickup current) which is determined by the secondary current and the winding ratio. If this happens for several consecutive cycles, the primary current may go beyond the saturation current of the transformer 56. To avoid this, current through the power FET is monitored by sensing is drain voltage (the on resistance of power FET 60 is relatively constant) and power FET 60 is switched off when the current reaches a certain value. In order to suppress interference from this circuit, FET 60 is switched with a constant frequency and a variable duty cycle. The converter is driven at a frequency of 32 kz developed by oscillator 66, powered by the lithium iodine battery, which is driven by the crystal 68 and provides the basic timing clock for all the pulse generator timing and logic circuits. The power FET 60 is driven on and off by the the flip-flop 70 which is set at the leading edge of the clock pulses developed by the oscillator 66 and reset by an output signal from NOR gate 94. Flip-flop 70 has a pair of output terminals Q 1 , Q 2 which go high (ungrounded) when it is set and complementary outputs Q 1 , Q 2 which go high when it is reset. The low state of the outputs Q 1 , Q 2 , Q 1 , Q 2 may be at ground. Power FET 60 is driven into conduction each time flip-flop 70 is set through the operation of the voltage doubler circuit 72. The on time of power FET 60 is governed by the time interval between the setting and resetting of flip-flop 70 which in turn is governed either by the current I p flowing through the primary winding 54 or as a function of a time limit circuit, which contains further circuitry to vary the time limit with battery impedance (represented schematically by resistor 53).
The voltage doubler circuit 72 comprises a pair of driving transistors 74 and 76, a diode 78, capacitor 80 and resistors 82, 84, 86. Assuming that flip-flop 70 is set and FET 60 is conducting, the resetting of flip-flop 70 causes the gate voltage of FET 60 to discharge through output Q 2 . Capacitor 80 charges to battery voltage through diode 78 and output Q 1 . When flip-flop 70 is again set, the battery voltage and the capacitor 80 voltage are additively applied to the emitter of transistor 76. Transistor 76 is biased to conduct by resistors 82 and 84, and when it switches on (when flip-flop 70 is set) 2 V Batt is applied to the gate of FET 60. FET 60 is switched on until the flip-flop 70 is again reset in the manner described hereinafter.
If primary current would be the only criteria for switching off power FET 60, then at low battery voltage (high internal impedance 53) the current would be so depleted that the saturation current level would not be reached before the next clock pulse. If that were to occur, power FET 60 would never be switched off and the flyback converter would cease functioning.
To avoid this problem, the on-time or duty cycle of power FET 60 is determined by an OR function of a time limit and a current limit. The current limit is determined by the first comparator 90 which compares the voltage drop across the source and drain of power FET 60 against a first voltage V refl . The signal is applied through resistor 92 to one input of the comparator 90, and whenever that signal exceeds reference V refl , the comparator 90 provides an output signal to one input of the OR gate 94. The signal applied to the OR gate 94 is passed through the reset input of flip-flop 70 which switches the Q 1 and Q 2 outputs low and switches the transistors 74 and 76 off in the manner previously described. During the time that the flip-flop 70 is reset, the Q 2 output of flip-flop 70 is high and the transistor 96 is rendered conductive. Thus, when the FET 60 drain voltage equals V refl , comparator 90 resets flip-flop 70 via OR gate 94 switching power FET 60 off, and the positive input of comparator 90 is grounded. When the flip-flop 70 is next set by a clock pulse, the power FET 60 is switched on and the positive input of comparator 90 is ungrounded.
Thus, by the means previously described, the duty cycle of the power FET 60 is current limited to efficiently operate the flyback converter as long as the batteries 50 and 52 provide a sufficiently high voltage and current. However, as current is drained from the batteries 50 and 52 to periodically recharge the high energy capacitor 64, the internal impedance 53 of the batteries will increase resulting in a lower available current. As the current lowers, the duty cycle of power FET 60 will tend to increase. The danger that the regulating circuitry 90-96 will be unable to reset the flip-flop 70 increases with time. The remaining circuitry of FIG. 4 provides a backup time limit circuit to the duty cycle while the batteries 50 and 52 exhibit normal voltage and current output and further compensating means for altering the time limit as the batteries 50 and 52 exhibit end-of-life voltage and impedance changes.
The time limit is determined by a one-shot circuit, comprising resistor 102, capacitor 104, comparator 106, flip-flop 108 and transistor 110. The time limit may be varied by altering the value of resistor 102 at the time of manufacture or through programming. The time limit interval is determined by the charge time of capacitor 104 through resistor 102 in comparison to a second reference voltage V ref2 . When voltage on capacitor 104 equals the reference voltage V ref2 , comparator 106 provides an output signal to the reset input of flip-flop 108 which provides a high output signal through coupling capacitor 112 to a second input of OR gate 94. Ordinarily it would be assumed that the time limit interval is longer than the current level interval detected by comparator 90. Therefore, the second input signal to the reset input of flip-flop 70 provided by the time limit interval circuit would have no effect. If, however, the current limit interval signal is delayed, then the time limit interval signal would provide the proper reset input signal to flip-flop 70.
When the flip-flop 108 is reset, its Q output goes high, and the transistor 110 is switched into conduction by the signal through resistor 111 to discharge capacitor 104 and ready the timing circuit for its next timing cycle which commences upon the delivery of the next clock impulse from oscillator 66 to the set input terminal of flip-flop 108. The time limit interval determining circuit therefore provides a backup system for insuring that the power FET 60 is turned off prior to the delivery of the next clock signal. The remaining circuit components are provided to modify the operation of the time limit interval circuit when the batteries 50 and 52 exhibit end-of-life behavior. As batteries 50 and 52 deplete, the internal resistance 53 increases. Then as current is drawn from the batteries 50, 52 (when power FET 60 is rendered conductive), the voltage across the transformer 54 and power FET 60 may be reduced by the internal resistance related voltage drop of the batteries. Battery voltage also becomes too low to maintain V cc at its stabilized voltage and thus too low to ensure proper action of the control circuit. V cc voltage is a regulated voltage below battery voltage established by circuits not shown in FIG. 4 to power certain control and logic circuits.
As long as battery voltage is sufficiently above V cc collector current of transistor 126 is sufficient to generate enough voltage across resistor 134 to keep transistor 128 conducting. In turn, the emitter voltage of transistor 124 is pulled low by the conduction of transistor 128. Transistor 130 and resistor 136 tend to bias transistor 124 to conduct, but it is prevented from conducting by transistor 128. Capacitor 104 is therefore only charged through resistor 102, and the time limit is established as described above.
When the voltage difference between battery voltage and V cc becomes lower, the collector current of transistor 126 decreases until the voltage generated across resistor 134 decreases and transistor 128 no longer conducts. Then the collector current of transistor 124 takes on a value, determined by resistor 122, which also charges capacitor 104 which is charged more quickly and decreases the time limit.
Thus, the compensation circuitry as described shortens the time limit interval whenever the battery voltage drops as a result of depletion and the consequent increase in internal resistance. The shortened interval reduces the mean current drain on the power source 50, 52 to prevent the battery voltage from collapsing further. The shortening of the time limit interval again provides assurance that the duty cycle of the on time of the power FET 60 is kept short enough to ensure that the flyback converter will work. This circuitry thus insures that the high energy capacitor 64 can be charged reliably and provide the energy necessary to provide the cardioversion function previously described whenever the batteries 50, 52 are able to deliver the required energy.
Further description of the output interface circuit 16 is contained in commonly assigned copending U.S. Ser. No. 577,631, filed Feb. 6, 1984, by Robert Leinders.
The invention described herein may advantageously be implemented in external cardioverters but is preferably employed in implantable cardioverters. The invention may also be implemented in any suitable analog or digital circuitry including software controlled custom or conventional microprocessors. These and other equivalent embodiments, modifications or uses of the invention will be apparent to those skilled in the art.
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An implantable medical device to deliver cardioverting energy to cardiac tissue in synchrony with detected ventricular depolarizations having a DC-DC flyback converter. The primary coil of the converter is periodically coupled and decoupled to ground by a timing circuit to effect charging of a high voltage output capacitor from a low voltage source through the secondary coil. A supply voltage detector alters the time period of the timing circuit to regulate the amount of current drawn by the primary coil. As the low voltage power supply depletes, its impedance increases tending to prolong the charging time of the output capacitor. Further regulating circuitry alters the one-shot time period to avoid loading down the supply voltage which could affect operation of other circuits. The preferred embodiment further includes a pacer, programmable memory and logic for controlling modes of operation of the pacer-cardioverter and parameters of the detection of arrhythmias and the pacing and cardioverting stimulus, and telemetry for telemetering out memory contents, heart signals and other data.
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CLAIM OF PRIORITY
[0001] This application is a Continuation application claiming priority from co-pending Divisional application Ser. No. 13/933,388, filed on Jul. 2, 2013, which claims priority from co-pending U.S. patent application Ser. No. 12/335,505, filed on Dec. 15, 2008, now issued as U.S. Pat. No. 8,542,902, which claims priority from Provisional Application No. 61/014,427, entitled “D YNAMIC THREE-DIMENSIONAL OBJECT MAPPING FOR USER-DEFINED CONTROL DEVICE ”, filed on Dec. 17, 2007, which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
Description of the Related Art
[0002] The video game industry has seen many changes over the years. As computing power has expanded, developers of video games have likewise created game software that takes advantage of these increases in computing power. To this end, video game developers have been coding games that incorporate sophisticated operations and mathematics to produce a very realistic game experience.
[0003] Example gaming platforms, may be the Sony Playstation, Sony Playstation2 (PS2), and Sony Playstation3 (PS3), each of which is sold in the form of a game console. As is well known, the game console is designed to connect to a monitor (usually a television) and enable user interaction through handheld controllers. The game console is designed with specialized processing hardware, including a CPU, a graphics synthesizer for processing intensive graphics operations, a vector unit for performing geometry transformations, and other glue hardware, firmware, and software. The game console is further designed with an optical disc tray for receiving game compact discs for local play through the game console. Online gaming is also possible, where a user can interactively play against or with other users over the Internet.
[0004] As game complexity continues to intrigue players, game and hardware manufacturers have continued to innovate to enable additional interactivity and computer programs. The traditional way of interacting with a computer program or interactive game has remained relatively unchanged, even thought there have been great advances in processing power. For example, computer systems still require basic input objects, such a computer mouse, a keyboard, and possibly other specially manufactured objects/devices. In a similar manner, computer gaming consoles generally require some type of controller, to enable interaction with a game and/or console. All of these input objects, however, are specially manufactured with a predefined purpose and have special buttons, configurations and functionality that is predefined. Accordingly, traditional interfacing devices must be purchased, and used for the purpose defined by the manufacturer.
[0005] It is within this context that embodiments of the invention arise.
SUMMARY
[0006] In one embodiment, a computer-implemented method to interactively capture and utilize a three-dimensional object as a controlling device for a computer system is disclosed. One operation of the method is capturing depth data of the three-dimensional object. In another operation, the depth data of the three-dimensional object undergoes processing to create geometric defining parameters for the three-dimensional object. The method can also include defining correlations between particular actions performed with the three-dimensional object and particular actions to be performed by the computer system. The method also includes an operation to save the geometric defining parameters of the three-dimensional object to a recognized object database. In another operation, the correlations between particular actions performed with the three-dimensional object and particular actions to be performed by the computer system in response to recognizing the particular actions are also saved to the recognized object database.
[0007] In one embodiment, a system for initiating and using a three-dimensional object as a controlling device when interfacing with a computer system used for interactive video game play, is provided. The system includes an interface for receiving data from a capturing device of a three-dimensional space and storage coupled with computer system. The computer system provides data to a screen and receiving user input to obtain geometric parameters of the three-dimensional object and assign actions to be performed with the three-dimensional object when moved or placed in positions in front of the capture device during interactive video game play. The geometric parameters and the assigned actions being saved to a database on the storage for access during interactive video game play or future interactive sessions.
[0008] In another embodiment, a computer-implemented method is disclosed to interactively capture and utilize a three-dimensional object to be a controlling device for a computer system. The method includes an operation for identifying the three-dimensional object. To identify the three-dimensional object, there are operations for capturing depth data of the three-dimensional object and processing captured depth data of the three-dimensional object to create geometric defining parameters for the three-dimensional object. There are also operations for defining correlations between particular actions performed with the three-dimensional object and particular actions to be performed by the computer system. Additionally, there are also operations for saving the geometric defining parameters of the three-dimensional object and correlations between particular actions performed with the three-dimensional object and particular actions to be performed by the computer system to a recognized object database. The method also includes operations for presenting the three-dimensional object to a camera and moving the presented three-dimensional object in front of the camera so as to trigger one or more of the particular actions to be performed by the computer system.
[0009] In yet another embodiment, a system for using a three-dimensional object as a controlling device when interfacing with a computer system is disclosed. The system includes a camera interfaced with the computer system that is configured to capture data from a three-dimensional space. Also include in the system is storage that is linked to the computer system. The system can also include a display that can be coupled to the computer system. The display can be configured to display a plurality of graphical display screens to enable set-up of a capture session to obtain geometric parameters of an object. The capture session can also be used to assign actions to be performed with the object when moved in front of the camera during an interactive session. During the interactive session, the geometric parameters and the assigned actions can be saved to a database for access on the storage linked to the computer system. Wherein the assigned actions can be custom defined by a user for particular movements made by the user on the object when holding the object in front of the camera.
[0010] Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention, together with further advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings.
[0012] FIG. 1 illustrates a scene 100 with a user 101 manipulating a generic three-dimensional object 102 to interact with a computer system 108 in accordance with one embodiment of the present invention.
[0013] FIG. 2A is an exemplary flow chart illustrating various operation that can be performed to allow the computer system 108 to recognize the three-dimensional object 102 , in accordance with one embodiment of the present invention.
[0014] FIG. 2B is another exemplary flow chart illustrating a procedure to define and use a three-dimensional object to control a computer system, in accordance with one embodiment of the present invention.
[0015] FIGS. 3A-3G illustrate real-world and virtual-world views of various actions performed by users while holding the three-dimensional object 102 , in accordance with various embodiments of the present invention.
[0016] FIGS. 4A-4D are examples where various three-dimensional objects can be recognized and used to control a variety of virtual devices based on the configuration of the three-dimensional object and the software being executed by the computer system, in accordance with one embodiment of the present invention.
[0017] FIG. 5A and FIG. 5B illustrate movements of a three-dimensional object to perform pre-configured remote control operations, in accordance with one embodiment of the present invention.
[0018] FIGS. 6A-6D illustrate capturing a three-dimensional object in various states of deformation, in accordance with one embodiment of the present invention.
[0019] FIG. 7 is an exemplary flow chart illustrating operations to map geometric defining parameters of a three-dimensional object, in accordance with one embodiment of the present invention.
[0020] FIG. 8 is an exemplary flow chart illustrating one method to configure an object to control virtual elements or the graphical user interface of the computer system, in accordance with one embodiment of the present invention.
[0021] FIG. 9 is an exemplary flow chart illustrating operations to utilize an object that has been mapped and configured, in accordance with one embodiment of the present invention.
[0022] FIG. 10 schematically illustrates the overall system architecture of the Sony® Playstation 3® entertainment device, a computer system capable of utilizing dynamic three-dimensional object mapping to create user-defined controllers in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
[0023] An invention is disclosed for capturing geometric identifying data for everyday objects and mapping controls to the everyday object to control a computer system. Broadly speaking, the computer system can be any type of system that takes input from a user, whether it be a general purpose computer (e.g., desktop, laptop, portable device, phone, etc.), or a special purpose computer like a game console. A camera capable of measuring depth data can be used to capture geometric data along with actions that can be correlated to controls for a variety of different programs. In one embodiment, a single camera is used, and in other embodiments, multiple cameras can be used to capture images from various locations or view perspectives. The correlated controls can be used to control aspects of a virtual object defined by a program executed by the computer system. The correlations between actions performed with the object and control of the virtual world element can be saved with the captured geometric identifying data of the object. Comparisons of real-time image data captured by the camera can be made to geometric identifying data that has been saved in order to recognize an object that is presented to the camera. Once recognized, the saved correlations can be loaded and the user can manipulate the object to control various aspects of a virtual object. Accordingly, the capturing sequences, methods and systems should be broadly understood to enable the capture of any real-world object, discern its geometric identifying data and enable mapping of various controls to the real-world object. Recognition of the object along with recognition of actions correlated to control of a program can improve user interaction with the computer system.
[0024] As used herein, a three-dimensional object should include any physical or material thing that can be touched, held, moved, captured in an image, captured in a video, compared to other things to discern its size or relative size, or identified based on height, width, length, or depth, and the like. A virtual-world object shall be broadly construed to include a computer generated image or images that can be displayed on a screen. The screen can represent the virtual-world object as a two or three dimensional thing and can be animated to move, be placed, be interacted with, or be modified based on user interactivity. The interactivity can include commands provided by the user, using a three-dimensional object or other interface devices such as keyboards, computer mice, touch screens, gaming controllers, motion sensors, or, acoustic or audible sounds and combinations thereof. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order not to unnecessarily obscure the present invention.
[0025] FIG. 1 illustrates a scene 100 with a user 101 manipulating a generic three-dimensional object 102 to interact with a computer system 108 in accordance with one embodiment of the present invention. The computer system 108 can output video to a display 106 . In some embodiments the display 106 can be a computer monitor while in other embodiments the display 106 can be a television. While not shown in the scene 100 , the computer system 108 can also output audio. Associated with the computer system 108 is a camera 104 . The camera 104 can capture images and video that can be processed by the computer system 108 . The computer system 108 is shown wirelessly communicating with the camera 104 , but wired connections can also be used.
[0026] The camera 104 can be configured to capture depth data, as shown by depth sensing lines 104 a . In some embodiments, the depth data from the camera 104 is transmitted to and processed by the computer system 108 . User input from a controller 110 is also transmitted to the computer system 108 . In various embodiments, the controller 110 transmits user input using wireless protocols such as, but not limited to, Bluetooth or WiFi. Thus, a controller with a wired connection to the computer system 108 can also be used. As will be discussed in greater detail below, a generic three-dimensional object 102 , recognized by the computer system 108 via images captured from the camera 104 can also be used to provide user input to the computer system 108 . The “U” shape of the three-dimensional object 102 should not be construed to be limiting, as the shape was chosen for illustrative clarity and simplicity. The term “three-dimensional object” is intended to describe any physical object capable of being held by a user. As such, the three-dimensional object 102 does not need to be specifically made to interface with the computer system 108 , but may have been a random object found in the home of user 101 .
[0027] FIG. 2A is an exemplary flow chart illustrating various operations that can be performed to allow the computer system 108 to recognize the three-dimensional object 102 , in accordance with one embodiment of the present invention. The flow chart is shown with exemplary images displayed to the user from the user's perspective. Operation 200 shows a user manipulating an exemplary graphical user interface to initiate an object capture procedure. A variety of user interfaces including various menus can be used to display and interact with the computer system. In other embodiments, audible commands, gestures, or user input into a controller or previously captured three-dimensional object can be recognized to initiate the capture process shown in operation 200 .
[0028] In operation 202 , the user presents the three-dimensional object 102 to the camera. For simplicity, the three-dimensional object 102 is shown as a blocky “U” shaped object. However, the three-dimensional object 102 can be any real-world object that can be manipulated by a person and perceived by the camera. Exemplary three-dimensional objects include items such as coffee mugs, drinking glasses, books, bottles, etc. Note that the previously discussed three-dimensional objects were intended to be exemplary and should not be construed as limiting.
[0029] In operation 204 , the user is prompted to rotate the three-dimensional object 102 in front of the camera. As shown in FIG. 2 , the user can be prompted to rotate the three-dimensional object 102 is different directions to allow the camera can capture views necessary to recognize the three-dimensional object 102 . When the user rotates the three-dimensional object 102 , the camera and computer system can capture and process geometric defining parameters associated with the three-dimensional object 102 . In another embodiment, more than a single camera can be used, when placed in various locations to allow image mapping from various angles of the space. In one embodiment, the computer system uses depth data from the camera to measure ratios between various geometric defining parameters on the three-dimensional object. Geometric defining parameters can include, but are not restricted to recognizable features of a three-dimensional object such as points, planes, transitional surfaces, fillets, accent lines, and the like. In such an embodiment, recognizing ratios between geometric defining parameters can allow the computer system to more readily recognize the three-dimensional object if the three-dimensional object is presented to the camera for recognition at a different distance than when it was captured. Operation 206 informs the user when sufficient views of the three-dimensional object 102 have been presented so the computer system can recognize the three-dimensional object 102 based on the defined geometric parameters.
[0030] In one embodiment, operation 206 displays a computer-generated model of the three-dimensional object 102 , as captured and modeled by the computer system. In another embodiment, operation 206 displays real-time video of the user holding the three-dimensional object 102 . Operation 206 allows a user to choose between saving the three-dimensional object 206 without configuration, or continue to configure the three-dimensional object 206 .
[0031] Continuing with FIG. 2A , Operation 208 is an exemplary view of a screen prompting the user to save the geometric parameters associated with the three-dimensional object 102 . Operation 208 is an exemplary screen where users can choose to save the geometric parameters of the three-dimensional object 102 or to cancel the save procedure. If a user chooses to configure the three-dimensional object, operation 210 allows a user to choose between pre-configured or custom configurations. In either case, configuring the three-dimensional object 102 allows a user to define correlations between particular actions performed with the three-dimensional object 102 and particular actions to be performed by the computer system. In one embodiment, the user can select a pre-configured setting that enables control the computer system user interface with user-performed actions with the three-dimensional object 102 . For example, the pre-configured setting can correlate user-performed actions with the three-dimensional object to navigation and selection of menus within a graphical user interface. In other embodiments, the user can custom configure the three-dimensional object to control aspects of a game being executed by the computer system, as will be discussed below.
[0032] FIG. 2B is another exemplary flow chart illustrating a procedure to define and use a three-dimensional object to control a computer system, in accordance with one embodiment of the present invention. The procedure beings with start operation 220 . In operation 222 , a user presents a three-dimensional object and depth data for the three-dimensional object is captured. As previously discussed, a single depth camera or multiple depth cameras can be used to capture depth data for the three-dimensional object. Operation 224 processing the captured depth data for the three-dimensional object to create geometric defining parameters. In one embodiment, the depth data can be used to create wire frame models of the three-dimensional object. In another embodiment, the depth data for the three-dimensional object can be processed to define particular features such as, but not limited to, length, height, and width.
[0033] Operation 226 is where a user can define correlation between actions performed with the three-dimensional object and specific actions that are to be performed by the computer. The actions performed with the three-dimensional object can include moving and manipulating the three-dimensional object in a manner than can be detected by the depth camera or other sensors associated with the computer system. The computer system can capture a sequence of images and depth data of a user performing actions with the three-dimensional object and determine a relative position of the three-dimensional object throughout the action. For example, in one embodiment, a user can wave the three-dimensional object in a single plane or wave the three-dimensional object across multiple planes. Similarly, in another embodiment a user can create complex or simple gestures in a real-world three-dimensional space while holding the three-dimensional object.
[0034] The user can associate or correlate particular real-world actions or gestures performed with the three-dimensional object to virtual world actions performed by the computer. Thus, when a user performs a particular gesture while holding the three-dimensional object, the computer system can perform a particular task or execute a particular instruction. In some embodiments, real-world actions performed with the three-dimensional object can be associated with particular virtual world motions such as swinging a virtual world golf club or tennis racquet. In other embodiments, real-world actions can be associated with user interface menu navigation.
[0035] Operation 228 saves the geometric defining parameters for the three-dimensional object along with the correlations between user actions with the three-dimensional object and virtual world actions performed by the computer to a database. Once saved in the database, the computer system can perform real-time analysis on depth data to recognize geometric defining parameters within the database if a user picks up the corresponding real-world three-dimensional object. Furthermore, the computer system can perform real-time analysis on user actions while holding the recognized three-dimensional object to recognize when a user performs an action correlating to a virtual world action or command for the computer system. The procedure is terminated with end operation 230 .
[0036] FIGS. 3A-3G illustrate real-world and virtual-world views of various actions performed by users while holding the three-dimensional object 102 , in accordance with various embodiments of the present invention. In the following examples, the three-dimensional object 102 has been configured to perform a particular function associated with various in-game actions. The following examples are exemplary and not intended to be limiting. Furthermore, it should be noted that a three-dimensional object could be recognized and configured to perform multiple functions for more for multiple different games.
[0037] FIG. 3A illustrates a how a three dimensional object 102 can be configured to be used like a baseball bat, in accordance with one embodiment of the present invention. In the real-world view, the user 101 a is shown holding the three-dimensional object 102 and swinging it like a baseball bat. Accordingly, as shown in the in-game view of FIG. 3A , an in game character 101 b , representative of the user 101 a , swings a virtual baseball bat 300 in response to the real-world swing of the three-dimensional object 102 . In one embodiment, the in game character 101 b is a computer-generated likeness of a real-world professional baseball player swinging a virtual baseball bat 300 in response to the user 101 a swinging the three-dimensional object 102 . In another embodiment, the in game character 101 b is a user created avatar integrated into a virtual baseball stadium. In other embodiments, the in game character 101 b can be a combination of computer generated real-world characters and user generated avatars swinging a virtual baseball bat 300 in response to the real-world swing of the three-dimensional object 102 .
[0038] FIG. 3B illustrates how different orientations of the three-dimensional object 102 can be configured to different actions of a virtual world light sword 302 a and 302 b , in accordance with one embodiment of the present invention. As illustrated in the real-world view, the user 101 is holding a three-dimensional object 102 a in a first orientation. In one embodiment, this first orientation 102 a is correlated to the virtual world light sword 302 a being turned “off”, as shown in the in-game view of FIG. 3B . Conversely, when the user 101 holds the three-dimensional object 102 b in a second orientation as shown in the real-world view, the virtual world light sword 302 b is shown in an “on” position, in the in-game view. Thus, when the user 101 is holding the three-dimensional as shown in orientation 102 b , the computer will display the in-game character with the light sword extended. Additionally, while held as three-dimensional object 102 b , in an “on” position, the camera and computer system can recognize movement of the three-dimensional object 102 b , and move the in-game light sword 302 b accordingly.
[0039] FIGS. 3C-3G illustrate other virtual-world objects that can be controlled using the three-dimensional object 102 , in accordance with other embodiments of the present invention. For example, in FIG. 3C , the three-dimensional object 102 can be used to control the swing of a virtual golf club 304 . Similarly, in FIG. 3D , a virtual tennis racquet 306 can be controlled by a user swinging the three-dimensional object 102 . In FIG. 3E , the three-dimensional object 102 can be used to allow a user to control a virtual bowling ball 308 . In FIG. 3F , the three-dimensional object 102 can be used in a virtual game of pool or billiards to control a virtual cue 310 . Another example of where the orientation of the three-dimensional object may need to be detected is found in FIG. 3G where the three-dimensional object 102 is used to control a virtual steering wheel 312 . Orientation of the three-dimensional object 102 can be used to determine when the virtual steering wheel 312 returns to a centered position resulting in the virtual car traveling in a substantially straight direction. Accordingly, orientation of a three-dimensional object 102 when held by a user can also be applied to control of other virtual world objects or even control of the computer system interface.
[0040] FIGS. 4A-4D are examples where various three-dimensional objects can be recognized and used to control a variety of virtual world devices based on the configuration of the three-dimensional object and the software being executed by the computer system, in accordance with one embodiment of the present invention. FIG. 4A shows a scene 400 with three-dimensional objects 102 , 402 , and 404 in front of a user 101 . In this example, three-dimensional objects 102 , 402 , and 404 have previously been captured by the computer system and can be recognized by the computer system when presented to the camera 104 .
[0041] In FIG. 4B , the user 100 picks up a three-dimensional object 102 and software being executed on the computer system determines if the three-dimensional object controls a baseball bat 406 , a steering wheel 408 , or a remote control 410 . In one embodiment, if the computer system is executing a baseball simulation program, the three-dimensional object 102 is recognized and rendered as a virtual world baseball bat 406 . Thus, the computer system can attempt to recognize batting swing motions performed by the user 100 with the three-dimensional object 102 . Similarly, if the computer system is executing software to simulate a tennis simulation, the user 100 can control a virtual world tennis racquet 408 based on the real-world movement of the three-dimensional object 102 . In another embodiment, movements and interactions with the three-dimensional object 102 can be configured and recognized functions from a remote control 410 . This can allow a user to perform motions with the three-dimensional object 102 that result in, but not limited to, increasing/decreasing volume, accessing a channel guide, and paging up/down within the channel guide.
[0042] In FIG. 4C , the user has picked up three-dimensional object 402 . The three-dimensional object 402 can be used as a remote control 410 . Alternatively, the three-dimensional object 402 can be used to control a virtual tennis racquet 412 , or a virtual bowling ball 414 . Similarly, in FIG. 4D , depending on the type of software being executed on the computer system, three-dimensional object 404 can be recognized as a virtual baseball bat 406 , a virtual golf club 416 or a remote control 410 . In some embodiments, where software executed on the computer system can recognize multiple virtual world counterparts associated with a three-dimensional object, the computer system can prompt the user to select which virtual world counterpart to control. In another embodiments, when a user picks up a three-dimensional object the computer system automatically recognizes the three-dimensional object as a user defined default virtual object. Thus, while executing the appropriate software, a user can configure the three-dimensional objects 102 , 402 and 404 to be associated respectively with the virtual baseball bat, the virtual bowling ball, and the virtual golf club. Thus, when object 102 is picked up, the on screen character is immediately shown holding a baseball bat. Likewise, when the user picks up three-dimensional object 402 , the on screen character is holding and has control of a virtual bowling ball. Similarly, the virtual golf club 416 is controlled by an on screen character when the user picks up three-dimensional object 404 . In another embodiment, the various three-dimensional objects 102 , 402 , 404 could be representative of different weapons that can be accessed by a character in a first-person shooter game. For example, object 102 can correspond to a knife, object 402 can correspond to a pistol, and object 404 can correspond to an assault rifle. Physically switching between real world three-dimensional objects can result in increase user interaction and enjoyment of the first person shooter game.
[0043] FIG. 5A and FIG. 5B illustrate movements or deformations of a three-dimensional object 102 to perform pre-configured remote control operations, in accordance with one embodiment of the present invention. After capturing and mapping both un-deformed and deformed geometric defining parameters of the three-dimensional object 102 to basic television functions, the computer system can recognize changes made to the three-dimensional object 102 to control television functions such as changing the channel or changing the volume. In the embodiment shown in FIG. 5A , rotating the three-dimensional object 102 around the Y-axis, can result in changing the channel up or down. Likewise, in the embodiment shown in FIG. 5B , rotating the three-dimensional object about the X-axis can change the volume up or down.
[0044] FIGS. 6A-6D illustrate capturing a three-dimensional object in various states of deformation, in accordance with one embodiment of the present invention. For example, the three-dimensional object can be twisted and bent to control various aspects of the software being executed on the computer system. In one embodiment, twisting the three-dimensional object from the original shape shown in FIG. 6A to the deformed shape in FIG. 6B can bring up a television schedule. Similarly, deforming the three-dimensional object as shown in FIG. 6C can be correlated to having the computer system display the next page of the television schedule. Conversely, deforming the three-dimensional object as shown in FIG. 6D can instruct the computer system to display the previous page of the television schedule.
[0045] The deformation and corresponding actions used in FIGS. 6A-6D are intended to be exemplary and should not be considered limiting. In other embodiments, three-dimensional mechanical objects can be captured in various states to control various aspects of virtual world machines, virtual world objects, or graphical user interfaces. For example, scissors or a stapler can be captured in both the open and closed position. In one embodiment, a virtual world character can be standing when the stapler or scissors are closed, and crouched when the stapler or scissors are open. Alternatively, opening and closing the stapler or scissors can make an in-game character jump.
[0046] FIG. 7 is an exemplary flow chart illustrating operations to map geometric defining parameters of a three-dimensional object for use to control a computer system, in accordance with one embodiment of the present invention. In operation 700 a user initiates the object capture system. In operation 702 , the user presents the object to the depth camera. The object can be any object discernable by the depth camera and the object does not need to be specifically configured to interface with the computer system. In operation 704 , the depth camera and computer system capture depth data from multiple viewing angles to define the object through geometric defining parameters. In some embodiments the geometric defining parameters can be associated with dimensions such as height, depth, and width. In other embodiments, ratios between particular features of the object can be used. In still other embodiments, a combination of dimensions and feature ratios can be used as geometric defining parameters.
[0047] In operation 706 , it is determined whether the object can be deformed or manipulated into a different or alternate form. In one embodiment, this operation can be as performed by prompting the user to indicate whether the object is deformable or capable of having an alternate configuration. In yet another embodiment, the computer system can include basic generic object shapes that can be recognized as deformable. For example, the computer system may be able to recognize a generic pair of scissors or a stapler. As such, when a user presents scissors or a stapler, the computer system can automatically prompt the user to capture depth data for the deformed or alternate configuration. Operation 708 captures depth data for the manipulated or deformed object. In some embodiments, Operation 708 may require the user to present the object in the alternate form to the depth camera from multiple viewing angles, similar to the viewing angles in operation 704 . Operation 710 saves all of the depth data associated with the object, including any alternate or manipulated form of the object.
[0048] FIG. 8 is an exemplary flow chart illustrating one method to configure an object to control virtual elements or the graphical user interface of the computer system, in accordance with one embodiment of the present invention. Operation 800 recalls saved depth data associated with an object. In some embodiments the recalled depth data is stored on local storage associated with the computer system such as a local hard drive or flash memory. In other embodiments, the depth data can be stored on a local network or in still further embodiments, on remote storage accessible via the internet. Operation 802 associates movement of the object with actions performed by the computer system. In other embodiments, operation 802 can associate actions performed with the object such as waving, shaking, or deforming the object with actions performed by the computer system. Operation 804 saves the associated movements and actions with the depth data associated with the object. The associated movements and actions can be saved to a local storage element such as a hard drive or other non-volatile memory. Alternatively, the associated movements and actions can be uploaded to network storage via the internet and publicly shared among friends.
[0049] FIG. 9 is an exemplary flow chart illustrating operations to utilize an object that has been mapped and configured, in accordance with one embodiment of the present invention. In operation 900 a user presents an object to the depth camera for recognition. In operation 902 , the computer system performs real-time analysis of the depth camera data and recognizes the object from stored geometric parameters. Operation 902 also loads any associated movements and actions that are stored with the depth data associated with the object. In operation 904 , the camera and computer system perform real-time image processing of the user manipulating and moving the object and perform the desired actions when actions with the object are recognized. It is possible for a user to have multiple objects mapped and configured and the computer system is capable of recognizing and switching between configurations as different objects are presented to the depth camera. Furthermore, a single object can have multiple configurations and upon recognition, a default configuration is loaded. In one embodiment, the user can selectively load an alternate configuration. In other embodiments, the user is asked to confirm loading the default configuration when multiple configurations for one object are present.
[0050] FIG. 10 schematically illustrates the overall system architecture of the Sony® Playstation 3® entertainment device, a computer system capable of utilizing dynamic three-dimensional object mapping to create user-defined controllers in accordance with one embodiment of the present invention. A system unit 1000 is provided, with various peripheral devices connectable to the system unit 1000 . The system unit 1000 comprises: a Cell processor 1028 ; a Rambus® dynamic random access memory (XDRAM) unit 1026 ; a Reality Synthesizer graphics unit 1030 with a dedicated video random access memory (VRAM) unit 1032 ; and an I/O bridge 1034 . The system unit 1000 also comprises a Blu Ray® Disk BD-ROM® optical disk reader 1040 for reading from a disk 1040 a and a removable slot-in hard disk drive (HDD) 1036 , accessible through the I/O bridge 1034 . Optionally the system unit 1000 also comprises a memory card reader 1038 for reading compact flash memory cards, Memory Stick® memory cards and the like, which is similarly accessible through the I/O bridge 1034 .
[0051] The I/O bridge 1034 also connects to six Universal Serial Bus (USB) 2 . 0 ports 1024 ; a gigabit Ethernet port 1022 ; an IEEE 802.11b/g wireless network (Wi-Fi) port 1020 ; and a Bluetooth® wireless link port 1018 capable of supporting of up to seven Bluetooth connections.
[0052] In operation the I/O bridge 1034 handles all wireless, USB and Ethernet data, including data from one or more game controllers 1002 . For example when a user is playing a game, the I/O bridge 1034 receives data from the game controller 1002 via a Bluetooth link and directs it to the Cell processor 1028 , which updates the current state of the game accordingly.
[0053] The wireless, USB and Ethernet ports also provide connectivity for other peripheral devices in addition to game controllers 1002 , such as: a remote control 1004 ; a keyboard 1006 ; a mouse 1008 ; a portable entertainment device 1010 such as a Sony Playstation Portable® entertainment device; a video camera such as an EyeToy® video camera 1012 ; and a microphone headset 1014 . Such peripheral devices may therefore in principle be connected to the system unit 1000 wirelessly; for example the portable entertainment device 1010 may communicate via a Wi-Fi ad-hoc connection, whilst the microphone headset 1014 may communicate via a Bluetooth link.
[0054] The provision of these interfaces means that the Playstation 3 device is also potentially compatible with other peripheral devices such as digital video recorders (DVRs), set-top boxes, digital cameras, portable media players, Voice over IP telephones, mobile telephones, printers and scanners.
[0055] In addition, a legacy memory card reader 1016 may be connected to the system unit via a USB port 1024 , enabling the reading of memory cards 1048 of the kind used by the Playstation® or Playstation 2® devices.
[0056] In the present embodiment, the game controller 1002 is operable to communicate wirelessly with the system unit 1000 via the Bluetooth link. However, the game controller 1002 can instead be connected to a USB port, thereby also providing power by which to charge the battery of the game controller 1002 . In addition to one or more analog joysticks and conventional control buttons, the game controller is sensitive to motion in six degrees of freedom, corresponding to translation and rotation in each axis. Consequently gestures and movements by the user of the game controller may be translated as inputs to a game in addition to or instead of conventional button or joystick commands. Optionally, other wirelessly enabled peripheral devices such as the Playstation Portable device may be used as a controller. In the case of the Playstation Portable device, additional game or control information (for example, control instructions or number of lives) may be provided on the screen of the device. Other alternative or supplementary control devices may also be used, such as a dance mat (not shown), a light gun (not shown), a steering wheel and pedals (not shown) or bespoke controllers, such as a single or several large buttons for a rapid-response quiz game (also not shown).
[0057] The remote control 1004 is also operable to communicate wirelessly with the system unit 1000 via a Bluetooth link. The remote control 1004 comprises controls suitable for the operation of the Blu Ray Disk BD-ROM reader 1040 and for the navigation of disk content.
[0058] The Blu Ray Disk BD-ROM reader 1040 is operable to read CD-ROMs compatible with the Playstation and PlayStation 2 devices, in addition to conventional pre-recorded and recordable CDs, and so-called Super Audio CDs. The reader 1040 is also operable to read DVD-ROMs compatible with the Playstation 2 and PlayStation 3 devices, in addition to conventional pre-recorded and recordable DVDs. The reader 1040 is further operable to read BD-ROMs compatible with the Playstation 3 device, as well as conventional pre-recorded and recordable Blu-Ray Disks.
[0059] The system unit 1000 is operable to supply audio and video, either generated or decoded by the Playstation 3 device via the Reality Synthesizer graphics unit 1030 , through audio and video connectors to a display and sound output device 1042 such as a monitor or television set having a display 1044 and one or more loudspeakers 1046 . The audio connectors 1050 may include conventional analogue and digital outputs whilst the video connectors 1052 may variously include component video, S-video, composite video and one or more High Definition Multimedia Interface (HDMI) outputs. Consequently, video output may be in formats such as PAL or NTSC, or in 720p, 1080i or 1080p high definition.
[0060] Audio processing (generation, decoding and so on) is performed by the Cell processor 1028 . The Playstation 3 device's operating system supports Dolby® 5.1 surround sound, Dolby® Theatre Surround (DTS), and the decoding of 7.1 surround sound from Blu-Ray® disks.
[0061] In the present embodiment, the video camera 1012 comprises a single charge coupled device (CCD), an LED indicator, and hardware-based real-time data compression and encoding apparatus so that compressed video data may be transmitted in an appropriate format such as an intra-image based MPEG (motion picture expert group) standard for decoding by the system unit 1000 . The camera LED indicator is arranged to illuminate in response to appropriate control data from the system unit 1000 , for example to signify adverse lighting conditions. Embodiments of the video camera 1012 may variously connect to the system unit 1000 via a USB, Bluetooth or Wi-Fi communication port. Embodiments of the video camera may include one or more associated microphones that are also capable of transmitting audio data. In embodiments of the video camera, the CCD may have a resolution suitable for high-definition video capture. In use, images captured by the video camera may for example be incorporated within a game or interpreted as game control inputs.
[0062] In general, in order for successful data communication to occur with a peripheral device such as a video camera or remote control via one of the communication ports of the system unit 1000 , an appropriate piece of software such as a device driver should be provided. Device driver technology is well-known and will not be described in detail here, except to say that the skilled man will be aware that a device driver or similar software interface may be required in the present embodiment described.
[0063] Embodiments may include capturing depth data to better identify the real-world user and to direct activity of an avatar or scene. The object can be something the person is holding or can also be the person's hand. In this description, the terms “depth camera” and “three-dimensional camera” refer to any camera that is capable of obtaining distance or depth information as well as two-dimensional pixel information. For example, a depth camera can utilize controlled infrared lighting to obtain distance information. Another exemplary depth camera can be a stereo camera pair, which triangulates distance information using two standard cameras. Similarly, the term “depth sensing device” refers to any type of device that is capable of obtaining distance information as well as two-dimensional pixel information.
[0064] Recent advances in three-dimensional imagery have opened the door for increased possibilities in real-time interactive computer animation. In particular, new “depth cameras” provide the ability to capture and map the third-dimension in addition to normal two-dimensional video imagery. With the new depth data, embodiments of the present invention allow the placement of computer-generated objects in various positions within a video scene in real-time, including behind other objects.
[0065] Moreover, embodiments of the present invention provide real-time interactive gaming experiences for users. For example, users can interact with various computer-generated objects in real-time. Furthermore, video scenes can be altered in real-time to enhance the user's game experience. For example, computer generated costumes can be inserted over the user's clothing, and computer generated light sources can be utilized to project virtual shadows within a video scene. Hence, using the embodiments of the present invention and a depth camera, users can experience an interactive game environment within their own living room. Similar to normal cameras, a depth camera captures two-dimensional data for a plurality of pixels that comprise the video image. These values are color values for the pixels, generally red, green, and blue (RGB) values for each pixel. In this manner, objects captured by the camera appear as two-dimension objects on a monitor.
[0066] Embodiments of the present invention also contemplate distributed image processing configurations. For example, the invention is not limited to the captured image and display image processing taking place in one or even two locations, such as in the CPU or in the CPU and one other element. For example, the input image processing can just as readily take place in an associated CPU, processor or device that can perform processing; essentially all of image processing can be distributed throughout the interconnected system. Thus, the present invention is not limited to any specific image processing hardware circuitry and/or software. The embodiments described herein are also not limited to any specific combination of general hardware circuitry and/or software, nor to any particular source for the instructions executed by processing components.
[0067] With the above embodiments in mind, it should be understood that the invention may employ various computer-implemented operations involving data stored in computer systems. These operations include operations requiring physical manipulation of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. Further, the manipulations performed are often referred to in terms, such as producing, identifying, determining, or comparing.
[0068] The above-described invention may be practiced with other computer system configurations including hand-held devices, microprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers and the like. The invention may also be practiced in distributing computing environments where tasks are performed by remote processing devices that are linked through a communications network.
[0069] The invention can also be embodied as computer readable code on a computer readable medium. The computer readable medium is any data storage device that can store data that can be thereafter read by a computer system, including an electromagnetic wave carrier. Examples of the computer readable medium include hard drives, network attached storage (NAS), read-only memory, random-access memory, CD-ROMs, CD-Rs, CD-RWs, magnetic tapes, and other optical and non-optical data storage devices. The computer readable medium can also be distributed over a network coupled computer system so that the computer readable code is stored and executed in a distributed fashion.
[0070] Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.
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A system for initiating and using a three-dimensional object as a controlling device when interfacing with a computer system used for interactive video game play is provided. One example system includes an interface for receiving data from a capturing device of a three-dimensional space and storage coupled with computer system. The computer system provides data to a screen and receiving user input to obtain geometric parameters of the three-dimensional object and assign actions to be performed with the three-dimensional object when moved or placed in positions in front of the capture device during interactive video game play. The geometric parameters and the assigned actions being saved to a database on the storage for access during interactive video game play or future interactive sessions.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of and a burner for burning liquid or gaseous fuels in a firebox with a decreased formation of NO x , whereby the combustion air is supplied in portions in the form of primary and secondary air, the portions are fed in one after the other at axial intervals parallel to the flow of the combustion gases, and the primary air generates an injector effect that draws combustion gases in.
The combustion air in a burner of this type can be fed in in component currents with the combustion in an initial combustion section being reducing. The combustion air in known pulverized-coal burners is supplied through concentric channels with their exit cross-sections essentially in the same plane (Jahrbuch der Dampferzeugungstechnik, 4th Ed., 1980, 81, pp. 748-763). Decreasing the content of NO x by recirculating flue gas and mixing it with all or part of the combustion air is also known (DE OS No. 2 306 537 and DE OS No. 3 110 186).
The use of a burner of this type, with air-channel exits in the same plane, as a gas or oil burner resulted in an essentially slighter decrease in NO x content than that obtained with a pulverized-coal burner. Obviously, the proportions of the gas or oil flame in the burner were not affected as much by the discontinuous supply of air in the same exit place as in a pulverized-coal flame.
An oil burner in which the component currents of combustion air are supplied at intervals along the axis of the burner is known (U.S. Pat. No. 4,004,875). Since the proportion of primary air in that device is lower than that of secondary air, an initial flame can become established with insufficient ultraviolet radiation. Some of the incompletely burned reaction products that occur in the primary combustion section of the burner are also drawn back and returned to that section. These incompletely burned gases lead as the result of cooling and flow-dependent deposition to coke caking and contamination inside the burner. The known burner is accordingly inappropriate for burning heavy heating oil.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a method of and a burner for burning liquid and/or gaseous fuels, by means of which the formation of NO x during combustion can be effectively suppressed, whereas the flame can be unobjectionably monitored and the burner will not be contaminated.
This object is attained first in accordance with the invention by means of a method of the aforesaid type, characterized in that the primary air is supplied in a percentage of the total combustion air that is higher than that of the secondary air and in that extensively burned combustion gases are drawn out of the firebox and conducted to a flame-initiation point between the primary-air and secondary-air feeds.
The primary air can be supplied at 60 to 80% and preferably at about 70% of the total combustion air.
The secondary air can be supplied either parallel to the axis or swirled.
The primary air can be supplied parallel to the axis, swirled, or partly parallel to the axis and partly swirled.
The secondary air can be fed in in several portions one after the other at axial intervals parallel to the flow of the combustion gases.
The secondary air can be deflected outward as it emerges into the firebox.
The combustion gases that are drawn in can be cooled before being mixed with flame gases by spraying them with water.
The object is also attained in accordance with the invention by means of a burner of the aforesaid type, in which burner lances extend through a air box and are surrounded by a supply pipe with an entrance inside the air box and an exit in the mouth of the burner and in which another supply pipe is positioned inside the mouth of and along the axis of the burner, the burner being especially intended to carry out the aforesaid method and being characterized in that the second supply pipe is axially separated from the exit of the first supply pipe and is surrounded by a third supply pipe that is radially separated from the wall of the mouth of the burner and axially separated from the air box and in that an annular channel between the second and third supply pipe communicates with the air box through connecting pipes.
The connecting pipes can empty into an air-access chamber that communicates with the air box through an entrance that can be adjusted by means of a sliding drum.
The exit of the third supply pipe can extend toward the firebox beyond the exit of the second supply pipe.
The exit of the second supply pipe can on the other hand extend toward the firebox beyond the exit of the third supply pipe and have a diverting edge that points outward.
The exit of the third supply pipe can also extend to where the mouth of the burner meets the firebox.
The second supply pipe can have lateral bores.
There can be a section between the second and third supply pipe with its entrance cross-section upstream and its exit cross-section downstream of the exit cross-section of the second supply pipe with respect to the firebox.
The wall of the burner mouth can be surrounded by an annular chamber that has an air connection and is connected to the air box.
A swirl generator and an axially displaceable air duct can extend to the rear on the first supply pipe and the air duct can, when it is in one limiting position, block off the air intake to the swirl generator and, when it is in the other limiting position, the residual air intake to the first supply pipe.
There can be an annular connecting channel between the wall of the burner mouth and the third supply pipe with an annular line in it that has nozzles and conducts water.
Inside the air box there can be a cooling-air line with pipe connections that project into the connecting pipes.
The air box can be separated from the mouth of the burner by a cover plate, the cover plate can have an aperture in the vicinity of the annular connecting channel, and the aperture can be capable of being blocked off with a sliding drum inside the air box.
Thus, the combustion air is supplied in the method and burner in accordance with the invention in two or more stages through concentric channels with a succession of openings along the axis of the burner. The result is discontinuous mixture of the combustion air into the oil or gas flame in order to decelerate combustion, lower the temperature of the flame, and hence effectively suppress the formation of NO x . The formation of NO x is further suppressed by recirculating the flue gas by means of an injection draft on the part of the flow of primary air. The flue gas is simultaneously removed from the firebox, where it is extensively burned up, in order to prevent coke caking and contamination. The high percentage of primary air generates and initial flame with enough ultraviolet radiation to allow the flame to be unobjectionably monitored by an ultraviolet photoelectric cell. The high percentage of primary air also increases the proportion of recirculated flue gas. The essential elements in the design of an oil and gas burner that have been proven in operation are, however, retained. The oil flame, for instance, must be stabilized in the potential turbulence behind a large enough impeller and the oil nozzles and gas lances can be positioned to ensure a stable and thoroughly ignited initial flame.
Some preferred embodiments of the invention will now be described with reference to the attached drawings, wherein
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section through a burner in accordance with the invention and
FIGS. 2 through 5 are longitudinal sections through the throat of various other embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The burner system consists of an air box 1 with a burner lance 2 for oil and several burner lances 3 for gas extending through it. Gas-burner lances 3 are positioned around oil-burner lance 2. An impeller 4 is attached to oil-burner lance 2.
Burner lances 2 and 3 are surrounded by a supply pipe 5 with an entrance 6 inside air box 1 and an exit 7 inside the mouth of the burner, which consists of a throat 8. Burner throat 8 opens into a firebox 9. Air box 1 is separated from throat 8 by a cover plate 10, through which supply pipe 5 extends.
A swirl generator 11 and an air duct 12 extend to the rear on the supply pipe 5. Air duct 12 can be axially displaced by means of a rod 13 that extends outside the burner. When it is in one limiting position, air duct 12 blocks off the air intake to swirl generator 11. When it is in the other limiting position, air duct 12 releases the air intake to swirl generator 11 and blocks off the residual air intake to supply pipe 5. The former position of air duct 12 is illustrated in the upper half of FIG. 1 and the latter in the bottom half. Positions intermediate to the two limiting positions are also possible.
A second supply pipe 14 is positioned inside throat 8 along the longitudinal axis of the burner and axially separated from the exit 7 of first supply pipe 5 and from the cover plate 10 on air box 1. Second supply pipe 14 preferably consists of a conically expanding section connected to a cylindrical section.
Second supply pipe 14 is surrounded inside throat 8 by a third supply pipe 16 in such a way as to leave space between the two pipes. Although third supply pipe 16 can, like pipes 5 and 14, be made out of metal, it can also, depending on the temperatures that are to be expected, be made out a fire-resistant ceramic material. Third supply pipe 16 can, as illustrated in FIG. 1, extend to where throat 8 meets firebox 9 or, as illustrated in FIG. 2, terminate just before that point. The exit cross-section of third supply pipe 16 is in either case nearer firebox 9 than the exit cross-section of second supply pipe 14 is.
The second supply pipe 14 illustrated in FIG. 4 extends farther into throat 8 than third supply pipe 16 does. In this case second supply pipe 14 has a diversion edge 28 that points outward.
Second supply pipe 14 can, as illustrated in FIG. 3, have lateral bores 17 that allow communication between an annular channel 15 between pipes 14 and 16 and the inside of second supply pipe 14.
Second supply pipe 14 can also be extended by a section 18 that partly surrounds second supply pipe 14 inside third supply pipe 16. The entrance cross-section of pipe section 18 will then be upstream and its exit cross-section downstream of the exit cross-section of second supply pipe 14 with respect to firebox 9. Annular channel 15 will accordingly have two exit cross-sections, one downstream of the other.
The end of annular channel 15 facing air box 1 is closed. The channel communicates with air box 1 th rough connecting pipes 19. Connecting pipes 19 can empty into an air-access chamber 20 inside air box 1, into which it opens through an entrance. The entrance in air-access chamber 20 can be adjusted with a sliding drum 21 that can be axially displaced by means of a rod 22. Sliding drum 21 is illustrated at the top of FIG. 1 in the position in which it leaves the entrance to air-access chamber 20 free and at the bottom of FIG. 1 in the position in which it blocks it off.
In one simplified embodiment of the invention the connecting pipes empty directly into the air box. The embodiment accordingly lacks the air-access chamber with an entrance that can be blocked off by a sliding drum.
Third supply pipe 16 is radially separated from the wall 23 of throat 8 and axially separated from the cover plate 10 of air box 1, leaving an annular connecting channel 24 that connects firebox 9 with the inside of second supply pipe 14.
The wall 23 of throat 8 can, as illustrated in FIG. 2, consist of cooling pipes or, as illustrated in FIG. 3, be fire-proofed. The cooling-pipe version is to be recommended when the burner is connected to a once-through steam generator.
The wall 23 of the throat 8 illustrated in FIG. 1 is surrounded by an annular chamber 25. Annular chamber 25 is provided with an air connection 26. A booster fan supplies air to chamber 25 through connection 26. Annular chamber 25 is connected to air box 1. A bent sheet-metal deflector 27 that demarcates the sides of annular chamber 25 and is positioned at a distance from the wall 23 of throat 8 controls the flow of air that cools the wall.
Another potential accessory, illustrated in FIG. 4, is an annular line 29 connected to a source of water supply and positioned in the vicinity of cover plate 10 in annular connecting channel 24. Annular line 29 is equipped with nozzles that spray the water into channel 24.
Cooling air is blown through annular channel 15 when the burner is turned off to protect supply pipes 5, 14, and 16 and pipe section 18 from heat radiating from firebox 9 when the burner is off. Air box 1 accordingly accommodates a cooling-air line 30 supplied with cool air from outside the box. Cooling-air line 30 can also be in the form of a distribution box connected to the annular chamber 25 illustrated in FIG. 1 to cool the wall 23 of throat 8. Cooling-air line 30 is provided with pipe connections 31 that extend into connecting pipes 19. Cooling-air line 30 is supplied with air only when the burner is off.
The embodiment illustrated in FIG. 5 can be operated either with air as a combustion medium by drawing combustion gas out of firebox 9 or with the exhaust gas from a gas turbine. The air or exhaust gas is supplied as desired to air box 1. A sliding drum 32 that can be displaced along the length of the burner is positioned in air box 1. The cover plate 10 that separates air box 1 from throat 8 has an annular aperture 33 as an extension of annular connecting channel 24.
Sliding drum 32 is illustrated at the bottom of FIG. 5 in the position assumed when the burner is operated with air as a combustion medium. In this position drum 32 blocks off annular aperture 33 and the injector effect of the primary air draws combustion gases out of firebox 9 through annular connecting channel 24 as previously described herein.
For operation with exhaust gas from a gas turbine sliding drum 32 is positioned as illustrated at the top of FIG. 5. In this position sliding drum 32 releases annular aperture 33 and exhaust gas can flow through first supply pipe 5 and annular channel 15 as well as through annular connecting channel 24. This provided the exhaust gas with a large enough flow cross-section.
The burner just described can be employed to carry out the method that will now be described.
A volume of air that has previously been determined in relation to the volume of gas is supplied to air box 1. Air volume is controlled by controls in the feed line. The combustion air is divided into primary air and secondary air in air box 1. The primary air flows through inner supply pipe 5 and burns the fuel emerging from oil-burner lance 2 or gas-burner lances 3 in a flame subject to less than stoichiometric conditions. The secondary air arrives through connecting pipes 19 in the annular channel 15 between second and third supply pipes 14 and 16. The secondary is then fed through the exit of second supply pipe 14 at an axial interval behind the primary air. The secondary air is, in the embodiments illustrated in FIGS. 1 and 2, again divided in second supply pipe 14 and supplied to the flame in a sequence of two stages.
In the embodiment illustrated in FIG. 4, the secondary air emerging from annular channel 15 is deflected outward, away from the flame, that is, by diversion edge 28. This further delays the mixture of secondary air with the flame gases.
The proportion of primary air in the total combustion air is higher than that of the secondary air, amounting to between 60 and 80% and preferably about 70%. The combustion air is portioned out by sliding drum 21 or by division in accordance with the dimensions of the flow-through cross-sections.
The primary air is supplied exclusively swirled, exclusively parallel to the axis, or partly swirled and partly parallel to the axis to the mouth of the burner, depending on the state of air duct 12. Since swirl generators can also be permanently positioned in the path of the secondary air, the secondary air can also be supplied either parallel to the axis or swirled.
The injector effect exerted by the primary air flowing out of first supply pipe 5 draws burned-out flue gases out of of firebox 9. The flue gases are supplied to the inside of second supply pipe 14 through annular connecting channel 24 and through the space between the entrance into second supply pipe 14 and the cover plate 10 of air box 1. Thus supplied, they arrive at the flame-initiation point between the primary-air and secondary-air feeds.
The flue gases that have been drawn in can be cooled before they are mixed with the flame gases inside second supply pipe 14. They can be cooled by water sprayed by annular line 29 into the flow of flue gases. Cooling prevents the temperature of the flame from increasing too much and contributes to a decrease in the formation of NO x .
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To allow liquid and/or gaseous fuels to be burned with decreased NO x formation, the combustion air is fed in at axial intervals one after the other. The percentage of primary air is higher than that of secondary air. The injector effect of the primary air draws flue gas out of the firebox and supplies it to a flame-initiation point between the primary-air and secondary-air feeds.
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TECHNICAL FIELD
[0001] The invention the subject of this application relates to apparatus and methods for the amplification of DNA. In particular, the invention relates to apparatus and methods having improvements in the manner of carrying out the DNA denaturation step of the amplification process.
BACKGROUND ART
[0002] In a number of applications such as gene analysis and DNA profiling, it is desirable to multiply the amount of particular nucleic acid sequences present in a sample. For example, a duplex DNA segment of up to approximately six thousand base pairs in length may be amplified many million fold by means of the polymerase chain reaction (PCR), starting from as little as a single copy. In this technique, a denatured duplex DNA sample is incubated with a molar excess of two oligonucleotide primers, one being complementary to a first short sequence of the DNA duplex and the other being identical to a second short sequence upstream of the first short sequence (i.e., more 5′ of the first short sequence).
[0003] Each primer anneals to its complementary sequence and primes the template dependent synthesis by DNA polymerase of a complementary strand which extends beyond the site of annealing of the other primer through the incorporation of deoxynucleotide triphosphates. Each cycle of denaturation, annealing and synthesis affords an approximate doubling of the amount of target sequence, where the target sequence is defined as the DNA sequence subtended by and including the primers. A cycle is controlled by varying the temperature to permit successive denaturation of complementary strands of duplex DNA, annealing of the primers to their complementary sequences, and primed synthesis of new complementary sequences. The use of a thermostable DNA polymerase obviates the necessity of adding new enzyme for each cycle, thus allowing automation of the DNA amplification process by thermal cycling. Twenty amplification cycles increases the amount of target sequence by approximately one million-fold.
[0004] More detailed information regarding the polymerase chain reaction can be found in standard texts such as PCR Protocols—A Guide to Methods and Application (M. A. Innis, D. I Gelfard, J. J. Sainskey and T. J. White ed's, Academic Press, Inc., San Diego, 1990), the entire content of which is incorporated herein by cross reference.
[0005] A key step in the DNA amplification process is the denaturation step. The double stranded DNA—either as the starting material of the amplification or the product of an amplification cycle—must be denatured to allow annealing of primers for a further round of complementary strand synthesis. Without complementary stand synthesis, there is no amplification.
[0006] A number of devices have been described for carrying out DNA amplifications. For example, in U.S. Pat. No. 5,656,493 there is described a thermal cycling system in which reaction mixtures are cycled through different temperatures to effect the denaturation, annealing and polymerisation steps. The system apparatus includes a metal block having a plurality of cavities therein for holding tubes containing the reaction mixtures. The block is heated or cooled to give the temperatures required for denaturation, annealing and complementary strand synthesis.
[0007] An alternative type of device is disclosed in International Patent Application No. PCT/AU98/00277 (Publication No. WO 98/49340). In the PCT/AU98/00277 device, reaction mixture vessels are held in a rotor which rotates in a controlled temperature environment. The different temperatures required for denaturation and complementary strand synthesis are reached by heating and cooling the environment.
[0008] For efficient execution of amplification using the apparatus referred to in the previous paragraphs, operation of the apparatus is computer controlled. Other known apparatus for carrying out DNA amplifications are similarly computer controlled.
[0009] The computer control of apparatus for DNA amplification reactions includes temperature control in accordance with user defined temperatures. That is, an operator of a piece of amplification apparatus presets the temperatures at which the various steps of the amplification process will be conducted. The time at which reaction mixtures will be held at a particular temperature is also defined by the operator.
[0010] User defined times and temperatures can diminish the efficiency of an amplification process. This is particularly the case with the denaturation step where the reaction mixture may be held at the denaturation temperature far in excess of the time necessary to actually denature the DNA. The extended time taken for the denaturation step can considerably increase the overall time of an amplification. Maximising the efficiency of amplifications is of considerable importance where large numbers of amplifications need to be processed.
[0011] There is therefore a need for amplification apparatus and methods where at least the denaturation step of a DNA amplification can be carried out more efficiently.
SUMMARY OF THE INVENTION
[0012] An object of the invention is to provide a method and apparatus for DNA amplifications in which the denaturation step is executed more efficiently.
[0013] According to a first embodiment of the invention, there is provided a method for the amplification of DNA, the method comprising the steps of:
[0014] i) forming a reaction mixture comprising said DNA, an oligonucleotide primer complementary to at least one strand of said DNA, nucleotides, and a thermostable DNA polymerase;
[0015] ii) heating said mixture to denature said DNA with optical detection of denaturation or the desired denaturation temperature;
[0016] iii) on detecting denaturation of said DNA or attainment of the denaturation temperature, allowing said mixture to cool to a temperature at which primer anneals to its complementary strand;
[0017] iv) incubating said mixture at a temperature which allows synthesis of a DNA strand complementary to the strand to which said at least one primer anneals; and
[0018] v) repeating steps (ii) to (iv) until the desired level of amplification is attained.
[0019] In a second embodiment, the invention provides apparatus for the amplification of DNA in a reaction mixture, the apparatus comprising:
[0020] a temperature controllable chamber including a rotor for holding a plurality of reaction vessels for reaction mixtures including DNA;
[0021] a drive means for said rotor;
[0022] a heater within said chamber for transiently supplying infrared energy to said reaction vessels; and
[0023] an optical system for determining denaturation of at least a reference DNA or for detecting attainment of a desired denaturation temperature in at least a reference reaction vessel.
[0024] The principle of the method as defined above is that rather than the denaturation on step being done by raising the mixture to a preset temperature and holding it at that temperature for a preset time as in known amplification protocols, the actual denaturation event is used as a control feature, or alternatively detection of the temperature at which denaturation will have occurred. This allows the denaturation on step to be carried out more efficiently since depending on the DNA sample used, the denaturation temperature may vary from sample to sample. Also, the denaturation temperature may vary after repetitive denaturation cycles: when DNA has bee denatured multiple times, the actual denaturation temperature will reduce.
[0025] Apparatus according to the second embodiment includes as a feature an optical system for detecting when denaturation has occurred or alternatively when the denaturation temperature has been reached. It is through this system that the denaturation event per se can control this step in an amplification rather than the step being controlled by preset temperatures and times.
[0026] With regard to the method according to the first embodiment, it will be appreciated by one of skill in the art that the mixture prepared for step (i) of the mixture is a standard amplification mixture and can include additional components such as buffers and salts normally used in amplification reactions. Commercially available reaction kits can also be used in the method. Typical reaction mixtures are described, for example in standard reference texts such as PCR: a Practical Approach (M J McPherson et al., Ed's), IRL Press, Oxford, England, 1991, and numerous brochures provided by suppliers of amplification reagents and consumables.
[0027] With regard to step (ii) of the method, the optical detection of denaturation is advantageously done by measuring the fluorescence emitted by an intercalating fluorophore present in a tube containing a reference DNA or in at least one of the reaction mixtures. The reference DNA can be any convenient DNA but advantageously has a similar melting temperature to that of the DNA being amplified. It will be appreciated that with appropriate excitation of the fluorophore, emitted fluorescence will dramatically decrease at denaturation of the double stranded DNA with which the fluorophore has intercalated.
[0028] The intercalating fluorophore can be any suitable compound such as ethidium bromide or a commercially available dye such as SYBR™ Green.
[0029] The optical system can also utilise a thermochromic liquid crystal to determine when the denaturation temperature has been reached. Such crystals, which will hereafter be referred to as “TLCs”, undergo a colour change at a certain temperature, the “transition temperature”. The system advantageously uses a clearing point TLC in conjunction with a fluorophore. The TLC is selected to have a transition temperature that is the same or close to the denaturation temperature of the DNA to be amplified. Suitable TLCs for the foregoing purpose include high transition point custom TLCs that are designed to have a clearing point or a color transition point at approx 92-95° C.
[0030] In the TLC/fluorophore system, a vessel containing the TLC/fluorophore combination is illuminated with light that includes the excitation wavelength of the fluorophore. Below the clearing point of the TLC, there is a diminished detection of fluorescence due to blocking of emission by the TLC. At and above the transition temperature, there is a heightened detection of fluorescence due to the “clearance” of the TLC. The increase in fluorescence thus marks the temperate at which transition occurred. With appropriate selection of the TLC, attainment of the desired temperature in a reaction vessel can be detected.
[0031] TLC/fluorophore systems are described in the Australian provisional application entitled “Optical Means for Calibrating Temperature”, the entire content of which is incorporated herein by cross reference.
[0032] In step (iii) of the method, cooling of reaction mixtures can be effected merely as a result of terminating the heating carried out in step (ii). Advantageously, however, cooling is aided by supplying a cooling agent to the environment of the reaction mixtures. This will be explained in greater detail below in connection with the apparatus of the invention. Using the apparatus of the invention, vessels containing reaction mixtures are heated by infrared energy. As a consequence of this, the chamber temperature is not raised by a significant amount and therefore cools faster than in conventional amplification procedures and apparatus.
[0033] The annealing temperature to which mixtures are cooled is selected in consideration of the primer-template combination but generally falls within the range of 50-65° C. as will be appreciated by those of skill in the art.
[0034] Step (iv) of the method is carried out in accordance with usual practice for synthesis of DNA in an amplification reaction.
[0035] Steps (ii) to (iv) will generally be repeated of the order of twenty times or more as with conventional amplification methods.
[0036] The method according to the invention can be used for linear amplification of DNA or for the more usual exponential amplification. It will be appreciated, however, that for exponential amplification, a primer is required for each strand of the duplex DNA to be amplified.
[0037] While not essential, the method of the invention can be conveniently carried out using apparatus according to the second embodiment. With regard to that embodiment, the apparatus is like that described in the international application referred to above—PCT/AU98/00277—the entire content of which is incorporated herein by cross-reference. However, the PCT/AU98/00277 device is modified to include the infrared heater and optical detection system.
[0038] In broad terms, the apparatus chamber can be any suitable, typically insulated, container for the internal device components and for association of ancillary components therewith. The chamber advantageously has a lid or sealable opening for loading the device rotor.
[0039] The temperature control of the apparatus chamber is effected by providing a heater linked to a temperature sensor so that a set temperature can be maintained. Typically, heating is by a heater located within the chamber with circulation of heated air within the chamber aided by a fan. Alternatively, heated air can be supplied to the chamber from a port or ports in a chamber wall.
[0040] Temperature control can also include a cooling system. For example, air supply to the chamber can be provided wherein the air is either at ambient temperature or less than ambient by passage through or over a cooling means. The temperature sensor referred to above is advantageously linked to the cooling system.
[0041] Rotors are typically a flat disc with an annular ring forming an outward portion thereof which is angled upwardly and has apertures therein for holding a plurality of reaction vessels which can be flat vertical or angled in orientation. The rotor can be a disposable item which is used for a single set of amplifications.
[0042] The rotor drive means can be any drive means used for rotor devices in scientific equipment. For example, the drive means can be a direct-coupled AC motor, a DC motor, or an AC motor that drives the rotor via a gearbox or pulleys or the like. Preferably, the drive means is a direct-coupled AC motor, DC motor or stepper motor wit the motor external to the chamber.
[0043] The infrared heater can be any suitable heater but is advantageously capable of delivering at least 100 watts. A preferred heater is a stainless steel tube with an outer diameter of approximately 2 mm and an internal diameter of 1.5 mm or a ni-chrome element wound in a spiral configuration. The heater is conveniently located at the bottom of the apparatus chamber in close proximity to the rotating reaction vessels. The stainless steel tube is advantageously mounted on ceramic insulators that are fixed to a metal reflector plate located at the bottom of the chamber. The reflector directs energy to the reaction vessels, has a large surface area, and has a low thermal mass. During infrared optical denaturation, the non-infrared heating system used for holding lower temperatures of 50 to 65° C. is deactivated. As a consequence of this, only the tips of reaction vessels are heated by the infrared energy. Once optical denaturation is complete, the non-infrared heating system is activated and the chamber cooled to the lower temperature of 50 to 65° C.
[0044] The optical system comprises a light source and detector. These components can be any of the light sources and detectors known to those of skill in the art. For example, the light source can be an LED, a laser light source or a halogen lamp, with an appropriate filter to provide light of an appropriate wavelength for excitation of the fluorophore in the reaction mixture. Emitted fluorescence is typically filtered and then measured by a photomultiplier tube, CCD array, photodiode or CCD camera.
[0045] The fluorescence detector of the optical system can also be used to monitor the progress of a reaction. For example, the level of fluorescence prior to denaturation can be used to assess the amount of DNA synthesised. Devices can furthermore include additional monitoring equipment such as a spectrophotometer or photometer. The additional monitoring equipment can be dedicated to assessing the progress of a reaction while the fluorescence detector of the optical system can be dedicated to its role in detection of denaturation. However, a photomultiplier used to detect reference sample optical denaturation can also be used to monitor sample fluorescence ding the reaction.
[0046] Apparatus according to the invention can have associated herewith a computer for controlling such operations as:
[0047] rotor start up and speed (any speed greater than 10 rpm or even as low as 1 rpm is suitable but typically rotors are rotated at 500 rpm);
[0048] the annealing and polymerisation temperatures and the time for each of these steps;
[0049] operation of the infrared heater during denaturation of DNA;
[0050] processing of data generated by the optical system and any system used to measure the amount of DNA synthesised;
[0051] rotor braking; and
[0052] cooling of the device chamber if necessary such as at the beginning and end of the amplification.
[0053] It will be appreciated that the computer can be used to control any other equipment or mechanisms associated with the device.
[0054] Because apparatus according to the invention has a dedicated (infixed) heater for denaturation of DNA, the chamber (convection) heater can be deactivated during the denaturation step along with the re-circulating blower ( 5 ). Typically, the chamber heater ( 5 ) is not activated until the denaturation step has been executed and any cooling of the chamber has been terminated.
[0055] Having broadly described the embodiments of the invention, an apparatus and use thereof will now be exemplified with reference to the accompanying drawings briefly described hereafter.
BRIEF DESCRIPTION OF THE DRAWING
[0056] FIG. 1 is a schematic cross-sectional view of apparatus according to the invention.
[0057] FIG. 2 is a graph of fluorescence emitted from a reference sample subjected to an amplification protocol.
[0058] FIG. 3 is a graph of fluorescence emitted by a reference mixture during a denaturation step.
[0059] FIG. 4 is a graph of fluorescence emitted by an actual reaction mixture when measured at the end of each DNA synthesis step over the total number of cycles.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0060] With reference to FIG. 1 , apparatus 1 comprises a cylindrical chamber 2 having rotor 3 which is driven by a stepper motor not shown in the drawing. Chamber 2 also includes a radial heater 4 and a fan 5 for distributing heated air throughout the chamber. Heater 4 and fan 5 are mounted to hinged lid 6 of the device, which lid can be pivoted out of the way to gain access to rotor 3 . Rotor 3 has a plurality of holes for holding reaction vessels, one of which vessels is item 7 .
[0061] Device 1 also includes an infrared heater 8 at the bottom of chamber 2 . Since chamber 2 is circular in cross section, heater 8 is also circular, items 9 and 10 being crop sections of the heater. The position of heater 8 at the bottom of the chamber places it near reaction vessels in rotor 3 , two such vessels being the previously-identified item 7 , and item 11 of the drawing. A light source 12 is provided for illuminating a reaction vessel as it passes through beam 13 . Light 14 emitted from reaction vessel 7 passes through filter 15 to be detected by photomultiplier tube 16 .
[0062] Device components such as the rotor drive, heater 4 , fan 5 , infrared heater 8 , and light source 12 , are controlled by a computer not shown in the drawing.
[0063] Operation of the device is as follows. Reaction mixtures are dispensed into reaction vessels using manual pipettors or automated robotic pippetting means and heated to the denaturation temperature to activate the enzyme via heater 4 and fan 5 under the control of the associated computer. Rotor 3 is rotated at greater than 10 rpm under the control of the computer during this step and subsequent steps to average reaction vessel temperatures. The reaction tubes are then cooled to the annealing/extension temperature as usually both steps can be combined in the single temperature of approximately 60° C.
[0064] On command from the computer to denature double stranded DNA present in reaction mixtures, infrared heater 8 is activated. At that point, the chamber heater 4 and fan 5 are deactivated and are not reactivated until the denaturation step has ended. At least one reaction mixture or a reference mixture contains an intercalating dye such as ethidium bromide or SYBR™ Green. The dye is excited by light source 12 and fluorescence measured by photomultiplier tube 16 after selection of light of the appropriate wavelengths by filter 15 . Fan 5 can be left on at a low speed during this step if desired. This has the effect of minimizing the surface temperature of each reaction vessel and prevents empty vessels from melting during optical denaturation. The time taken to perform an optical denaturation can be increased by this variation however.
[0065] With denaturation of the double stranded DNA, fluorescence emission diminishes and on reaching a preset level causes the computer to deactivate infrared heater 8 .
[0066] On shut down of infrared heater 8 , chamber 2 is cooled to the annealing temperature through the action of a cooling system not shown in the drawing. At the annealing temperature, the progress of the reaction can be monitored by way of a fluorescent probe present in reaction mixtures or by measuring the creased energy of the intercalating dye referred to above. This monitoring is by way of light source 12 , filter 15 and photomultiplier tube 16 . Results can be recorded by the computer.
[0067] Repetition of the above steps results in amplification of the DNA present in reaction mixture. In the following example, greater detail of the role of the optical system is given.
[0068] A reaction mixture was prepared comprising the following:
Final 1 × 25 Master Concentration Reaction Mix Reagent (in 25 μl) (μl) (μl) dH 2 O — 10.95 219 10× buffer 1× 2.5 50 MgCl 2 (50 mM) 3 mM 1.5 30 dNTP (2.5 mM) 0.2 mM 2.0 40 GAPDH-For (2.5 μM) 0.3 μM 3.0 60 GAPDH-Rev (2.5 μM) 0.3 μM 3.0 60 SG (1:1000) 1:31250 0.8 16 Taq Polymerase (5 U/μl) 0.05 U/μl 0.25 5 DNA template 3 × 10 8 to 1.0 — 3 × 10 3 copies
[0069] The mixture contained in a 0.2 ml Eppendorf™ tube was loaded into the rotor of the apparatus exemplified above. After rotor activation, the following steps were carried out:
[0070] 1) an optical denaturation command was issued by the computer,
[0071] 2) the chamber was cooled to 60° C. and held at that temperature for 15-60 seconds for data acquisition;
[0072] 3) an optical denaturation command was issued by the computer,
[0073] 4) on denaturation of the DNA, the chamber was cooled to the hold temperature of (2) and held for the same time as in (2) for annealing of primer and DNA synthesis to occur; and
[0074] 5) steps (3) and (4) were repeated for a further 14 cycles.
[0075] The following were effected by the optical denaturation command:
[0076] a) infrared heater 8 was turned on, and heater 4 and fan 5 turned off;
[0077] b) a reference tube containing DNA and an intercalating dye was monitored by the optical system at approximately 2 to 10 measurements per second;
[0078] c) on detection of DNA denaturation, heater 8 was turned off and the hold temperature re-established.
[0079] The fluorescence emitted by the reference tube through each of the 20 denaturation cycles is depicted in FIG. 2 . The 100% fluorescence reading represents emission from the tube prior to denaturation. At denaturation, the fluorescence can be seen to drop to about 20% of the fill-scale value. It is at this point that the den on step is terminated. Algorithms can be developed to detect when the denaturation curve goes from a maximum decrease in rate to a minimum decrease in rate at the base of a typical denaturation curve.
[0080] It can be appreciated from the foregoing that the optical detection system permits sensitive determination of denaturation and thus reduces to a minimum the time taken for this step of the amplification process. Maximum energy can be applied to reaction vessels as optical denaturation is a direct measure of the average temperature of the liquid within vessels. Consequently, samples can be rapidly denatured without any overshoot in temperature.
[0081] FIG. 3 is a graph of fluorescence versus temperature for the reference tube during a single denaturation sequence. It can be seen that there is a steady decrease in fluorescence as temperature increases towards the denaturation point at which there is an abrupt decrease in fluorescence. This decrease is marked “knee” in the figure.
[0082] The knee of a fluorescence plot can be exploited to terminate the infrared heating for the denaturation sequence by application of an appropriate algorithm.
[0083] FIG. 4 is a plot of the fluorescence of replicate samples of the actual reaction mixture described above measured at the end of each hold sequence and over the 20 cycles of the amplification. The plot clearly shows the degree of amplification attained as evidenced by the increase in fluorescence.
[0084] It will be appreciated by a person of skill in the art that many changes can be made to the device and its use as exemplified above without departing from the broad ambit and scope of the invention.
[0085] The term “comprise” and variants of the term such as “comprises” or “comprising” are used herein to denote the inclusion of a stated integer or stated integers but not to exclude any other integer or any other integers, unless in the context or usage an exclusive interpretation of the term is required.
[0086] The reference to the publications cited in the Background Art section of this specification is not an admission that the disclosures constitute common general knowledge in Australia.
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The invention relates to a method for the amplification of DNA and apparatus for such amplification. The method comprises steps typically found in amplification methods but utilises an optical procedure to detect denaturation of DNA or attainment of the desired denaturation temperature. The apparatus ( 1 ) comprises a temperature controllable chamber ( 2 ) including a rotor ( 3 ) for holding a plurality of reaction vessels (see 7 for example) for reaction mixtures including DNA, a drive means for the rotor, a heater ( 8 ) within the chamber for transiently supplying infrared energy to the reaction vessels, and an optical system ( 12 - 16 ) for determining denaturation of at least a reference DNA or for detecting attainment of a desired denaturation temperature in at least a reference reaction vessel.
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CROSS-REFERENCE TO RELATED COPENDING APPLICATION
This application is a continuation-in-part of copending application Ser. No. 827,694, filed Aug. 25, 1977, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to battery power supplies for electric devices. In particular, the invention relates to rechargeable battery packs which can be recharged in either a recessed receptacle, the receptacle being often referred to as an "outlet," or in a non-recessed receptacle and wherein the battery pack is adapted to reside within a pocket of a portable, cordless, electric device for powering the device.
2. Description of the Prior Art
The availability of rechargeable batteries has led to a variety of rechargeable, battery-operated, portable, cordless devices including grass shears, hedge trimmers, shrub trimmers, lawn mowers, sprayers, soldering irons, flashlights, screwdrivers, and the like. In some cases, the batteries are housed in a nonremovable pack while the recharging circuitry is housed in a separate charging unit. In other cases, the charging circuitry is incorporated as a part of a rechargeable battery pack. It has also been previously proposed to provide a removable battery pack having its own recharging circuitry, the pack having conventional United States-type AC prongs and arranged so that the pack can be interconnected through the prongs to the device to be powered or through the same prongs to a conventional 120 volt United States-household receptacle for recharging. U.S. Pat. Nos. 3,275,819 and 3,281,636 and French Pat. No. 1.418.746 are illustrative of such devices. It has also been suggested to have a removable, rechargeable battery pack that could be connected to any one of several battery power consuming devices.
In a recent development described in U.S. Pat. No. 3,952,239, a system now on the market is directed to a range of cordless devices including grass shears, lanterns, drills, and shrub trimmers. Each device mates with a standardized power handle which serves both as a handle and a housing for a rechargeable battery.
As described in the commonly-assigned, copending application Ser. No. 607,376, now U.S. Pat. No. 4,084,123, the most recent known development in the art of battery power packs is the advent of a relatively flat, rectangular, box-shaped battery pack which fits into a mating pocket in a device. This battery pack carries a pair of standard AC prongs extending from a flat sidewall surface of the pack. The prongs are adapted for insertion into a standard United States-type, 120 volt, AC receptacle for charging the battery pack through rectifier means contained in the pack thus eliminating the need for a separate charger. When the battery pack is positioned in the respective pocket of the tool or device, a mechanical switch is actuated by mating formations on the pack and pocket and connects the battery pack in a discharge mode so that the particular tool or device can be powered through the batteries using the same set of AC prongs. Heavy duty tools or devices are provided with multiple pockets for the reception of a corresponding number of identical battery packs.
While adapted to receptacles of the type found in the United States, the rechargeable pack described in copending application Ser. No. 607,376 does not adapt to recharging conditions as are encountered in Europe and other areas of the world where recessed-type receptacles are employed.
U.S. Pat. Nos. 3,067,373 and 3,120,632 are illustrative of combined power unit-load unit assemblies which can be easily disconnected from the load unit and connected to any readily available source of alternating current such as a conventional household receptacle. Also, these patents illustrate prongs slidably arranged in the unit assembly.
Also, U.S. Pat. No. 3,996,546 is illustrative of a dual voltage, electrical plug which is adaptable to connect an appliance, such as an electric shaver, alternatively to sockets belonging to either one of two main supplies of differing voltage, e.g., 110 volt United States or 220 volt European.
With all of the foregoing considerations in mind, it thus becomes the object of this invention to provide a type of rechargeable battery pack which improves on the foregoing prior art and is adaptable for recharging in either flush or recessed-type receptacles, whether shallow or deeply recessed.
SUMMARY OF THE INVENTION
Many of the features of the battery pack disclosed in copending application Ser. No. 607,376 are retained. More specifically, according to the present invention, there is provided a rechargeable, battery pack which may be recharged in flush or recessed-type receptacles comprising a hollow housing of a rather rectangular, flat, box-like shape and having a pair of prongs mounted on a movable plug projecting from one flat-sidewall or base surface of the pack. The prongs are adapted to be received by a corresponding set of prong-receiving openings provided in a mating base plate or liner in an outwardly-opening pocket of a tool or device for discharge purposes.
For charging purposes in the recessed-type, European 220 volt receptacle, the plug and its prongs are withdrawn from within the pack by releasing the plug which mounts the prongs and which is forced outward by a spring inside the housing. The plug is then locked in an appropriate extended position and the plug and prong unit is placed in the receptacle. In a preferred embodiment, means are provided for locking the plug in a plurality of extended positions to accommodate shallow and deeply-recessed receptacles.
For charging purposes in the flush or non-recessed-type receptacle, the plug is depressed and locked within the pack housing so that only the prongs extend from the pack. The prongs are then inserted in the receptacle for charging.
For discharging, the plug is depressed and locked within the pack housing so that only the prongs extend from the pack as when in the non-recessed or flush-type receptacle charging position. When the plug is depressed within the pack, a DC voltage and DC supply is available at the prongs for operating the tool or device but not until a switch actuator located between the prongs is depressed. This action occurs automatically when the power pack is inserted into the tool or device which is designed with a mating actuating post. This provides protection in that no voltage or power is present at the prongs except when the power pack is properly and fully inserted into the tool or device. The switching action is accomplished via a plug slide arrangement which moves up and down a printed circuit board within the power pack housing.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating the rechargeable battery pack of the present invention.
FIG. 2 is an inverted perspective view of the battery pack and showing the position of the prongs as they would be either for discharge or for charging in a flush-type receptacle.
FIG. 3 is an inverted perspective view similar to that of FIG. 2 illustrating the withdrawn plug as it would appear for insertion in a deeply-recessed, European-type, 220 volt receptacle.
FIG. 4 is an inverted perspective view similar to that of FIG. 3 illustrating the withdrawn plug as it would appear for insertion in a European-type receptacle having a shallow recess.
FIG. 5 is a side view of a grass shear adapted to receive the battery pack of the present invention and with a portion of the shear housing broken away to illustrate the pocket and liner and a battery pack in the partially-inserted position.
FIG. 6 is a view similar to FIG. 5 with the battery pack fully inserted into the tool.
FIG. 7 is a longitudinal section of the pack showing the plug and prongs in a normal charge position for flush receptacles and with the wiring and springs removed for purposes of illustration.
FIG. 8 is a longitudinal section of the pack showing the plug and prongs in a normal charge position for receptacles having a shallow recess and with the wiring and springs removed for purposes of illustration.
FIG. 9 is a longitudinal section of the pack showing the plug and prongs in a normal charge position for deeply recessed receptacles and with the wiring and springs removed for purposes of illustration.
FIG. 10 is a view similar to that of FIG. 7 but illustrating the discharge mode with the actuator button depressed.
FIG. 11 is a lateral section view of the pack in the FIG. 7 position.
FIG. 12 is a lateral section view of the pack in the FIG. 8 position.
FIG. 13 is a lateral section view of the pack in the FIG. 9 position.
FIG. 14 is a lateral section view of the pack in the FIG. 10 position with the prongs broken to illustrate the contacts.
FIG. 15 is a plan view of the inside surface of the bottom wall member showing the plug, latch and return spring and with the batteries and wiring removed for purpose of illustration.
FIG. 16 is a top view of the pocket base plate or liner and showing the openings for receiving the prongs of the pack.
FIG. 17 is a side view of the pocket base plate or liner illustrated in FIG. 16.
FIG. 18 is a bottom view of the liner of FIGS. 16 and 17.
FIG. 19 is an enlarged, fragmentary view of the spring contact member as it is initially engaged by the prong of the battery pack during insertion of the pack into the pocket.
FIG. 20 is a view similar to FIG. 19 showing the prongs fully inserted and ready for discharge to operate the shear.
FIG. 21 is a schematic circuit diagram of the pack ready for charging in a flush-type receptacle.
FIG. 22 is a schematic circuit diagram of the pack ready for charging in a receptacle of the type having a shallow recess.
FIG. 23 is a schematic circuit diagram of the charging circuitry of the battery pack for use with a 220 volt European receptacle of the deeply-recessed-type.
FIG. 24 is a schematic circuit diagram of the discharging circuitry of the battery pack with the actuator button depressed.
FIG. 25 is a side view of the battery pack as it is inserted into a flush or non-recessed type receptacle.
FIG. 26 is a side view of the battery pack as it is inserted into a receptacle having a shallow recess.
FIG. 27 is a side view of the battery pack as it is inserted into a deeply-recessed receptacle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, rechargeable battery pack 10 adaptable for charging in recessed or flush-type receptacles, has a hollow housing of rather rectangular, flat, box-like shape. Pack 10 has a generally flat, bottom wall 11 and a top wall 12 having a pair of generally flat surfaces 13, 14 and an angled surface 15. The sides of pack 10 are made up of components 16a, 16b, 17a, 17b, 18a, 18b, 19a and 19b. Once bottom wall 11 and top wall 12 are assembled together to form the housing of pack 10, side components 16a through 19b form a groove 20 which encircles pack 10. Pack 10 of the present embodiment has its own latch as will be described; however, if the latch is made a part of the tool or device, housing groove 20 can be used to receive a latch and retain the pack.
Side surface components 17a, 17b are provided with a resilient latch member 21 which is adapted to engage a ledge portion of the tool pocket in order to hold the pack in place.
FIGS. 7, 8, 9 and 10 are longitudinal, section views which show the internal components of battery pack 10. Top wall 12 and bottom wall 11 are essentially a pair of secured rectangular, pan-shaped, clamshell members. The internal components, illustrated in FIGS. 7-14 and FIGS. 21-24, include rechargeable, nickel-cadmium batteries 25, 26, 27; capacitor 28; printed circuit board 29; plug 30; diode bridge 31; and resistors 32, 33. Such circuitry minimizes weight and heat with both a rectifier and rectifier bypass.
Bottom wall member 11 is approximately 21/4 inches by 41/2 inches by 3/4 inch, has a wall thickness of about 5/64 inch and is preferably molded of an impact-resistant, flame-retardant polycarbonate. The interior wall surfaces of bottom wall member 11 is provided with circuit board locators 35 into which circuit board 29 slides into place during assembly. A recessed area 36 is provided in sidewall surface 17b of member 11 to accommodate latch member 21. The recessed area and associated structural members will be described in conjunction with the description of latch 21. The interior surface of bottom wall member 11 is provided with battery locating ribs 37 that aid in locating batteries 25, 26, 27 during assembly and also serve to keep the batteries in position during use and thereby reduce rattling. Ribs 37 serve to provide compartments for batteries 25, 26, 27. Ribs 37 are designed to be resilient and absorb shock from the batteries when pack 10 is accidentally dropped. While absorbing shock, ribs 37 also lend strength to the overall construction of pack 10.
Top wall member 12 is approximately 21/4 inches by 41/2 inches by 3/4 inch at its deepest point and approximately 1/2 inch at its shallowest point, has a wall thickness of about 5/64 inch and is preferably molded of an impact resistant, flame retardant polycarbonate. The interior wall surfaces of member 12 are provided with circuit board 29 locators into which circuit board 29 slides into place during assembly. Circuit board 29 mounts the circuitry diagrammed in FIGS. 21-24 and against which contacts 65 slide in the various operating modes. A recessed area 42 is provided in sidewall surface 17a of member 12 to mate with recessed area 36 of member 11 and which together accommodate latch member 21. The recessed area and associated structural members will be described in conjunction with the description of latch 21. The interior surface of top wall member 12 is provided with battery locating resilient, shock-absorbing ribs 43 which, in conjunction with ribs 37, aid in locating batteries 25, 26, 27 during assembly, serve to keep the batteries in position during use and also lend strength to the overall construction of pack 10. Top wall member 12 and bottom wall member 11 are snap-fitted together and are then ultrasonically welded together once all components are assembled therein.
Referring back to bottom member 11, member 11 is provided with a slot 44 shaped like plug 30 and in which plug 30 slides and through which prongs 46, 47 and plug 30 protrude. Prongs 46, 47 are maintained in a fixed position within plug 30 at all times. Internal guides 48 align and guide plug 30 in a sliding relation in slot 44. Plug 30 is molded as two hollow half-sections 30a, 30b which are held together by screw 50 passing through bosses 51, 52 and being threadably retained therein. Tabs 49 are molded integral with plug 30 and prevent plug 30 from being withdrawn from within the housing.
In addition to plug 30 itself having a sliding relation with respect to wall member 11, certain parts of the switching mechanism within plug 30 have a sliding relation to plug 30 itself and effect various switching operations. In this regard, a switch actuator 55 is slidably mounted within plug 30 and has a switch actuating post 56 and below post 56 a recess 57 molded integral therewith. Post 56 extends through a hole 58 in plug 30 and the end of post 56 resides flush with the outside of plug 30. Actuator 55 and its post 56 are held in this flush position by spring 59 which resides in recess 57 and the other end of which rests on boss 51. The force exerted by spring 59 maintains post 56 in this flush position but when post 56 is depressed, spring 59 is compressed and switch actuator 55 moves downward within plug 30. Release of the depressing force on post 56 allows spring 59 to return switch actuator 55 to its original position. Thus, it can be seen that actuator 55 can move relative to the plug itself that is relative to the plug housing sections 30a, 30b.
The outwardly extending prongs 46, 47 are held fixed in plug 30 and the intermediate portions thereof pass through switch actuator 55 in a sliding relation so that actuator 55 may slide on prongs 46, 47. The innermost ends of prongs 46, 47 are of a reduced diameter 60 and are secured in sleeves 61 which are molded integral with sections 30a and 30b respectively of plug 30. The extreme outward ends of prongs 46, 47 comprise tips which actually make contact in the tool or receptacle. Contacts 65 are fixedly received by switch actuator 55 and slide up and down on the intermediate thickened portion of prongs 46, 47 as actuator 55 slides within plug 30. Contacts 65 extend through hole 66 in plug section 30a and extend slightly beyond the outside wall of section 30a. Contacts 65 are flexible and can move outwardly and inwardly in holes 66 as required to maintain good prong contact and function as later described with respect to circuit board 29.
The in and out movement of plug 30 within pack 10 is provided by spring 70 which is compressed when plug 30 is forced into pack 10 and which is relaxed when plug 30 is allowed to extend outwardly from pack 10. Spring 70 is maintained in a recess 71 in plug 30 by post 72 which is integral with recess 71 and plug 30. When compressed within pack 10, spring 70 rests at one end against boss 51 and at the other end against the inside of flat wall surface 13. The in and out movement of plug 30 is allowed or prevented, depending upon the position of latch 75 which is slidably retained in the inside surface of flat bottom wall 11.
FIG. 15 shows in plan view the relationship of latch 75 with the inside surface of bottom wall 11. Latch 75 has a finger-engaging portion 76 which resides external of pack 10 and substantially flush with the outside wall of bottom wall 11. Finger portion 76 slides back and forth in opening 77 in wall 11. Finger portion 76 also has an elongated, integral internal side portion 78, one end of which is designed to engage an opening 79, 87 or 83 in side 30b of plug 30, as shown in FIGS. 7, 8, 9 and 10. End 80 of slide portion 78 engages opening 83 when plug 30 is within pack 10 and engages openings 87 or 79 when plug 30 is in a withdrawn position ready for recharging purposes. Spring 81 exerts a force against finger portion 76 and forces end 80 into opening 79, 87 or 83. Spring 81 is mounted on a post 82 molded integral with the internal surface of wall 11. A further opening 89 in side 30a of plug 30 allows for finger grip and aids in withdrawal of plug 30 from within pack 10 when latch 75 is released. Spring 70 and the aid of finger pull in opening 83, 89 withdraws plug 30 from within pack 10 and assures locking. Once released, end 80 of latch 75 is forced into opening 87 or 79 and locks plug 30 external of pack 10. When end 80 of latch 75 is forced into opening 79 plug 30 is locked in a position in which it is substantially fully extended from pack 10. On the other hand, when end 80 of latch 75 is forced into opening 87, the plug is locked in a partially extended position. It will be understood that although at least one opening below opening 83 is required to lock plug 30 in an extended position from pack 10, any number of such openings may be provided to accommodate varying levels of extension.
FIGS. 5 and 6 illustrate pack 10 being inserted and, when inserted, ready for discharge and powering of the tool. In order for pack 10 to be inserted in the tool, shear 90 has a pocket 91 and liner 92, which is a common component of any tool or device in which pack 10 is used. Liner 92 serves as a base wall in pocket 91 and includes a flat surface 93, an inclined surface 94, a lip portion 95, and an extension 96 as seen in FIGS. 16-18. Flat surface 93 is adapted to engage the flat inner wall surface of battery pack 10 when pack 10 is inserted into pocket 91. Surfaces 94 and 95 are adapted to facilitate the pivotal insertion and removal of pack 10, as later described. Surface 93 provides two prong receiving slots 97, 98. Such pocket is described in copending application 607, 376.
The circuitry as illustrated in the accompanying drawings, provides for the internal battery pack to be connected to the prongs for recharging in three positions: (a) when plug 30 is withdrawn from pack 10 for deeply-recessed receptacles as in FIGS. 3, 9, 13 and 23; (b) when plug 30 is partially withdrawn from pack 10 for receptacles having a shallow recess as in FIGS. 4, 8, 12 and 22; and (c) when plug 30 is within pack 10 for flush receptacles as in FIGS. 2, 7, 11 and 21. However, as previously explained, the battery pack and device housing pocket are also provided with means to switch the internal battery pack circuitry to connect the prongs to the battery for discharge and use as a power source when plug 30 is within pack 10 and pack 10 is inserted in pocket 91 as in FIGS. 6, 10, 14 and 24. In this regard, it may be noted that liner post 99 is located on the wall of liner 92 against which pack 10 resides when in pocket 91. When pack 10 is fully inserted into pocket 91, with plug 30 within pack 10, pack prongs 46, 47 enter the prong-receiving slots 97, 98 and post 99 engages switch actuating post 56 so as to switch the circuitry of pack 10 into discharging mode as in FIG. 24. Contact spring holders 121, 122 (FIGS. 16, 19, 20) provide in a central portion thereof post members 123, 124 which are each adapted to receive a contact spring 115 as best shown in FIGS. 19 and 20. Contact springs 115 contact the inserted prongs 46, 47 and comprise curved leaf springs of resilient conductive metal having a loop portion 110, an elbow portion 116, a U-shaped prong engagement portion 126, and a wire lead solder contact 114 (FIGS. 19, 20). Loop 110 and elbow 116 are press-fitted over one of the grooved post members 123, 124 and hold contact spring 115 in place. Prong engagement portion 126 is normally in the external position shown in FIG. 19. As pack 10 is pivoted into pocket 91, one of prongs 46, 47 contacts spring 115 and bends it until pack 10 is fully inserted as in FIG. 20. Springs 115 are, thus, adapted to provide exceptionally reliable electrical contact with the leading edges of prongs 46, 47. Wire lead solder contact 114 of contact spring 115 is adapted to electrically connect spring 115 to the appropriate wire leads of the tool motor or other device apparatus.
The method of insertion and removal of pack 10 into and from pocket 91 is best illustrated in FIGS. 5 and 6 with respect to a typical grass shear adapted with a single pocket and battery pack according to the invention. The shear 90 is held by one hand with the pocket 91 facing downwardly. With the other hand, the operator picks up pack 10 with prongs 46, 47 facing upwardly and with plug 30 within pack 10. The end of pack 10 opposite latch 21 is then inserted into pocket 91 with surface 14 of pack 10 resting on pocket ledge 100 and with generally flat bottom wall surface 11 of pack 10 residing proximate incline surface 94. Pack 10 is now rocked about ledge 100 until the generally flat bottom wall surface 11 of pack 10 lies flush against flat surface 93 of liner 92 (FIG. 6). During this rocking movement, prongs 46, 47 enter slots 97, 98 until prongs 46, 47 engage and bend contact springs 115. Also, during this rocking motion, liner post 99 engages switch actuating post 56. When pack 10 is fully inserted, pocket lip 125 engages latch groove 105 in order to hold pack 10 in place without requiring guideways, or the like. Thus, the front receptacle portion of the pocket formed by the portions 94, 95 of liner 92, housing wall 106, and ledge 100 locates pack 10 for insertion, supports pack 10 during the rocking movement and holds the forward end of pack 10 securely in place.
It should be noted that the internal spring 59 for switch actuator 55 and the pair of contact springs 115 (FIG. 19) are all compressed by latching of pack 10. Thus, pack 10 tends to tilt and pop out when unlatched. The removal of pack 10 from pocket 91 becomes a two-step operation which provides a degree of protection against accidental unlatching or dropping of pack 10. First, latch 21 is depressed so that latch groove 105 disengages pocket lip 125 and by the mentioned spring action and possible force of gravity, dependent on how the tool or device is positioned, pack 10 moves to and is held in a partially removed position as illustrated by FIG. 5. Thus, if latch 21 is accidentally depressed, pack 10 can move to the partially removed position and remain there until reinserted or removed. In the embodiment illustrated, it is recognized that in shear 90, the operator trigger or other type on-off switch 101 and safety 102 is suitably placed for operator control as shown in FIGS. 5 and 6.
The charging and discharging circuitry of pack 10 will now be described with reference to the schematic circuit diagrams of FIGS. 21, 22, 23 and 24. FIG. 23 illustrates schematically the charging circuitry of pack 10 for charging in a deeply-recessed receptacle. With plug 30 withdrawn from pack 10, pack 10 is ready for charging through a conventional European-type, deeply recessed, 220 volt receptacle. Contacts 65 are movable with switch actuator 55. The charging circuitry of FIG. 23 comprises: (1) prongs 46, 47; (2) contacts 65; (3) charging contact terminals 141, 142; (4) a capacitor 28 which is adapted to drop the input voltage; (5) a diode bridge full wave rectifier 31; (6) batteries 25, 26, 27 connected in series; (7) a bleed resistor 32 which is selected to quickly bleed by completing a RC circuit with a short time constant; and (8) a surge resistor 33 which prevents the diode bridge 31 from receiving a large surge when capacitor 28 is completely discharged.
FIG. 22 illustrates a schematic circuit diagram of pack 10 for charging in a receptacle having a relatively shallow recess. Plug 30 is partially withdrawn from pack 10 to an intermediate position of extension. With plug 30 in this position, the prong contacts 65 are brought into electrical connection with charging contact terminals 145 and 146.
FIG. 21 illustrates a schematic circuit diagram of pack 10 ready for charging with plug 30 in a retracted position and which is useful for flush-type receptacles. With plug 30 in this position, the prong contacts 65 are brought into electrical connection with charging contact terminals 147 and 148.
FIG. 24 illustrates the discharge circuitry of pack 10. The discharge circuitry is, of course, a direct connection between: (1) prongs 46, 47; (2) contacts 65; (3) terminals 143, 144; and (4) batteries 25, 26, 27. Once plug 30 is moved into a locked position within pack 10, pack 10 can now be placed in a shear 90 for powering the device. Liner post 99 contacts switch-actuating post 56 and forces switch actuator 55 and contacts 65 inward in plug 30 so that contacts 65 now contact discharge contact terminals 143, 144. The discharge circuitry is now actuated. Removal of pack 10 from shear 90 releases the force upon post 56 and spring 59 moves actuator 55 back to its FIG. 21 charge position for flush-type receptacles.
The described pack circuitry has several practical advantages in that such full wave rectification circuitry minimizes both weight and internal heat. Pack 10 can essentially be encapsulated, though hole 58 is preferably designed to provide sufficient clearance, both for post 56 and to vent pack 10 in the event of extraneous battery gases. In contrast, recharging circuitry of other types, e.g., half-wave rectification, would both increase weight and temperature and require positive venting. Those skilled in the art will recognize that the circuitry can be readily adapted for charging when plug 30 is withdrawn from pack 10 to positions other than those which have been illustrated.
In summary, it can be seen that pack 10 of the present invention, thus, provides both a unique battery pack suited for recharging from various type receptacles as well as a unique battery pack-tool pocket combination which is economical to mass produce. It will also be seen that the several advantages of the universal-type power pack and pocket arrangement previously described in copending application Ser. No. 607,376 have been retained while adapting such type of pack and pocket arrangement for use in Europe and other parts of the world where electrical outlet design differs from that found in the United States.
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A relatively flat, rectangular, box-shaped, rechargeable, battery pack has a multi-positionable plug with prongs. The plug can be appropriately positioned for recharging the pack by insertion of the plug into either a European-type, deeply recessed receptacle, in a shallow recessed receptacle or in a flush, non-recessed United States-type receptacle. The pack is adapted to interchangeably fit into a pocket or any one of a plurality of pockets in a device in which the pack is to be employed. The prongs on the plug furnish voltage to the device when the pack is in a device pocket and furnish voltage to the pack during recharging. In a discharge mode, the plug is depressed and latched within the battery pack leaving only the prongs external of the battery pack for insertion into the device to be powered. The plug is likewise depressed for recharging in a flush-type receptacle. The pack discharge circuitry is actuated by a mating post in the housing of the device to be powered.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to semiconductor fabrication and more specifically to processes of fabricating high-k dielectric layers.
BACKGROUND OF THE INVENTION
[0002] Current high-k gate dielectric processes developed to meet the future transistor performance requirements in the 0.10 μm generation and beyond consist of generally two types: atomic layer chemical vapor deposition (ALCVD) and metal organic chemical vapor deposition (MOCVD). These processes permit formation of the necessary high-k film thickness and thickness uniformity.
[0003] However, MOCVD processes introduce undesired carbon (C)-containing impurities and the more mature ALCVD processes which use chlorine (Cl)-containing precursors create a sufficiently high chlorine content in the high-k films that degrades the electric performance of the devices using those high-k films.
[0004] For example, while an MOCVD process may use Zr(OC 2 H 5 ) 4 to form an ZrO 2 film, carbon impurities (and hydrogen impurities) are formed in the high-k ZrO 2 dielectric layer.
[0005] In another example, in an ALCVD process H 2 O is pulsed, then purged and then an HfCl 4 precursor is pulsed then purged to form an HfO 2 film. However, chlorine (Cl) impurities are formed in the high-k HfO 2 film, especially proximate the interface between the HfO film and the substrate over which it is formed. ALCVD processes generally have a low process temperature of from about 250 to 350° C.
[0006] U.S. Pat. No. 6,271,094 B1 to Boyd et al. describes a method of making MOSFET with a high dielectric constant (k) gate insulator and minimum overlap capacitance.
[0007] U.S. Pat. No. 6,153,477 to Gardner et al. describes a process of forming an ultra-short transistor channel length using a gate dielectric having a relatively high dielectric constant.
[0008] U.S. Pat. No. 6,114,228 to Gardner et al. describes a method of making a semiconductor device with a composite gate dielectric layer and gate barrier layer.
[0009] U.S. Pat. No. 6,090,723 to Thakur et al. describes conditioning processes including annealing or high-k dielectrics.
[0010] U.S. Pat. No. 6,008,095 to Gardner et al. describes a process for the formation of isolation trenches with high-k gate dielectrics.
SUMMARY OF THE INVENTION
[0011] Accordingly, it is an object of one or more embodiments of the present invention to provide a improved process of forming high-k dielectric layers.
[0012] It is another object of one or more embodiments of the present invention to provide an improved annealing process for repairing defects at silicon/high-k dielectric layer interfaces.
[0013] Other objects will appear hereinafter.
[0014] It has now been discovered that the above and other objects of the present invention may be accomplished in the following manner. Specifically, a substrate is provided. A high-k dielectric layer having impurities is formed over the substrate. The high-k dielectric layer being formed by an MOCVD or an ALCVD process. The high-k dielectric layer is annealed to reduce the impurities within the high-k dielectric layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will be more clearly understood from the following description taken in conjunction with the accompanying drawings in which like reference numerals designate similar or corresponding elements, regions and portions and in which:
[0016] FIGS. 1 to 4 schematically illustrate a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Unless otherwise specified, all structures, layers, steps, methods, etc. may be formed or accomplished by conventional steps or methods known in the prior art.
Initial Structure
[0018] As shown in FIG. 1 , structure 10 includes shallow trench isolation (STI) structures 12 formed therein. Structure 10 is preferably a silicon substrate and is understood to possibly include a semiconductor wafer or substrate. STIs 12 are comprised of thermal oxide, SACVD oxide or HDP-CVD oxide and are more preferably HDP-CVD oxide.
[0019] A high-k dielectric layer 14 is formed over silicon substrate 10 generally between STIs 12 to a thickness of preferably from about 5 to 200 Å and more preferably from about 20 to 100 Å . High-k dielectric layer 14 is preferably comprised of a metal oxide or a metal silicate formed by either an MOCVD process which introduces carbon (and hydrogen) impurities or an ALCVD process which introduces chlorine impurities, and does not decompose under the annealing 16 conditions of the present invention.
[0020] High-k dielectric layer 14 is preferably: (1) a metal oxide such as HfO 2 , ZrO 2 , La 2 O 3 , Y 2 O 3 , Al 2 O 3 or TiO 2 and more preferably HfO 2 , ZrO 2 or Al 2 O 3 ; or (2) a metal silicate such as HfSi x O y , ZrSi x O y , LaSi x O y , YSi x O y , AlSi x O y or TiSi x O y and more preferably HfSi x O y or ZrSi x O y .
Anneal of Deposited High-k Dielectric Layer 14 —One Key Step of the Invention
[0021] In one key step of the invention and as illustrated in FIG. 2 , the deposited high-k dielectric layer 14 is annealed 16 at a temperature of preferably from about 280 to 820° C., more preferably from about 300 to 800° C. and most preferably from about 300 to 700° C. for preferably from about 0.5 to 300 seconds, more preferably from about 2 to 100 seconds for rapid thermal anneal (RTA) process and from about 5 to 300 minutes for furnace annealing processes to drive out the chlorine; and carbon and hydrogen impurities to form an impurity-free high-k dielectric layer 14 ′. That is the chlorine, carbon and/or hydrogen impurities are reduced to preferably less than about 20% to 2 times which improves the electrical performance of the subsequently formed transistors/devices incorporating impurity-free high-k dielectric layer 14 ′.
[0022] The anneal 16 is preferably by rapid thermal processing (RTP) or by a furnace anneal and is conducted so as to minimize recrystallization of the high-k dielectric layerl 4 . The anneal 16 is carried out in the presence of ambients that are preferably H 2 , N 2 , H 2 /N 2 , H 2 /O 2 , O 2 /N 2 , He or Ar and are more preferably H 2 /N 2 or O 2 /N 2 . The presence of oxygen (O 2 ) is kept low to avoid additional oxidation of the high-k dielectric layer 14 .
Formation of Gate Layer 18
[0023] As shown in FIG. 3 , a gate layer 18 is formed over impurity-free high-k dielectric layer 14 ′ to a thickness of preferably from about 100 to 3000 Å and more preferably from about 500 to 2000 Å. Gate layer 18 is preferably comprised of polysilicon (poly) or a metal (metal gate) such as TaN/W, TiN/W, TaN/Al or TiN/Al and is more preferably polysilicon.
Further Processing
[0024] Further processing may then proceed. For example, as shown in FIG. 4 , gate layer 18 and impurity-free high-k dielectric layer 14 ′ are patterned to form gate electrode 20 comprised of patterned gate layer 18 ′ and impurity-free high-k dielectric layer 14 ″.
[0025] Additional processing may continue thereafter. For example, silicide formation, LDD implants, gate sidewall spacer formation, HDD implants, etc. to complete formation of a transistor or device incorporating gate electrode 20 .
Advantages of the Present Invention
[0026] The advantages of one or more embodiments of the present invention include:
[0027] 1.improved transistor/device electrical performance; and
[0028] 2.improved process for high-k film quality.
[0029] While particular embodiments of the present invention have been illustrated and described, it is not intended to limit the invention, except as defined by the following claims.
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A method of reducing impurities in a high-k dielectric layer comprising the following steps. A substrate is provided. A high-k dielectric layer having impurities is formed over the substrate. The high-k dielectric layer being formed by an MOCVD or an ALCVD process. The high-k dielectric layer is annealed to reduce the impurities within the high-k dielectric layer.
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This application is a continuation of application Ser. No. 09/616,616, filed Jul. 14, 2000, now abandoned.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to a printing substrate for signage and the like formed from a continuous fabric web and, more particularly, to a printing substrate formed and finished in a single operation which is substantially distortion free.
(2) Description of the Prior Art
Recent years have seen a proliferation of outdoor advertising media for such events as outdoor sporting events, concerts, celebrations, etc. As the volume of advertising has grown, so has the demand for more visible media which can be cost effectively produced quickly and with a high level of quality. Traditionally, printing substrates for such signage has been formed from woven fabrics because paper and non-woven fabrics are not strong enough for these applications. Woven fabrics can be produced as relatively large panels for use as banners and can be coated with print receptive materials that are resistant to running and fading of the printed materials. However, because of inherent problems with instability in the larger denier, high strength yarns needed and with fabric distortion created during the handling and subsequent coating of these fabrics, image quality often suffers in the form of streaking and uneven color absorption.
Knitted fabrics have heretofore not been suitable for use in outdoor signage because even higher degrees of distortion are usually introduced into a knitted fabric than a woven fabric as a result of movement and handling required to coat the knitted fabric in preparation for its intended use. However, knitted fabrics, if they could meet the required surface stability, would offer huge economic advantages over woven printing substrates. For example, warp knitting machines can produce large width continuous fabric webs at extremely high speed when compared to the speed of a loom. Fabric webs produced by warp knitting machines have many industrial applications but generally are subsequently coated with another material, such as plastic, to produce a composite material. In such cases, the fabric web acts as a substrate to give added strength and the plastic coating may be, for example, a roofing material. Because the fabric web is only used for reinforcement, distortion in the fabric web is not critical, nor is it usually seen by the end user.
While warp knitting machines having widths greater than 72 inches are common and relatively inexpensive, finishing machines having widths greater than 72 inches become exponentially expensive. In addition, the costs associated with moving such wide rolls of fabric can add substantial cost per yard to the final material. Prior art attempts to integrate the fabric forming and finishing operations into a single operation have not been very successful. Specifically, it is very difficult to control the thickness of the coating operation unless the coating operation is continuous. However, by its nature, fabric forming must be stopped and started when defects, such as broken yarns, occur.
Thus, there remains a need for a printing substrate for signage or the like formed economically from a weft inserted, warp knitted continuous fabric web while, at the same time, the fabric web can be finished in a single operation so as to be substantially distortion free for improved print quality.
SUMMARY OF THE INVENTION
The present invention is directed to a printing substrate. The printing substrate is formed from a weft inserted, warp knit fabric web finished in a single operation having at least an 8×9 construction and a print receptive coating. In the preferred embodiment, the print receptive coating is polyvinyl chloride, such as a vinyl and acrylate blend. In the most preferred embodiment, the print receptive coating is a plastisol coating. The print receptive coating may further include an opacifier, such as titanium dioxide and a flame retardant.
Also, in the preferred embodiment, the fabric web is formed and finished in a single operation. Because of this unique manufacturing method, the fabric web is substantially distortion free. Specifically, the variation in the warp direction of the finished fabric web is less than about 6%, and preferably less than about 3%. In addition, the variation in the weft direction of the finished fabric web is less than about 16%, and preferably less than about 5%.
Preferably, the finished fabric web is formed from synthetic yarn, such as polyester yarn. The finished fabric web may be manufactured in widths greater than about 72, 96 or 120 inches wide. In the preferred embodiment, the fabric web is formed with between about an 8×9 and an 18×18 construction and preferably about a 9×18 construction with at least 500 d ends.
One apparatus and method for producing the present invention is disclosed in application Ser. No. 09/479,678, filed Jan. 7, 2000, now U.S. Pat. No. 6,405,418, which is hereby incorporated by reference in its entirety. This application discloses an apparatus for forming and finishing a continuous fabric web in a single operation. The apparatus includes a fabric web forming station for forming a continuous fabric web and a finishing station downstream from the fabric web forming station for receiving the continuous fabric web from the fabric web forming station and for providing a finishing treatment to the continuous fabric web. In the preferred embodiment, the fabric web forming station is a warp knitting machine having a creel and a plurality of yarn packages for supplying yarn to the warp knitting machine.
In the preferred embodiment, the finishing station includes a substantially excess-free applicator which helps to prevent thick spots in the coated fabric web which may occur when a coating applicator is stopped and restarted. The applicator of the present invention includes a liquid coating supply; an elongated pan extending across the width of the fabric web for containing the liquid coating; and an elongated knurled roller positioned in the pan in direct contact with the liquid coating and in direct contact with the bottom surface of the fabric web, whereby the rotation of the knurled roller transfers a predetermined amount of the liquid coating to the fabric web.
The volume of the grooves in the knurled surface of the knurled roller is proportional to the predetermined amount of the liquid coating being transferred to the fabric web. The predetermined amount of the liquid coating being transferred to the fabric web is substantially equal to the desired liquid take-up of the fabric web, thereby eliminating the need for removing excess liquid take-up from the fabric web.
To further control the accuracy of the amount of liquid being transferred from the knurled roller to the continuous fabric web, the deflection of the knurled roller is minimized in several ways. First, the bulk density of the knurled roller is less than about 3 times greater than the density of the liquid coating, thereby providing buoyancy to support the weight of the knurled roller. In the preferred embodiment the knurled roller is formed substantially from aluminum; however, the knurled roller could be jacketed with a high-density outer sheath and a low-density inner core. Second, a level control maintains the amount of liquid in the elongated pan at a predetermined level. Third, a deflection compensator attached to the knurled roller.
The deflection compensator is attached to the knurled roller includes a frame located at least one end of the knurled roller, a journal extending outwardly from the knurled roller, a first bearing attached to the frame for receiving the journal, a second bearing located at the outermost end of the journal and a pneumatic cylinder linkage attached between the second bearing and the frame for providing a downward force to compensate for the deflection of the knurled roller.
In the preferred embodiment, the finishing station includes a curing station downstream from the applicator. The curing station may include both a drying station and a heat set station downstream from the drying station. In the preferred embodiment the drying station includes a heat drum having a temperature between about 180 F and 225 F to remove most of the moisture from the coated continuous fabric web but not to produce VOCs which occur during curing of the coating. Desirably, a temperature of about 212 F will optimize the amount of moisture removed from the coated continuous fabric, while minimizing shrinkage of the fabric. A hood is located above the drying station for removing moisture driven off from the fabric web by the drying station. The airflow velocity of the hood is greater than about 400 CFM/ft of the width of the continuous fabric web which aids in drying the coated continuous fabric web. However, since the vapors include little or no VOCs, this large amount of air does not need to be treated further before being discharged into the atmosphere.
In the preferred embodiment, the heat set station includes a low thermal mass heat source which quickly cools when turned off. This permits the finishing station to be stopped and started as needed without burning the coated continuous fabric web. The heat set station also includes a hood located above the heat set station for removing VOCs driven off from the fabric web by the heat set station. Unlike the drying station, the airflow velocity of the hood is less than about 100 CFM/ft of the width of the continuous fabric web. This is a much smaller amount of air to be treated before being discharged into the atmosphere and results in substantial cost savings. In the preferred embodiment, the heat set station further includes a tenter frame for heat setting the continuous fabric web to a predetermined width.
Also in the preferred embodiment of the present invention is an accumulator located between the fabric web forming station and the finishing station for providing a fabric web reserve between the fabric web forming station and the finishing station. The accumulator includes a frame extending across the width of the continuous fabric web, a pair of arms each having one end attached to the frame on opposite edges of the continuous fabric web, a biased roller attached between the other ends of the pair of rollers and extending across the width of the continuous fabric web and a control system for varying the speed of the finishing station in response to the position of the accumulator arms.
Accordingly, one aspect of the present invention is a printing substrate, said printing substrate comprising a weft inserted, warp knit fabric web having at least an 8×9 construction.
Another aspect of the present invention is a printing substrate, said printing substrate comprising a weft inserted, warp knit fabric web finished in a single operation having at least an 8×9 construction.
Still another aspect of the present invention is a printing substrate, said printing substrate comprising a weft inserted, warp knit fabric web finished in a single operation having at least an 8×9 construction; and a print receptive coating.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a fabric making apparatus constructed according to the present invention;
FIG. 2 is a front view of the apparatus shown in FIG. 1 ;
FIGS. 3A and 3B is a side view of the apparatus shown in FIG. 1 ;
FIG. 4 is an enlarged front perspective view of the finishing station shown in FIG. 3 ;
FIG. 5 is an enlarged rear perspective view of the finishing station applicator shown in FIG. 3 ;
FIG. 6A is an enlarged side view of the finishing station applicator shown in FIG. 3 ;
FIG. 6B is an enlarged side view of the opposite end of the finishing station applicator shown in FIG. 6A ;
FIG. 6C is an enlarged front view of the finishing station applicator shown in FIG. 6A ;
FIG. 7 is a greatly enlarged view of the knurled roller of the finishing station applicator shown in FIG. 6C ;
FIG. 8 is an enlarged side view of the accumulator shown in FIG. 3 ;
FIG. 9 is an enlarged side view of the control system for accumulator shown in FIG. 8 ;
FIG. 10 is a chart showing the relationship between relative fabric forming costs and fabric width;
FIG. 11A is a chart showing the relationship between relative VOCs and fabric drying temperature, and between moisture percentage and fabric drying temperature;
FIG. 11B is a chart showing shrinkage and moisture removed, and the relationship between shrinkage and moisture removal, as fabric drying temperature is varied;
FIG. 12 is a chart showing the relative costs, in dollars, associated with various drying and heat set airflow velocities;
FIG. 13 is a diagram showing how the speed of the finishing station, shown in FIG. 4 , is varied.
FIG. 14 is a graph illustrating the relative costs, in dollars, associated with the preferred ranges of warp knitted constructions in comparison with the print resolution which may be obtained for each construction, illustrating the balance between cost and print resolution achieved by the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.
The present invention includes a weft-inserted warp knitted fabric having a fabric construction of at least 8 warp yarns to 9 weft yarns (8×9) and a print receptive coating. For use as printed substrates having sufficient printing surface areas, fabric constructions between about 8×9 and 18×18 are suitable. Both warp and weft yarns are synthetic, and polyester is desired because of its durability and handling characteristics. As banners and the like for outdoor advertising or the display of other information are by necessity large, larger one-piece fabric panels are desired. Warp knitting machines known in the art are capable of producing single panels in excess of 72 inches in width and up to about 120 inches in width. Thus, the printing substrate of the present invention is produced in panels at least 72 inches in width.
The print receptive coating of this embodiment of the present invention is desirably polyvinyl chloride (PVC), and preferably a vinyl acrylic blended coating since acrylic provides enhanced printability and durability. Plastisol is one such preferred vinyl acrylic blend with 100% of the coating remaining on the material since it contains no carriers or solvents that must be evaporated or otherwise removed. However, plastisol has not proven satisfactory as a coating on woven fabrics since a slower process speed is required for its satisfactory application. To enhance light transmission through the printing substrate, an opacifier such as titanium oxide may be used in the finishing process. Further, to meet the requirements of current fire protection codes, such large printed substrates must be flame retardant. Thus, depending upon the specific application, a flame retardant is also applied during the finishing process.
The present invention provides a weft-inserted warp knitted printing substrate having a print receptive coating that may be manufactured during a single operation without the need for additional moving or handling steps. Such a single fabric forming and coating manufacture is disclosed in previously cited application Ser. No. 09/479,678. As described in that application, an apparatus for forming a fabric web in a single operation includes a fabric web forming station for forming a continuous fabric web and a finishing station downstream of the fabric web forming station for providing treatment to the continuous fabric web. Specifically, as best seen in FIGS. 1 and 2 , the fabric making apparatus, generally designated 10 , is shown constructed according to the related and present invention. The fabric making apparatus 10 includes three major sub-assemblies: a fabric web station 12 ; a finishing station 13 ; and an accumulator 16 .
As best seen in FIG. 3 , in the preferred embodiment, the fabric web forming station 12 is a warp knitting machine having a creel 20 and a plurality of yarn packages 22 for supplying yarn to the warp knitting machine. One such machine is available from LIBA Maschinenfabrik, Naila of West Germany. This machine is described in part by U.S. Pat. Nos. 4,154,068; 3,724,241; and 3,584,479 which are hereby incorporated by reference in their entirety. As discussed above, while warp knitting machines having widths greater than 72 inches are common and relatively inexpensive, finishing machines having widths greater than 72 inches become exponentially expensive. In addition, the overhead costs associated with moving such large rolls can add substantial cost per yard to the final material. This relationship can be best seen in FIG. 10 in which the fabric finishing costs increase at a much higher rate than the fabric forming costs. In the present invention, forming and finishing costs only increase at a slightly higher rate than forming alone. This may result in cost savings up to 25 cents per square yard.
As seen in FIGS. 3A , 4 and 5 , the finishing station 13 includes an applicator 14 and a curing station 15 . As best seen in FIG. 13 , fabric web 11 exiting the front face of the fabric forming station 12 passes under rollers 17 and 74 and over rollers 18 and 19 before feeding into finishing station 13 where a liquid coating 26 is applied to the fabric web 11 by the substantially excess-free applicator. In the preferred embodiment, the substantially excess-free applicator system includes a knurled roller assembly 32 . As best seen in FIGS. 6B , 6 C and 7 , the knurled roller assembly includes a knurled roller 34 for picking up a liquid coating 26 contained in pan 24 by grooves 35 on the surface of the knurled roller 34 and evenly applied to continuous fabric web 11 passing across the top of the knurled roller 34 .
The bulk density of the knurled roller 34 is less than about 3 times greater than the density of the liquid coating 26 , thereby providing buoyancy to support the weight of the knurled roller 34 . In the preferred embodiment the knurled roller 34 is formed substantially from aluminum; however, the knurled roller 34 could be jacketed with a high-density outer sheath and a low-density inner core. As seen in FIG. 5 , a level control system 30 maintains an optimum level of liquid coating 26 in pan 24 such that knurled roller 34 is floatably supported.
As best seen in FIGS. 6A and 6B , a deflection compensator 36 also is provided to further prevent sagging of knurled roller 34 . In the preferred embodiment, the deflection compensator 36 is comprised of a frame 40 which supports a pivotal first bearing 42 , a journal 44 , and a second bearing 46 . A variable linkage 50 is attached to the second bearing 46 to vary the amount of force applied to knurled roller 34 . In the preferred embodiment, an actuator 52 replaces or is attached to variable linkage 50 .
Referring back to FIG. 4 , in the preferred embodiment, curing station 15 is comprised of both a drying station 54 and a heat set station 60 . The coated continuous fabric web 11 feeds into drying station 54 across heat drum 55 where moisture is substantially removed from the coated fabric. Ambient air is drawn through hood 56 mounted directly above heat drum 55 to aid in the drying process. The heat drum is maintained at a temperature between about 180 F and about 225 F to remove most of the moisture from the coated continuous fabric web but not to produce VOCs which occur during curing of the coating. This relationship can be best seen in FIG. 11A in which the moisture content decreases at a much higher rate than the VOCs emission rate. FIG. 11B shows how a heat drum temperature of approximately 212 F optimizes moisture removal while minimizing shrinkage of the coated fabric.
The air flow velocity of the hood 56 is greater than about 400 CFM/ft of the width of the continuous fabric web 11 which aids in drying the coated continuous fabric web 11 . However, since the vapors include little or no VOCs, this large amount of air does not need to be treated further before being discharged into the atmosphere.
Downstream of heat drum 55 , dried fabric web 11 is fed into heat set station 60 where the fabric web 11 passes under heaters 64 for final finishing. In the preferred embodiment, heaters 64 are low-mass infrared lights which quickly cool when turned off. This permits the finishing station 13 to be stopped and started as needed without burning the coated continuous fabric web 11 . The heat set station 60 also includes a hood 66 located above the heat set station 60 for removing VOCs driven off from the fabric web 11 by the heat set station 60 . Unlike the drying station 54 , the airflow velocity of the hood is less than about 100 CFM/ft of the width of the continuous fabric web. This is a much smaller amount of air to be treated before being discharged into the atmosphere and results in substantial cost savings. This relationship can be best seen in FIG. 12 in which the relative process costs on a 1 to 5 scale are shown as a function of drying and heat set CFM rates per foot of fabric web. In the present invention, being able to use low CFM rates for heat setting keeps the total curing station cost low.
In the preferred embodiment, the heat set station 60 further includes a tenter frame 62 for heat setting the continuous fabric web 11 to a predetermined width. One such machine is available from Marshall & Williams Company of Greenville, S.C. This machine is described in part by U.S. Pat. No. 3,179,975 which is hereby incorporated by reference in its entirety. The fabric is then taken up on a conventional take-up unit such as that manufactured by Greenville Machinery Corporation of Greenville, S.C.
In the preferred embodiment, the present invention also provides a fabric web reserve between the fabric making station 12 and the finishing station 13 . As seen in FIGS. 8 and 9 , accumulator 16 includes a biased roller 74 which is supported by two arms 70 , 72 on a frame 75 . A control system 76 includes a position sensor 80 for varying the speed of electric motor 86 and the finishing station 13 in response to the position of the accumulator arms 70 , 72 . As best seen in FIG. 13 , position sensor 80 senses the relative position of accumulator arms 70 , 72 and provides an input to a microprocessor 82 . Microprocessor 82 provides an output signal to a DC electric voltage controller 84 which varies the speed of electric motor 86 and the finishing station 13 . Electric motor 86 is coupled to and turns pulling roller 88 . The lower the position of accumulator arms 70 , 72 , the higher the speed of electric motor 86 . Conversely, as arms 70 , 72 rise, the speed of electric motor 86 is reduced.
In operation, the fabric web 11 is formed by the warp-knitting machine 12 and passes to the finishing station 13 . Fabric web 11 exiting the front face of the fabric forming station 12 passes under rollers 17 and 74 and over rollers 18 and 19 before feeding into finishing station 13 where the liquid coating 26 is applied to the fabric web 11 by the substantially excess-free applicator and knurled roller assembly 32 . Level control system 30 maintains an optimum level of liquid coating 26 in pan 24 such that knurled roller 34 is floatably supported and deflection compensator 36 also further prevent sagging of knurled roller 34 .
A fabric web reserve is provided between the fabric making station 12 and the finishing station 13 by accumulator 16 . Control system 76 varies the speed of electric motor 86 and finishing station 13 in response to the position of the accumulator arms 70 , 72 .
The coated continuous fabric web 11 then feeds into drying station 54 across heat drum 55 where moisture is substantially removed from the coated fabric. Ambient air is drawn through hood 56 mounted directly above heat drum 55 to aid in the drying process.
Downstream of heat drum 55 , the dried fabric web 11 is fed into heat set station 60 where the fabric web 11 passes under heaters 64 for final finishing by the tenter frame 62 for heat setting the continuous fabric web 11 to a predetermined width.
The present invention is able to use relatively common warp knitting machines having widths greater than 72 inches without the need for very expensive finishing machines having widths greater than 72 inches. In addition, the overhead costs associated with moving such large rolls are substantially reduced as shown in FIG. 10 in which the fabric finishing costs increase at a much higher rate than the fabric forming costs. Specifically, in the present invention, forming and finishing costs only increase at a slightly higher rate than forming alone thereby resulting in cost savings up to 25 cents per square yard.
In addition, the present invention provides a measurably superior coated fabric web when compared to a standard tenter frame coated fabric web in which the fabric web is separately formed and then finished on the tenter frame and to a conventional high speed finishing, tenter frame system. Samples of all three processes were tested for yarn uniformity in the warp and weft directions shown in Table 1.
TABLE 1
WARP DIRECTION
WEFT DIRECTION
PROCESS
Spacing
SD
% Var
Spacing
SD
% Var
Present Invention
2.03 mm
0.05
3
1.77 mm
0.08
5
Tenter Frame (I)
2.04 mm
0.12
6
1.82 mm
0.30
16
Tenter Frame (II)
too curvy to measure
too curvy to measure
As can be seen, the tenter frame standard deviation is between about 2¼ and 4 times greater than that of the present invention. The high speed finishing, tenter frame system was so curvy as not to be meaningfully measurable. Handling alone appears to be the cause of the tenter frame variability. However, speed appears to be a major contributor for the high speed finishing, tenter frame system process. Specifically, the present invention operates between about 1 and 4 yards per minute and preferably at about 3 yards per minute. In contrast, the high speed process operates at about 90 yards per minute. Accordingly, the present invention avoids both of these problems and produces a continuous fabric web finished in a single operation which is substantially distortion free. Specifically, the variation in the warp direction of the finished fabric web is less than about 3% (0.05 SD (standard deviation)/2.03) and the variation in the weft direction of the finished fabric web is less than about 5% (0.08 SD/1.77).
Thus, the present invention is able to produce a continuous fabric web finished in a single operation is which the finished fabric web is substantially distortion free. Compared to the prior art, the variation in the warp direction of the finished fabric web is less than about 6% and, preferably, less than about 3%. In addition, the variation in the weft direction of the finished fabric web is less than about 16% and, preferable, less than about 5%.
In the preferred embodiment, the finished fabric web is a warp knit fabric and, preferable, is a weft inserted, warp knit fabric. The finished fabric web is formed from synthetic yarn which, unlike fiberglass-type yarns, are much more difficult to stabilize. Preferably, the finished fabric web is formed from polyester yarn.
The present invention is thus able to produce a finished fabric web greater than about 72 inches wide and, preferably, greater than about 96 inches wide or greater than about 120 inches wide depending on the width of the knitting machine.
A weft-inserted, warp knit printing substrate constructed according to the present invention is formed in a single operation as a 9×18 construction (9 yarns in the warp to 18 yarns in the weft); however, fabric constructions between about 8×9 and 18×18 are satisfactory for such purpose. As described in pending application Ser. No. 09/479,678, fabric webs of greater than about 120 inches may be formed and treated on a single apparatus without the need for moving and handling to other stations. Such a single operation provides a fabric construction that is substantially distortion free, and hence, superior for use as a printing substrate. Desirably, yarn uniformity in the warp direction is less than about 3% and less than about 5% in the weft direction.
For printed substrate construction, both warp and weft yarns are polyester with deniers between about 500 d and 1000 d. As best illustrated in FIG. 14 , a graph is shown that illustrates the relative costs, in dollars, associated with the preferred ranges of warp knitted constructions in comparison with the print resolution, which may be obtained for each construction. As can be seen, the present invention achieves a balance between cost and print resolution FIG. 14 demonstrates that a fabric construction of at least about 8×9 is required to provide sufficient print area for good print resolution, but that a fabric construction greater than about 18×18 will not be economical. Since fabric cost increases linearly as surface coverage increases geometrically, there is a substantial economical advantage due to increasing surface coverage per unit fabric web cost.
In addition, for large signage intended for outdoor use, the printing substrate must be sufficiently perforate to withstand wind loading and to permit adequate airflow. Fabric constructions greater than about 18×18 may be too tightly formed to provide sufficient permeability for air passage therethrough.
After formation of the weft-inserted, warp knit fabric, a print receptive coating, desirably polyvinyl chloride (PVC), is applied to the knitted fabric. In the preferred embodiment, the knurled roller applicator described in application Ser. No. 09/479,678 is replaced with a smooth roll for applying the print receptive plastisol for the plastisol viscosity preferably used and for the desired % add-on.
For enhanced durability and printability, a vinyl acrylic blend such as plastisol is applied. While not suitable for higher speed processes, plastisol is a superior coating for lower speed fabric producing and treating machines such as that described in pending application Ser. No. 09/479,678. A distinct advantage of plastisol is that substantially 100% of the coating remains on the fabric since solvents or other carriers are not required. Thus, such a coating can be applied with greater safety during manufacture and without emissions due to evaporation or removal of carriers. For applications involving signage, an opacifier such as titanium dioxide is applied during the finishing process to enhance light transmissibility, and a flame retardant such as aluminum trihydrate is applied to meet fire code requirements for large printed media.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
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A printing substrate is formed in a single operation by a method of forming and finishing a fabric web. The forming step creates a continuous fabric web. That fabric is sent to an accumulator, then downstream for finishing. The finishing step includes applying a printable coating via a knurled applicator, controlling the level of liquid in the applicator and compensating for knurled roller deflection. The finishing step further includes curing the coated fabric and selectively employing VOC hoods where needed.
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FIELD OF THE INVENTION
This invention relates to casters, and in particular to casters having elastomeric shock and vibration isolation elements.
DISCUSSION OF THE PRIOR ART
Casters having elastomeric torsion elements for absorbing shocks and vibrations are known, for example, from U.S. Pat. No. 4,312,096. In these casters, a yoke shaped bearing support is secured to the structure to be mounted on casters, a pair of wheel supports rotatably mounts a wheel between them, and an elastomeric torsion element is bonded between the bearing support and the wheel supports. The wheel supports are rotatable relative to the bearing support about an axis which is longitudinally offset from the wheel axis so that vertical loads applied to the wheel subject the elastomeric element to torsional shear stresses.
With these types of casters, for any given wheel diameter, the height of the caster itself has in some cases been excessive. The overall height of the caster has been reduced by increasing the angle between the bearing axis and the wheel axis (as measured from a vertical line through and below the bearing axis), but this results in a relatively long caster and high preloading forces being applied to the elastomeric torsion element, since for a large angle a significant proportion of the static weight load must be borne by the torsional resistance of the elastomeric element. In addition, when subjecting the elastomeric element to high and continuous torsional loads, it is possible that the bonds between the element and the wheel support and bearing support may fail or that the element itself may shear and therefore cause the caster to collapse. In addition, these types of casters had a relatively narrow stance, which resulted in instability in some applications.
SUMMARY OF THE INVENTION
The invention provides a caster which overcomes the above shortcomings of the prior art. In a caster of the invention, two spaced apart wheels are provided with a shock and vibration isolation suspension utilizing elastomeric torsional spring/damper elements disposed inboard of the wheels. This results in a low profile wheel of a short length and with a wide and stable stance. It also allows a relatively small angle between the wheel axis and the bearing axis to reduce the torsional static and dynamic loads to which the elastomeric element is subjected. In addition, in a preferred aspect, a fail-safe snubber can be provided on the bearing support to arrest excessive upward travel of the wheel relative to the bearing support.
In a preferred form, a wheel support is provided for each wheel with the wheel supports disposed inboard of the wheels along the wheel axis. A wheel axle, which may be provided as a single shaft or multiple coaxial shafts, extends through the wheel supports, and rotatably mounts the wheels to rotate about the wheel axis. An elastomeric torsion element for each wheel support, for a total of two in the preferred embodiment, are disposed inboard of the wheels along the wheel axis and each is bonded on one side to a corresponding wheel support and on the other side to a bearing support which is inboard of the wheels. A pivot bearing having a bearing axis which is parallel to the wheel axis extends through the wheel supports, the torsion elements and the bearing support, and allows rotation of the wheel supports relative to the bearing support about the pivot bearing axis. Means are also provided for mounting the bearing support to a structure to be supported by the caster. In an especially useful form, each of the elastomeric torsion elements is disposed inboard of its corresponding wheel support and the bearing support is arranged inboard of the elastomeric torsion elements along the wheel axis.
Preferably, the bearing support provides a snubbing bumper for abutting the axle at an upper limit of rotation of the wheel supports relative to the bearing support. This arrests excessive angular motion of the wheel supports and makes the caster fail-safe. In one form, the wheel axle is a single shaft which extends between the wheels and through slots in the bearing support, which provides limits for the upward as well as the downward rotation of the wheel supports.
Other features and advantages of the invention will be apparent from the following detailed description and from the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a caster of the invention;
FIG. 2 is an exploded perspective view of the caster of FIG. 1;
FIG. 3 is a perspective view of a second embodiment of a caster of the invention;
FIG. 4 is an exploded perspective view of the caster of FIG. 3;
FIG. 5 is a sectional view of a third embodiment of a caster of the invention;
FIG. 6 is a sectional view taken along the plane of the line 6--6 of FIG. 5;
FIG. 7 is a front plan view of a fourth embodiment of a caster of the invention;
FIG. 8 is a side elevational view of the caster of FIG. 7; and
FIG. 9 is a top plan view of the caster of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 illustrate a caster 10 of the invention having a pair of spaced apart wheels 12, a pair of wheel supports 14, an axle 16 spanning the wheels 12 and having an axis 17, elastomeric torsion elements 18, a bearing support 20 and a bearing support mount 22.
Each wheel support 14 is preferably a steel plate, as is the bearing support 20. The mount 22 is also a steel plate bent at a right angle and welded or otherwise secured to the bearing support 20 so as to hold the bearing support 20 in a generally vertical plane.
The axle 16 in the caster 10 is provided as a single axle which spans the wheels 12 and is secured at its ends to each wheel 12 by a press fit, adhesive or other suitable means so that the axle 16 and the wheels 12 rotate together about wheel axis 17. The wheel supports 14 each have a hole 24 through which the axle 16 extends and the axle 16, being a live axle, is journaled in the holes 24. Suitable anti-friction journal bearings may be provided in the holes 24 which may also help space the wheels 12 from the adjacent wheel supports (as shown in FIG. 5) if desired.
The axle 16 also preferably extends through spacers 26 and 28 which are disposed between the wheel supports 14 and serve to maintain the spacing between the wheel supports 14. The wheel supports 14 are generally tear-drop shaped with the holes 24 spaced apart from holes 30 at the center of the round portion of each support 14. Holes 30 are aligned axially along bearing axis 31. The inboard surface of the round portion of each wheel support 14 is bonded, such as by adhesive, vulcanizing or any other suitable means, to the outboard surface of a disk 32 made of an elastomeric material. The inboard surfaces of the disks 32 are bonded by similar means to opposite side surfaces of the bearing support 20. A pivot bearing 34 in the shape of a circular shaft extends through the holes 30, through the disks 32 and through the bearing support 20, and is secured at its ends to the supports 14 by welding, swaging, a C or E clip or other suitable means. In any event, the pivot bearing 34 allows the wheel supports to rotate relative to the bearing support 20 about the axis of the pivot bearing 34. The mount 22 is fixed to the bearing support 20 and has holes 36 for securing the mount 22 to a structure to be supported by the caster 10 such as a cart, bed, chair or other structure.
The caster 10 also includes a snubber 38 provided on the bearing support 20 to abut spacer 28 at the upper limit of rotation of the wheel supports 14 relative to the bearing support 20. Such abutment may occur, for example, if one or more of the bonds between the disks 18 and the bearing support 20 or wheel supports 14 failed or if any unusually large shock were encountered by the caster. In either event, this snubber 38 would arrest movement of the wheels 12 upwardly when the spacer 28 abutted the snubber 38. Preferably, the snubber 38 is provided as a small piece of elastomer to act as a cushion, although it could be made of metal and an integral part of the bearing support 20.
FIGS. 3 and 4 show a second embodiment 50 of a caster of the invention which is constructed essentially the same as the caster 10 but is provided with a swivel mount 52 rather than a fixed mount 22 as in the caster 10. Bearing support 20 is welded or otherwise secured along its top and front edges to lower portion 54 of swivel mount 52 and upper portion 56 of swivel mount 52 is secured to the cart, bed, chair or other structure to which the caster is to be mounted. The lower portion 54 can swivel about a vertical axis 55 relative to the upper portion 56 to facilitate turning and maneuvering the structure mounted on the caster 50.
The swivel mount 52 may be of the well known ball bearing type or any other type which provides for rotation of the lower portion 54 relative to the upper portion 56. Other elements of the caster 50 corresponding to elements of the caster 10 have been numbered with the same numbers. It is noted that in the snubber 38 of the caster 50, a separate elastomeric pad 38a is provided to cushion abutment with the spacer 28.
FIGS. 5 and 6 illustrate a third embodiment 60 of a caster of the invention. In the caster 60, a pair of wheels 62 are provided with a live axle 64 between them. The axle 64 is journaled to rotate about axis 65 in bearings 66 which are inserted in holes of wheel support plates 68 and have flanges to space the wheels 12 from the plates 68. The axle 64 extends through aligned arcuate slots 76 formed in elastomeric torsion disks 70 and plates 72.
In the caster 60, the plates 72 are secured by welding or other suitable means to a mounting stem 74, but instead of a mounting stem a fixed plate (like mount 22 in FIGS. 1 and 2) or a swivel mount (like mount 52 in FIGS. 3 and 4) could be fixed to the plates 72. The mounting stem 74 is inserted up into a hole of the structure to which the caster 60 is to be mounted, in well known fashion.
Both plates 72 make up a bearing support which is bonded to the inboard side surfaces of the elastomeric torsion disks 70. The outboard side surfaces of the disks 70 are each bonded to the inboard side surface of the adjacent plate 68. A pivot bearing 34 is secured at its ends to the plates 68 and extends through the disks 70 and the plates 72 to allow rotation of the plates 68 relative to the plates 72 about bearing axis 73.
Referring to FIG. 6, the slots 76 are centered on the axis 73 as shown. The wheel axle 64 rides in the slots 76 and the slots 76 provide an upper limit at their top ends and a lower limit at their bottom ends for the rotation of the plates 68 relative to the plates 72. These limits serve to arrest excessive rotation of the plates 68 relative to the plates 72, much in the same manner as the snubber 38, although in the caster 60, snubbing is provided at both the upper and the lower limits of angular motion. It should also be noted in the caster 60, with particular reference to FIG. 6, that a relatively small angle β exists between the wheel axle and the pivot bearing.
FIGS. 7-9 illustrate a fourth embodiment 90 of a caster of the invention. The caster 90 is similar to the caster 60 except that the plates 72 are spaced further apart, a separate stem 92 is provided for each plate 72, and the pivot bearing 34 is provided in two separate shafts, one at each side of the caster. Note that the axle 64 could also be provided in two separate shafts, if so desired. In the embodiment 90, each stem 92 may be disposed at opposite sides of the structure to be supported by the caster 90, such as at opposite side legs of a cart. Also, as best shown in FIG. 8, the angle β is approximately 90°. This angle would yield high torsional loading of the elements 70 relative to a smaller angle for any given vertical load, such as the weight of a cart or other structure supported by the caster 90. However, because of the relatively compact size in which a caster of the invention may be made, and therefore a relatively short distance between the pivot bearing 34 and the axle 64, the torsional loads on the disk 70 would not necessarily be excessive, depending upon the cart or other structure supported by the caster 90.
Preferred embodiments of the invention have been described in considerable detail. Many modifications and variations will be apparent to those skilled in the art which will still embody the invention. For example, it may be possible to incorporate the invention in another type of two-wheeled caster such as one having a brake or other accessories, or in a caster in which the wheel axle was not live. Therefore, the invention should not be limited to the preferred embodiment, but should be defined by the claims which follow.
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A caster has two spaced apart wheels with an elastomeric torsional shock and vibration isolating suspension between them. The wheel axis is spaced longitudinally from a bearing axis to subject elastomeric disks positioned between the wheels to torsional shear stresses to help absorb shocks and vibrations. A snubber is provided for limiting the angular motion of the wheels about a bearing axis.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Provisional Patent Application Ser. No. 60/450,847 filed Feb. 28, 2003, to which priority is claimed under 35 U.S.C. §120 and which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to soil aerification (or “aeration”). More particularly, it relates to a method and apparatus for the aerification of turf grasses using a self-rotating turf drill.
[0004] 2. Description of the Related Art
[0000] What is Aerification
[0005] Aerification is a mechanical process that creates more air space in the soil and promotes deeper rooting, thus helping plants stay healthy. In most cases, this is achieved by removing cores (often called plugs) and then filling the holes with topdressing. Topdressing is often a certain grade of sand which may have other amendments added to allow the soil to maintain air space, improve water penetration, and encourage healthy root growth. The sand is brushed or poured into the holes which are usually healed within several days.
[0006] The condition of turf largely depends on the events occurring below the surface. For grass to grow, deep healthy roots are needed, and roots require oxygen. In good soil, they receive oxygen from tiny pockets of air trapped between soil and sand particles. On a sports field, the everyday traffic from players combined with the weight of heavy mowing equipment causes the soil to become compacted and the air pockets on which the roots depend for oxygen are lost. Aerification is a mechanical process that creates more air space in the soil and promotes deeper rooting, water percolation and compaction relief.
[0007] The practice of aerating turf is becoming increasingly widespread. The benefits of aerification include:
improved water infiltration and better drainage Deeper penetration of fertilizers Improved plant rooting Thatch control Increased stress tolerance Break up of sod layers that can restrict rooting and water movement Release of toxic gases from soils Increased drying and drainage of persistently wet soils Loosening of soil, allowing for increased air space Softening of sports fields to reduce risk of injury
[0018] The principal reason for aerification is soil compaction relief. In addition, putting green aerification can provide for additional surface smoothing.
[0000] Compaction Relief
[0000] Definition of Compaction
[0019] Compaction of sports playing fields and golf course tees, greens and fairways is an inevitable product of their use—golf carts, maintenance machinery and feet all contribute to the process that is defined as “the consolidation of soil particles.” Compaction decreases water and oxygen movement in the soil, hinders root growth and lessens the ability of the soil to drain. Soil compaction causes these negative effects by turning macropores (larger voids in the soil largely responsible for drainage and air flow) into many micropores (smaller voids that hold water). As compaction increases, bulk density also usually increases, which means that more soil solids occupy a unit volume of soil, reducing the porosity.
[0020] With turfgrass, techniques used to relieve compaction must be effective without being highly visible. Aerification—either with solid tines that create a hole in the soil, or with hollow tines or drills that remove a core of soil—is one of the more common ways of improving compacted soils.
[0021] When a soil compaction condition is accompanied by excessive thatch buildup, as is almost always the case in poorly maintained turf, each condition contributes to the effect of the other. Thatch is a mat of undecomposed plant material (e.g., grass clippings) accumulated next to the soil in a grassy area (as a lawn, sports field or putting green). It is a tightly intermingled layer of living and dead stems, leaves and roots of grasses, which develops between the layer of green vegetation and the soil surface. When thatch exceeds about ½ inch of undecomposed material, it acts as a barrier to water and air infiltration into the soil below and will provide an environment encouraging turf diseases and harmful insects. Compacted soils, on the other hand, are subject to greater temperature extremes than loose soils, because of limited air movement; microbial activity necessary to thatch decomposition is reduced or halted.
[0022] Water that cannot penetrate the soil runs off or accumulates in low spots where it harbors fungus growth.
[0023] Alleviating either condition will help, but only when thatch is kept under control and the soil is properly aerified will turf have the best chance for healthy, vigorous growth and disease resistance.
[0024] The accumulation of organic matter (thatch) and fine particles (silt and/or clay) can, over time, produce a surface layer that reduces porosity. Aerification can modify the profile, improving oxygen, water, and root movement, especially when the use of hollow tines or turf drills is combined with core removal and backfilling channels with high-quality topdressing sand.
[0000] Prior Art Methods of Aerification
[0025] Turfgrass cultivation activities include hollow tine aerification, solid tine aerification, spiking, slicing, and water injection. These activities, to varying degrees, can reduce thatch, prepare turf for overseeding, and relieve soil compaction. Perhaps the best machine for working large areas is a piston driven aerator that thrusts the core cutters vertically. Direct up and down coring leaves a clearly defined hole. Drum-type roller aerators will work but may cause tearing damage to the remaining grass since this type of cutter enters the turf at one angle, moves in an arc with the drum movement, and is withdrawn at a different angle.
[0000] Solid Tine
[0026] Solid-tine aerification allows turf managers to aerate more frequently, since the procedure produces less surface disruption. Solid tines larger than ¼ inch in diameter open turf to allow water and air infiltration, but the process compresses displaced soil downward and to the sides. This actually increases soil compaction around newly created aerification holes. Repeated solid-tine aerification with larger-diameter tines can create a hardpan at the aerating depth.
[0027] Related to solid tine aerification are slicing and spiking aerifiers. Slicing, spiking, and solid tine aerification do not pull plugs of soil from the turf. Slicing aerifiers cut thin slits into the soil and spiking aerifiers cut thin, triangular-shaped holes in turf. While they do not relieve soil compaction as efficiently as hollow tine aerification, these practices cause less surface disruption and can be done anytime.
[0000] Hollow Tine
[0028] These devices pull out plugs of soil that are deposited on the surface. One of the most common operations that one can perform using a hollow tine aerator is conducting a soil exchange program, offering the professional an ideal opportunity to remove soil cores and replace them with a suitable top dressing, altering the soil profile.
[0029] Self-powered hollow tine aerifiers (core aerifiers) insert hollow tines into the soil, removing a soil plug ¼″ to ¾″ in diameter and 2″ to 12″ deep, depending or soil type, soil moisture, and type of machine. Core spacing varies depending upon the make and model of the machine. In general, the more cores removed per square foot, the more effective the cultivation will be; removing fifteen to thirty cores per square foot is recommended. Hollow tine aerification is considered the most efficient compaction reliever of the prior art methods. It is preferably done during active turf growth.
[0000] Slitting
[0030] Using triangular blades ranging in size 100-250 mm (4″ to 10″), these machines create lots of short, narrow, close slits; slitting is useful for getting air down into the soil; it's quick; it does a fairjob in dethatching; however, this approach is not highly effective at reducing compaction. Slitting also has its benefits, particularly in autumn when it can be employed to help ‘connect’ the surface of the soil with the underlying drainage layers. In the spring and summer, slitting ensures that water from rain and irrigation soak through the turf rather than being shed in a sideways fashion by the thatch.
[0000] Water Injection
[0031] Water injection aerification is a recently-introduced method of turf aerification. Water, under high pressure, is injected into the turf surface to relieve soil compaction. In addition, it can be used to inject turf management chemicals into the soil. It causes little surface disruption and can be done anytime during the growing season. This new technology has not been commonly available for use outside of golf course applications.
[0000] Deep Drill Aerification
[0032] Drill-type aerifiers employ rotating turf drills. The drill bits eliminate compaction along the sides and bottom of the aerification hole, and allow for quick and effective penetration even in heavily compacted soils including hardpan, muck and roots. The “gentle footprint” of drill-type aerifiers, in conjunction with the absence of cyclic vibration and the “straight in, straight out” action of the drill bits, gives this type of machine the capability of aerating fields that are wet, dry or experiencing periods of high stress.
[0033] Deep drill aerifiers are also preferred for use in all problem areas because the rotating drill bits will penetrate subsoil areas, where other machines tend to walk or bounce, often causing trauma to the playing surface. Turf drill bits fracture the cylinder wall without glazing, thereby allowing lateral movement of air and water. “Drill & Fill” aerifiers are available which back-fill the drilled holes with a selected top dressing, usually sand, thereby modifying the soil profile.
[0034] Turf drill bits are commercially available in ⅝″×12″, ⅝″×16″, ¾″×12″, and 1 ″×12″ sizes. One particular deep drill aerifier currently on the market produces 5″ spacing of holes. Drill aerification is especially preferred when one must penetrate hard soils. However, drill aerification is a very slow process as compared to reciprocating type aerifiers.
[0035] As noted above, aerification has the added benefit of smoothing the surface of a putting green. The process of punching holes and either reincorporating the plugs brought up or removing the plugs and filling the channels can offer some surface smoothing. Surface topdressing alone will fill/smooth low spots. The combination of aerifying and the follow-up topdressing will, over time, both fill low spots and soften high spots, resulting in more efficient surface smoothing than topdressing alone.
SUMMARY OF THE INVENTION
[0036] The method and apparatus of the present invention combines the speed and mechanical simplicity of solid or hollow tine aerification with the penetration depth, clean cutting and cylinder wall fracturing of deep drill aerification. A turf drill is held in a chuck which permits free rotation of the drill bit when it is pushed into the ground (loaded in compression) but which restricts rotation of the bit when it is withdrawn from the ground (loaded in tension). When the chuck is locked and the drill bit is pulled from the soil, the flutes on the bit cut a clean, generally cylindrical hole in the soil with minimal compaction of the surrounding earth. In one embodiment, the drill bit comprises a non-fluted upper portion which helps prevent entanglement and lifting of the turf as the bit is withdrawn.
[0037] In some embodiments, the distal end of the drill bit is provided with opposing beveled surfaces which impart a rotational movement to the bit as it is pushed into the soil. Since the bit is self-rotating, there is no need for rotational means in the aerifier head, and therefore drills according to the present invention can be utilized in aerifiers previously equipped with solid or hollow-core tines. Since rotational means are not needed in the aerifier's heads, the tines may be placed in greater proximity to one another which permits greater density of aerification holes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a partial cut-away view of a simplified, reciprocating-type aerifier equipped with a turf drill according to the present invention.
[0039] FIG. 2 is a partial cross-sectional view of the chuck of the present invention in its free rotation state.
[0040] FIG. 3 is a cross-sectional view taken along line 3 - 3 in FIG. 2 .
[0041] FIG. 4 is a side view of the lower portion of the central shaft of the chuck.
[0042] FIG. 5 is a partial cross-sectional view of the chuck of the present invention in its locked, rotation-inhibiting state.
[0043] FIG. 6 is a side view of a drill bit according to the present invention.
[0044] FIG. 7 is an end view of the tip of the drill bit illustrated in FIG. 6 taken along line 7 - 7 .
[0045] FIG. 8 is an enlarged, side view of the tip of the drill bit illustrated in FIG. 6 .
[0046] FIG. 9 is an enlarged, side view of the tip of the drill bit illustrated in FIG. 6 rotated 90°.
[0047] FIG. 10 is a partial cross-sectional view of another embodiment of the chuck of the present invention in its free rotation state.
[0048] FIG. 11 is a cross-sectional view taken along line 11 - 11 in FIG. 10 .
[0049] FIG. 12 is a cross section taken along line 12 - 12 in FIG. 10 .
[0050] FIG. 13 is a partial cross-sectional view an alternative embodiment of the chuck of the present invention in its locked, rotation-inhibiting state.
DETAILED DESCRIPTION
[0051] In the following description, “drill” should be understood to mean an apparatus comprising both a drill chuck and a drill bit held within the chuck.
[0052] Referring now to FIG. 1 , a portion of a reciprocating turf aerator is shown as a partial cut-away drawing. The aerator is shown in simplified form to illustrate how the turf drill of the present invention may be used in practice. Aerator 12 may be moved across an expanse of ground such as soil 22 on wheel(s) 14 . Reciprocating heads 20 are connected to crankshaft 16 by connecting rods 18 which cause heads 20 to move generally up and down as crankshaft 16 rotates. Drills 10 , attached to heads 20 , are thereby alternately thrust into and withdrawn from soil 22 . In some commercially-available aerators, crankshaft 16 is driven by the power take off (PTO) of a tractor used to pull aerator 12 across a putting green, for example.
[0053] As mentioned above, this is a simplified view of a reciprocating aerator. Commercial aerators are typically equipped with articulating heads that additionally move fore and aft relative to the track of the aerator across the ground such that during insertion, withdrawal and the interval there between during which the drill bits are in the soil, the heads and drills (or tines) do not move transversely with respect to the ground. In this way, cylindrical, vertical holes may be achieved while the aerator advances continuously across the ground. Apparatus which provide this type of motion are described in U.S. Pat. No. 6,041,869 entitled “Turf Aerator with Constantly Vertical Tines” and are available from manufacturers such as Redexim/Charterhouse, Jacobsen (under the Ryan® brand name) and others.
[0054] The chuck 24 of one particular embodiment of the present invention is shown in partial cross section in FIG. 2 . Shaft 26 may be adapted at its upper or distal end to engage the head platforms 20 of a mechanical aerator. Reciprocating aerators are particularly preferred, but the drill embodiments illustrated in the drawing figures can be employed in a variety of aerators.
[0055] The proximal end (lower end in FIG. 2 ) of shaft 26 is contained within rotating body 28 of chuck 24 and is rotatably supported by bushing 30 and thrust bearing 32 . In the particular embodiment illustrated in FIG. 2 , the proximal end of shaft 26 has conical tip 48 (see FIG. 4 ) which fits within a corresponding conical portion of bearing 32 . Bushing 30 and thrust bearing 32 may be fabricated from a softer metal than that used for shaft 26 to reduce frictional wear. Additionally, chuck 24 may be provided with grease fitting 36 (also known as a Zerk fitting) through which a suitable lubricant may be introduced for lubricating shaft 26 within bushing 30 and bearing 32 . One preferred lubricant is lithium grease. In other embodiments of chuck 24 , self-lubricating bearings and bushings may be used, in which case it may not be necessary to provide means for introducing lubricant from an external supply.
[0056] Shaft 26 is free to both rotate within bushing 30 and thrust bearing 32 and to slide longitudinally (within limits, as described below) within bushing 30 and the upper, cylindrical portion of thrust bearing 32 . As indicated by the arrow in FIG. 2 , chuck 24 is shown loaded in compression such as would occur when the drill was being pushed into the ground. The conical tip at the proximal end of shaft 26 is shown fully engaged in thrust bearing 32 in FIG. 2 as it would be during insertion of the drill in the ground.
[0057] Chuck 24 comprises a lock which engages when a turf bit held in the chuck is loaded in tension and which disengages when the bit is loaded in compression. In the embodiment illustrated in FIG. 2 , rotating body 28 has an opposing pair of set screws 34 . The set screws 34 have a conventional threaded portion for engaging the threads of tapped holes within rotating body 28 and also a cylindrical tip 35 of reduced diameter which is sized to project into the upper central bore of rotating body 28 . Such set screws are sometimes referred to as “dog point” set screws. In the embodiment illustrated, the holes in rotating body 28 into which set screws 34 are screwed are not threaded the full thickness of the wall of rotating body 28 . Rather, the threads begin at the exterior surface of rotating body 28 and end prior to reaching the central bore of rotating body 28 . In this way, the insertion of projecting points 35 may be limited. It is preferred that projecting points 35 do not contact shaft 26 when set screws 34 are fully seated within rotating body 28 . The rotation and sliding of shaft 26 within rotating body 28 would be inhibited if projecting tips 35 were to contact shaft 26 . Alternatively, bushing 30 may be sized and positioned such that the shoulders of set screws 34 contact bushing 30 . In this way, over-insertion of set screws 34 may be prevented and bushing 30 may be secured within rotating body 28 .
[0058] As illustrated in the detail of FIG. 4 , shaft 26 includes stop collar 44 which prevents withdrawal of shaft 26 from rotating body 28 when a tensile force is applied to shaft 26 (such as occurs during withdrawal of the drill from the soil). Stop collar 44 may be provided on its upper surface with one or more indentions. In the embodiment illustrated, four such indentions are provided spaced 90° apart and each describes an arc of a circle in cross section. Indentations 46 and conical tips 35 of set screws 34 are preferably sized such that projections 35 will seat in indentations 46 when stop collar 44 is brought into contact with set screws 34 . This condition is illustrated in FIG. 5 .
[0059] FIG. 5 shows the same embodiment as that illustrated in FIG. 2 . In this case, however, the drill is loaded in tension, as indicated by the arrow in the drawing. This condition obtains when the drill is being withdrawn from the soil and frictional forces on the drill bit 50 are opposing the upward motion imparted by the aerator. It will be noted that the conical tip of shaft 26 is partly withdrawn from the conical portion of thrust bearing 32 and stop collar 44 is in contact with cylindrical projections 35 of set screws 34 . Further upward motion of shaft 26 relative to rotating body 28 is thereby prevented. Since stop collar 44 may be coated with lubricant, contact of the upper surface of stop collar 44 with cylindrical projections 35 may not inhibit the rotation of shaft 26 relative to rotating body 28 until an opposing pair of indentations 46 align with set screw projections 35 at which point shaft 26 may move slightly further upward, seating projections 35 within indentations 46 at which point further rotation of shaft 26 is significantly inhibited. It will be appreciated that the number and spacing of set screws 34 in rotating body 28 and the number and spacing of indentations 46 in stop collar 44 may vary from that of the embodiment shown in FIGS. 2 through 5 .
[0060] Also shown in FIGS. 2 and 5 is dirt shield 38 which may be used to help deflect dirt, sand and other soil components from the interface of bushing 30 and shaft 26 . Dirt shield 38 may be a stamped metal fitting which is concentric with shaft 26 . Rotating body 28 may also be provided with chamfer 42 to further aid in the shedding of dirt from the top of rotating body 28 . In operation in aerifiers having multiple drills in close proximity one to another, dirt particles are often thrown up by the drills as they are withdrawn from the ground which particles may land on nearby drill chucks. It is, of course, advantageous to shield bearings from the introduction of abrasive particles.
[0061] Also shown in FIG. 2 and FIG. 5 is the upper portion of the shank of turf drill bit 50 . Rotating body 28 is provided with a central bore on its lower surface for receiving drill bit 50 . Drill bit 50 may be provided with notch or flat 52 for engaging set screw 40 which both retains bit 50 within chuck 24 and prevents the rotation of bit 50 relative to rotating body 28 . In the illustrated embodiment, set screw 40 is shown as being a dog point set screw. Set screw 40 may be a conventional set screw, but it may be convenient to have set screw 40 be of the same type and size as set screws 34 so as to reduce inventory and replacement parts requirements and to reduce the chance that a conventional set screw would be inserted in place of set screw 34 thereby impairing the function of chuck 24 . Alternatively, set screw 40 may be a different diameter from that of set screws 34 .
[0062] As will be appreciated by those skilled in the art, there are many ways a drill bit may be secured in a chuck. The securing method using a set screw described above and illustrated in the drawing figures has been found to be particularly suited to the application of the invention, but other methods may be used. By way of example, a hole may be provided in the chuck with a corresponding hole in the bit shank. A pin (such as a roll pin) or a machine screw passing through the hole in the chuck and into the hole in the bit shank would secure the bit in the chuck.
[0063] One embodiment of a drill bit of the present invention is shown in FIG. 6 . Bit or drill tine 50 is comprised of an unfluted, generally cylindrical upper portion 54 and a lower, fluted section 56 . As noted above, the upper portion of the shank of bit 50 may be provided with flat or notch 52 which provides a planar contact area for set screw 40 of chuck 24 used to secure bit 50 in the lower central bore of rotating body 28 .
[0064] Flutes 58 , which may be generally rectangular in cross-section, are formed in a helical pattern around core or central shaft 62 . Smooth portion 54 is provided to lessen the chance of turf entanglement when the bit is withdrawn from the turf. In practice, the insertion depth may be adjusted such that fluted portion 56 penetrates to a soil depth just below the turf layer while portion 54 is within the turf layer.
[0065] Details of the tip of bit 50 are shown in FIGS. 7, 8 and 9 . The tip may be formed by grinding generally planar, opposing flats 60 at the angle shown as a in FIG. 8 . The position of notch 52 is shown as a dashed line in FIG. 7 to illustrate the angular position of the dividing line or “chisel edge” between the opposing flats 60 . It will be noted that flats 60 are offset from each other with respect to the center line of the bit. Because of this offset, a torque is imparted to bit 50 (counterclockwise as viewed in FIG. 7 ) when it is inserted into the ground. Thus, when bit 50 is pushed into the ground by an aerator, it tends to rotate about its longitudinal axis and the flutes 58 create a pair of helical grooves in the soil around the central hole created by the displacement of the soil by central shaft 62 .
[0066] Conventional turf drills typically are carbide tipped to maintain sharpness for an adequate length of time. It has been surprisingly found that the drill bits of the present invention do not require carbide tips or inserts to provide adequate service life. The drill bits of the present invention rotate about 2½ revolutions per insertion. In contrast, bits used in conventional turf drilling machines rotate about 25 revolutions per insertion. It is contemplated that the reduction in friction engendered by the factor of 10 decrease in rotations per insertion is responsible for the longer-wearing nature of the bits of the present invention.
[0067] In one particularly preferred embodiment, L 1 is about 10½ inches, L 2 is about 7½ inches and D, the drill tine's diameter, is about ½ inch. The shank diameter may be chosen to fit the head of the particular aerator to be used and it may be greater than, less than, or the same as the tine diameter. In this embodiment, the diameter of central shaft or core 62 is about ¼ inch and the flutes 58 are about 0.1 inch wide (thick) and 0.125 inch high. The twist length, the linear distance over which a flute makes a complete revolution about central shaft 62 , is about 3 inches. The tip angle (a in FIG. 8 ) is about 45°. A particularly preferred drill tine is fabricated from American Iron and Steel Institute (AISI) Grade 4140 steel heat treated after fabrication to a value of at least about 50 on the Rockwell “C Scale” of hardness. Following heat treatment, drill tine 50 may be shot-peen finished.
[0068] It will be appreciated by those skilled in the art that there are many means for effecting the locking feature of the chuck of the present invention. By way of example, one such alternative is shown in FIGS. 10 through 13 , inclusive. In this embodiment, a spline 70 or splines 70 on shaft 26 is used in conjunction with keyway 69 or keyways 69 in locking member 68 held within rotating body 28 .
[0069] In the embodiment illustrated, bushing 30 is held within upper bore 72 of rotating body 28 by retaining ring 64 which fits within groove 65 in the wall of upper bore 72 . Locking member 68 which may include a plurality of keyways 69 rests on shoulder 73 at the lower boundary of upper bore 72 . Thrust washer 66 may be provided between locking member 68 and bushing 30 to protect the relatively softer material of bushing 30 from impact with splines 70 of shaft 26 when shaft 26 slides upward. Keyways 69 are sized and spaced such that splines 70 will fit within them when shaft 26 is urged upward (loaded in tension) and rotating body 28 rotates relative to shaft 26 until the splines 70 and keyways 69 align. FIG. 10 shows chuck 24 loaded in compression (as during insertion of the drill into the ground). In this condition, splines 70 are below locking member 68 and thus rotating body 28 can freely rotate relative to shaft 26 . FIG. 13 shows chuck 24 loaded in tension (as occurs during withdrawal of the drill from the ground). In this condition, splines 70 engage keyways 69 in locking member 68 and rotation of rotating body 28 (and bit 50 ) relative to shaft 26 is prevented.
[0070] Locking member 68 may be fabricated as an extrusion cross cut to the desired thickness. Rotating body 28 may be heated to expand the diameter of upper bore 72 and locking member 68 inserted while the bore is expanded. Upon cooling and contraction, locking member 68 (if appropriately sized) will be rotatably secured within upper bore 72 .
[0071] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
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A novel drill for the aerification of turf grasses is disclosed. The drill comprises a chuck and a fluted turf drill bit held by the chuck. The chuck includes a locking mechanism which permits the chuck to rotate freely about its longitudinal axis when loaded in compression (as when the drill is inserted into the ground) but which locks, preventing rotation, when the drill is loaded in tension (such as when the drill is withdrawn from the soil). The drill bit has a smooth upper section and a fluted lower section. The smooth section decreases the probability of entangling the turf in the drill bit with subsequent lifting of the turf when the drill is withdrawn. The tip of the drill bit is adapted to provide a torque to the drill bit during insertion into the ground. Thus, the bit spirals into the ground upon insertion, but locks upon removal, thereby permitting the flutes of the bit to cut a cylindrical hole in the ground while removing soil from the hole by retaining it in the space between the flutes. The drill of the present invention may be used in aerators previously limited to solid or hollow-core tines.
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BACKGROUND OF THE INVENTION
After urination there is often left moisture on the end of the male penis which stains the underclothing or trousers and sometimes causes a mess about the water closet. There does not seem to be any hygienic device available for such a situation. Bandages such as shown in U.S. Pat. No. 731,201 have been provided for medical treatment or for other uses and are not intended for the use for which this invention is intended and are complicated and expensive. This invention is intended to clean up the urine moisture after urination and prevent the staining of the underclothing or trousers and assist in preventing messy conditions about the water closet.
SUMMARY OF THE INVENTION
A cup of absorbent material is provided of a size to receive the end of the male penis after urination to absorb the moisture of urine which may be left thereon. The cup may also have been pretreated with a medication of a deodorant nature and is also provided with a tab or handle for manipulating the cup. The cup is completely disposable as one unit for flushing in usual sanitary systems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the cup of this invention with a handle shown thereon;
FIG. 2 is a sectional view through the handle showing several plies of paper of an absorbent nature; and
FIG. 3 is a sectional view of a dispenser for the cup.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Paper towels of an absorbent nature have long been used for blotting the hands after washing to remove the moisture therefrom, and it is this type of material of which the cup of this invention is formed.
With reference to the drawing, a cup 10 (shown in FIG. 1) is molded from an absorbent paper material in a shape such as shown and of a size to receive the end of the male penis. Preferably there would be three layers of paper 11, 12 and 13 although more or less may be utilized depending upon the weight of the paper which is used. These may be suitably molded or formed in the shape shown and in various sizes where it is found necessary.
The plies of paper may extend into a handle designated generally 14 and will consist of one or two or three layers of paper as may be found necessary. The handle will be of an extent capable of being grasped by the hand for manipulation of the cup. Preferably it will extend from the open edge of the cup and may be a continuation of the various plies of paper used in the cup. In some cases the handle may be separately formed and attached to the cup.
A device of this character may be dispensed from a tubular container 20 such as the drinking cups are dispensed from, which container may be handily used adjacent the water closet for use after each male urination and then flushed. Lips 21 at the lower edge of container 20 retain the cups in the container and sufficient flexibility between a cup and the container permit of the removal of a cup from the container by grasping the handle 14 which protrudes from the container through slot 22 of the container. Particularly, this device would be very useful in places where men handle or prepare food as they tend to be forgetful of washing hands after urinating. The device prevents any contact of the human hands with the penis. In the average home it would be placed beside the water closet and flushed down the same such as toilet paper, or in a men's washroom, in a small container.
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A cup of absorbent material of a size to cap the male organ for absorbing urine moisture after urination and provided with a tab or handle for manipulating the same.
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BACKGROUND OF THE INVENTION
It is well known that MOS devices build up trapped positive charges in the oxide and interface states at Si/SiO 2 interface, when exposed to ionizing radiation. These effects will induce threshold/flat band voltage shifts and the reduction of transconductance and, as a consequence, degrade the performance of devices and/or circuits. These effects are discussed in C. T. Sah, "Origin of Interface States and Oxide Charges Generated by Ionizing Radiation," IEEE Transactions on Nuclear Science, NS-23, No. 6, 1563-1568 (1976) and F. B. McLean, "A Framework for Understanding Radiation-Induced Interface States in SiO 2 MOS Structures," IEEE Transactions on Nuclear Science, NS-27, No. 6, 1651-1657 (1980). For example, the p-type substrate of N-channel MOSFET will be inverted to n-type because of the accumulation of trapped positive charges and interface states found in the gate oxide (or other insulator) so that, even without gate bias, these devices have large subthreshold leakage current. It is also expected that an apparent standby current will appear at non-operational states and that circuit function will fail during normal operation cycles with such circuits.
Generally MOS devices with thick gate oxide layers have larger degradation level. In conventional CMOS process, the electrical isolation between devices is achieved by LOCOS field oxide, as shown in FIG. 1. The source/drain regions of neighboring devices and field oxide between them therefore form a parasitic MOSFET, which has a thick equivalent gate oxide. The threshold voltage shift induced by irradiation is so substantial that a leakage path underneath the LOCOS region may appear. Many approaches have been developed to solve these problems:
Firstly, guard rings are added as shown in FIG. 2. This approach, however, is not practical for high packing density because of the waste of chip area. Also, the coupling capacitance to the gate region is too large, which usually reduces the speed of operation. J. E. Schroeder et al., "An Advanced, Radiation Hardened Bulk CMOS/LSI Technology, IEEE Transactions on Nuclear Science, NS-28, No. 6, 4033-4037 (1981).
Secondly, a closed structure is designed as shown in FIG. 3. Here the drain region is surrounded by gate region to cut off the leakage path. This construct still has low packing density and large coupling capacitance between the gate and the drain. Again, the speed of operation is reduced.
Thirdly, the conventional LOCOS process is replaced by another process. Unfortunately, these alternatives are still developmental and have not achieved commercial application (K. Kasama et al. "A Radiation-Hard Insulator for MOS LSI Device Isolation," IEEE Transactions on Nuclear Science, NS-32, No. 6, 3965-3970 (1985)).
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to a radiation-hardened bulk CMOS isolation structure and a process which eliminates the conventional LOCOS field oxide. The structure may be automatically generated by special layout procedures employing computer aided design, CAD. This unique process makes it possible to expeditiously fabricate a radiation-hardened VLSI circuit and to easily modify existing commercial products to form a radiation hardened version without the need for redesigning such product.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a conventional complementary metal oxide semiconductor where the electrical isolation between devices is achieved by a LOCOS field oxide.
FIG. 2 shows a known CMOS structure having a guard ring surrounding the N-channel transistor.
FIG. 3 illustrates an inverter and 2-NAND gate employing the closed structure of the prior art where the drain region is surrounded by a gate region.
FIG. 4-1-(a) illustrates a vertical cross-section of a portion of an integrated circuit embodying the invention showing the polysilicon gated isolation structure (GIS) locally adopted as electrical isolation between active N-channel MOSFETs in a CMOS.
FIG. 4-1-(b) represents a top view of the integrated circuit shown in the previous figure, illustrating the GIS, particularly in relation to the N-channels.
FIGS. 4-2 to 4-6 illustrate the formation of the device of the invention at various stages in the process. The completed device is shown in FIG. 4-6.
FIGS. 5-0 to 5-7 show the layout procedure employed in developing the GIS.
FIG. 5-0 shows the pattern generated for the thin oxide regions including the N-channel and P-channel.
FIG. 5-1 shows the pattern generated for the N-channel thin oxide region.
FIG. 5-2 shows the modification of the N-channel thin oxide region formed in step 2.
FIG. 5-3 shows the combining of the P-channel thin oxide region and the modified N-channel thin oxide region. Pattern A5 is the actual thin oxide layer used in the photolithography.
FIG. 5-4 shows the generation of the gated isolation structure for the N-channel device.
FIG. 5-5 shows the generation of the isolation implant region for the gated isolation structure.
FIG. 5-6 shows the patterning of the contact regions.
FIG. 5-7 shows the modification of the contact regions for electrically connecting the gated isolation structure to Vss.
DETAILED DESCRIPTION OF THE INVENTION
Because the gated isolation structure of the instant invention is integrated into the process for radiation-hardening, the process becomes a double polysilicon CMOS process. The first polysilicon layer is an isolation gate and the second polysilicon layer is the active device gate. FIG. 4-1-(a) shows a vertical section of the polysilicon gated isolation structure of the invention. The GIS serves to provide local electrical isolation about the active n-MOSFETs in the CMOS integrated circuit figure. FIG. 4-1-(b) illustrates a top view of a portion of the CMOS showing the gated isolation structure with respect to the two N-channels, N 1 and N 2 . This gated isolation structure is equivalent to an N-channel MOSFET and will be biased at the Vss=OV when the circuit is in operation. The isolation gate is kept at 0 bias to lower the threshold voltage shift of equivalent GIS MOSFETs after irradiation and to achieve electrical isolation between the active devices.
To commence the process of the invention, as shown in FIG. 4-2, a processing wafer 1, typically a p-type substrate with a resistivity of less than 65 ohm-cm and with a (100) orientation, is used. An isotropic epitaxial layer is grown on the bare P-substrate to provide latch-up immunity. The thickness of the epitaxial layer depends on the P+ to N- well and N+ to P- substrate rules.
FIG. 4-3 shows the formation of the N-well 2 and field oxide 3. In the gated isolation structure process, the N-well 2 is selected as the substrate for a P-channel active devices. It is formed in a conventional manner by P 31 ion implantation followed by high temperature drive-in. The implant energy, implant dose and drive-in temperatures are properly adjusted to obtain 3.5 to 4.5 μm depth for the N-well with a sheet resistance of 1200 to 1500 ohm/sq. to comply with the 2 μm design rule. The field oxide 3 which serves to isolate the P-channel device to P-channel or to N-channel device is grown to 7000 to 8000 Ang. by local oxidation of silicon (LOCOS) processing. The temperature is approximately 980° C. or higher.
FIG. 4--4 shows the formation of the gated isolation structure. Before the GIS is defined, a certain amount of B 11 is implanted into the isolation region, shown by the numeral 4, to adjust the threshold voltage of the GIS. The dopant concentration is dependent on the threshold voltage shift induced by irradiation and device characteristics, it being understood that junction breakdown may occur at the isolation region/N+ junction if the dopant concentration is too high. Usually the concentration is not higher than lE13 cm-2. The composite thermal oxide/nitride/oxynitride (ONO) structure is chosen as the GIS gate insulator 5. These layers are shown in detail on FIGS. 4-4(a) and 4-4-(b). The appropriate thickness of these layers depends on the radiation immunity of the composite film, the etching recipe for GIS polysilicon, and the integrity of the gate insulator. An insulator composition of 110 Ang. for the thermal bottom oxide, 110 Ang. for the chemical vapor deposition (CVD) intermediate silicon nitride, and 30 to 40 Ang. for the thermal oxynitride layer is typical.
In order to achieve the outstanding results of the invention, it is necessary that an ONO structure be chosen as the GIS gate insulator. The reason is that the nitride is a better material than thermal oxide with respect to radiation hardness. The oxynitride serves as the etching stopper for the GIS polysilicon 6, the thickness thereof being from 3,000 to 4,500 Ang. This layer is deposited on the ONO by CVD and doped with POC1 3 to obtain a sheet resistance of 10 to 20 ohm/sq. The GIS pattern is defined by using SF 6 /Ar plasma dry etching. The etching recipe must be highly selective for the polysilicon to silicon dioxide so that the end point can just stop at the oxynitride layer, consuming at most a small bit of the intermediate nitride. This is illustrated in FIG. 4-4-(a).
Because the nitride is difficult to oxidize, it serves as an oxidation mask for the thin oxide region when the GIS polyoxide 7 is grown. This layer 7, shown in FIGS. 4-4--(b) and 4-5, electrically isolates the GIS and the active device gate. In order to minimize parasitic capacitance, the thickness of the GIS polyoxide must not be less than 2,000 Ang. On the other hand, a thermal oxide layer may be used for the GIS gate insulator, but this is not preferred because, due to the lack of an oxidation mask, it is not easy to control the thickness and integrity of the GIS polyoxide when the thick residual oxide on top of the thin oxide region is etched back. For this reason, the use of nitride is most desirable.
FIG. 4-6 shows the formation of the N-channel and P-channel MOSFET. After removing the residual ONO layer by a suitable chemical solution, the threshold voltage of the N-channel and P-channel MOSFET is adjusted by ion implantation. Thereafter an active gate oxide 8 with a thickness of 250 to 300 Ang. is grown. The standard method for preparing the radiation-hardened gate oxide is either to use wet oxygen at 850° C. or dry oxygen with or without HCl at 920°-1000° C. To enhance radiation immunity, subsequent processes are all performed at a temperature lower than that at which the gate oxide is formed. This includes the gate polysilicon 9, 9', and 10, shown in FIG. 4-6. The thicknesses of these layers is 4000-5000 Ang. They are deposited on the gate oxide by CVD and doped with phosphorus using POCl 3 doping at 850°-900° C. Once again, the polysilicon gate is defined using SF 6 /Ar plasma etching and an etching recipe similar to that used in forming the gated isolation structure to obtain a reliable gate length.
The source/drain junctions of N-channel 11 and 11' and P-channel 12 are formed by self-aligned ion implantation into the P-substrate and N-well regions, respectively. Typically, the dopant is B 11 , for P-channel and P 31 for N-channel, while dopant concentration is on the order of approximately 10 15 . These two junction dopants are driven in simultaneously at a later flow step.
The electrical isolation between the P-channel and N-channel and between N-channel and N-channel devices is achieved effectively by the gated isolation structure constructed by the aforesaid steps. To illustrate the effectiveness of the device of the instant invention, 2 μm 2K×8 bit CMOS SRAM was tested for performance before and after radiation with cobalt 60 using various dosage levels. The chips Nos. 1, 2 and 3 were exposed to 100, 200 and 350 RADS, respectively. The data obtained are shown in the following table:
TABLE 1______________________________________BEFORE EXPOSURE AFTER EXPOSURE Speed SpeedCHIP Icc Icc (Acc Icc Icc (AccNo. (sta) (OP) time) (sta) (OP) time)______________________________________1 .31 uA 1.9 mA 95.4 nS 35.0 uA 16.5 mA 85.7 nS2 .24 uA 1.7 mA 90.0 nS 24.0 uA 17.5 mA 89.7 nS3 .293 uA 4.0 mA 90.3 nS 25.0 uA 17.14 mA 77.3 nS______________________________________
Even after exposure to 350K rads, the device of the invention still remains within data sheet limits. The typical access time is approximately 100 nsec. and the maximum stand-by (Icc Sta) and operational (Icc OP) currents are about 50 microamperes and 20 milliamperes, respectively.
The use of computer-assisted design (CAD) to construct the GIS structure directly at a computer terminal with a command file is concisely described by reference to FIGS. 5-0 through 5-7.
As shown in FIG. 5-0, the first step is to search and/or generate by the design rule the pattern for the thin oxide regions including N-channel and P-channel. The thin oxide region is represented by A1. Thereafter, the search and generation of the N-channel thin oxide region is made by CAD and defined as A2, as shown in FIG. 5-1. The searching method takes the intersection of the P-field implantation region and the thin oxide region A1, the P-channel thin oxide region thus equalling A1 minus A2.
FIG. 5-2-(I) shows the modification of the N-channel thin oxide region from step 2. Initially a design rule check (DRC) is performed. If the spacing between the thin oxide region is equal to or smaller than a1 μm, the thin oxide regions are directly merged to define the new thin oxide region A3. The merged thin oxide regions are outwardly extended by a2 μm, as shown in FIG. 5-2-(II), and defined as A4. As illustrated in FIG. 5-3, the P-channel thin oxide regions and the modified N-channel thin oxide regions are united and defined as A5. A5 thus represents the actual thin oxide layer in the photolithography processes.
FIG. 5-4 shows the generation of the GIS region B for the N-channel device. This region is formed by outwardly extending A4 by a3 μm and then subtracting the A2 region from the extended A4. (This is done because A2 is included in or extends A4.)
The generation of the isolation implant region C for the GIS is shown in FIG. 5-5. The isolation implant region is directly constructed by outwardly extending the GIS region B by a4 μm.
FIG. 5-6 shows the pattern for the contact regions generated by the standard rule to define D1. FIG. 5-7 shows the modifications of the contact regions for electrically connecting the GIS to the Vss. This is done by first taking the overlap regions of the Vss metal line and GIS and then inwardly shrinking it by a5 μm. The GIS is thus electrically connected to ground through the new generated contact. Thereafter, the newly generated contact region is combined with the normally designed contact region and defined as D2.
Design rule checks (DRC) and electrical rule checks (ERC) are performed. The purpose of performing design rule checks is to eliminate the line to line overlap between GIS and active device gate pattern which may result in the formation of a metal ribbon after metal line definition. The purpose of performing electrical rule checks is to screen out the electrical floating GIS and contact regions which violate design rule. The abnormal GIS and contact regions are processed further by manual or automatic assignment.
The values of a1, a2, a3, a4 and a5 depend on process capabilities and can be readily determined by those skilled in the art. Based on a 2 μm process design rule, representative values are as follows:
______________________________________Parameter Dimension, um______________________________________a1 5a2 2a3 1a4 0.5a5 0.5______________________________________
The GIS of the invention can be adapted as electrical isolation parts not only between N-channels in P-substrates, but also for P-channels in the N-well. Thus, the conventional LOCOS field oxide will be wholly replaced by GIS.
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The invention relates to a radiation hardened (R-H) bulk complementary metal oxide semiconductor (CMOS) isolation structure and a process for its formation. The isolation structure may be automatically generated from the original thin oxide layer of any commercial product by computer aided design and basically comprises a grounded MOS gate surrounding the active areas. The grounded MOS gate replaces the conventional LOCOS field oxide and consists of novel oxide-silicon nitride-oxynitride gate insulator and a CVD polysilicon film. The radiation resistance of this gated isolated structure (GIS) is suitable for application in radiation-immunity VLSI integrated circuit (≦2 μm design rule).
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This is a continuation in part of copending application Ser. No. 07/790,449, filed Nov. 12, 1991, abandoned which is a continuation in part of copending application Ser. No. 07/693,580, filed Apr. 30, 1991, now U.S. Pat. No. 5,236,938 both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to new 1-aryl-5-(substituted alkylideneimino)pyrazoles and to processes for their preparation. The invention further pertains to compositions of said compounds and methods, using said compounds, for the control of arthropod, nematode, helminth or protozoan pests. In particular it relates to the application of said compounds or compositions in agricultural methods of use, particularly as pesticides, for controlling arthropods, especially insects via ingestion or contact action.
2. Description of the Related Art
Various 1-(substituted phenyl or pyridyl)-5-(substituted amino) pyrazole compounds are known to exhibit a number of different types of pesticidal activity, including activity as herbicides, plant growth regulators, insecticides, and nematicides. Included among these are the following:
U.S. Pat. No. 4,863,937 discloses as insecticides, acaricides and nematicides 1-aryl-5-(substituted alkylideneimino)pyrazoles, which are unsubstituted or alkyl or haloalkyl substituted in the 3-position of the pyrazole ring;
EP 301,339 and corresponding CAS reference 111(5):39360c disclose 1-(substituted aryl)-5-(substituted aryl methylideneimino)pyrazole compounds-(per pages 3, 6, 10 and 16 of the reference) as intermediates to insecticidal compounds. The compounds are unsubstituted or alkyl or haloalkyl substituted in the 3-position of the pyrazole ring;
J. Prakt. Chem., 332(3), 351-8, 1990, Hennig L. et al., corresponding to CAS reference 113 (25):231264 g, is a chemistry article which discloses 1-phenyl-5-(substituted phenyl methylideneimino) pyrazole compounds, which are either methyl or phenyl substituted in the 3-position of the pyrazole ring. There appears to be no disclosed pesticidal activity;
GB 923,734 discloses 1-aryl-5-(substituted phenyl methylideneimino)pyrazole compounds as dyes and which are only substituted by cyano in the 3-position of the pyrazole ring;
U.S. Pat. No. 4,685,957 discloses 1-aryl-5-(substituted iminoamino)pyrazoles as herbicides and plant growth regulators, which compounds are unsubstituted or alkyl substituted in the 3-position of the pyrazole ring;
EP 295,117; WO 87/03781 (also corresponding to EP 234,119); EP 295, 118; and EP 350,311 disclose 1-phenyl-5-(substituted amino)pyrazole compounds for control of arthropod, nematode, helminth and protozoan pests;
GB 2,136,427 discloses as herbicides 1-(substituted-2-pyridyl)-5-(substituted amino)-4-cyanopyrazoles, which are unsubstituted at the 3-position of the pyrazole ring;
U.S. Pat. No. 4,772,312 discloses as herbicides 1-(substituted-2-pyridyl)-5-(substituted amino)pyrazoles, which are unsubstituted or alkyl substituted in the 3-position of the pyrazole ring;
U.S. Pat. No. 4,804,675 discloses as insecticides, acaricides, and nematicides 1-(substituted-2-pyridyl)-5-(substituted amino)pyrazoles, which are unsubstituted or alkyl or haloalkyl substituted in the 3-position of the pyrazole ring;
U.S. Pat. No. 4,740,232 discloses as herbicides 1 -(substituted phenyl)-5-(substituted amino)pyrazole compounds, which are unsubstituted in the 3-position of the pyrazole ring;
EP 398,499 discloses phenyl substituted heterocyclic compounds as insecticides and acaricides, including 1-(substituted phenyl)-5-(substituted amino)pyrazoles.
U.S. Pat. No. 4,822,810 discloses 1-aryl-4-cyano-3-(sulfur substituted)-5-(alkoxyalkylideneimino)pyrazoles for the control of arthropod pests.
U.S. Pat. No. 3,686,171 discloses N'-[(4-hydroxymethyl or formyl)-5-pyrazolyl]amidines as intermediates or anti-inflammatory agents.
U.S. Pat. No. 2,998,419 discloses the process of manufacture and use of affinity for proteins of 5-(substituted amino)-3,4-dicyanopyrazoles.
Acta Chimica Academiae Scientiarum Hungaricae, Tomus 105(2), 127-139 (1980), Simay, T. et al., discloses the chemical synthesis and physical properties of various 5-(substituted amino)pyrazoles (for examples compounds 2, 4, 7, 8 and 15-18).
It is thus apparent that the nature and position of substituent groups on a pyrazole ring provide widely different types of biological activity which type and level of activity is not readily apparent.
SUMMARY OF THE INVENTION
The present invention pertains to novel 1-aryl-5-(substituted alkylideneimino)pyrazoles which exhibit surprising, unexpected and excellent pesticidal properties, especially as insecticides for control via ingestion or contact action.
The compounds including their isomers, e.g. diastero and optical isomers, are compounds of a general formula (I) ##STR2## wherein:
R 1 is cyano, nitro, halogen:, formyl, alkylcarbonyl or cycloalkylcarbonyl; and wherein the alkyl moieties are linear or branched chains of 1-4 carbon atoms and the cycloalkyl moiety contains 3 to 7 carbon atoms;
R 2 is: halogen; alkyl; haloalkyl; alkoxy; haloalkoxy; nitro; thiocyanato; unsubstituted or mono- or dialkyl substituted sulfanoyl; unsubstituted or mono- or dialkyl substituted aminocarbonyl; alkoxycarbonyl; or unsubstituted or substituted R 9 S(O) n , in which n is 0, 1 or 2 and R 9 is alkyl, haloalkyl, cycloalkyl, halocycloalkyl, cycloalkylalkyl or halocycloalkylalkyl; and wherein the alkyl moieties are linear or branched chains of 1-4 carbon atoms, the cycloalkyl moiety contains 3 to 7 carbon atoms and the halo substitution consists of one or more halogen atoms, which are the same or different, up to full substitution of the alkyl and cycloalkyl moieties;
R 3 is hydrogen, C 1-4 alkyl, C 1-4 alkoxy, C 1-4 alkylthio or di-C 1-4 alkylamino; and wherein the alkyl moieties are linear or branched chains;
R 4 is unsubstituted or substituted phenyl or unsubstituted or substituted heteroaryl having a five or six membered monocyclic ring containing one or more of the same or different oxygen, sulfur or nitrogen hetero atoms; and wherein the phenyl or heteroaryl substitution is one or more or combinations of: hydroxy or inorganic or organic salt thereof; sulfhydryl or inorganic or organic salt thereof; halogen; cyano; nitro; alkyl; haloalkyl; alkoxy; -O-alkyl-O-; O-haloalkyl-O-; haloalkoxy; alkanoyloxy; phenoxy; trialkylsilyloxy; phenyl; alkyl-S(O) n or haloalkyl-S(O) n , in which n is 0, 1 or 2; NR 10 R 11 in which R 10 and R11 are individually hydrogen, alkyl, alkanoyl or haloalkanoyl; COR 12 in which R 12 is NR 10 R 11 , alkoxy, alkylthio, hydroxy or inorganic or organic salt thereof, hydrogen, alkyl or haloalkyl; or SO 2 R 13 in which R 13 is NR 10 R 11 , alkoxy, alkylthio, or hydroxy or inorganic or organic salt thereof; and wherein the alkyl and alkoxy moieties are linear or branched chains of 1-4 carbon atoms and the halo substitution consists of one or more halogen atoms, which are the same or different, up to full substitution of the alkyl and alkoxy moieties;
R 5 is hydrogen, halogen or linear or branched chain C 1-4 alkyl;
R 6 and R 8 are each individually hydrogen or fluorine;
R 7 is halogen, alkyl, haloalkyl, alkoxy, haloalkoxy, cyano, nitro, alkylcarbonyl, haloalkylcarbonyl, alkyl-S(O) n or haloalkyl-S(O) n in which n is 0, 1 or 2; and wherein the alkyl and alkoxy moieties are linear or branched chains of 1-4 carbon atoms and the halo substitution consists of one or more halogen atoms, which are the same or different, up to full substitution of the alkyl and alkoxy moieties; and
X is a nitrogen atom (N) or C-R 14 in which R 14 is hydrogen, halogen, cyano, nitro, C 1-4 alkyl, C 1-4 alkylthio or C 1-4 alkoxy; and the alkyl moieties are linear or branched chains.
In the compounds of formula (I), defined above, when R 4 is heteroaryl it is preferably, but not limited to unsubstituted or substituted pyridyl, pyridyl N-oxide, thienyl, furanyl, pyrrolyl, imidazolyl, triazolyl or the like.
More preferred compounds of formula (I) are compounds, wherein:
R 1 is cyano, nitro or halogen;
R 2 is unsubstituted or substituted R 9 S(O) n , in which n is 0, 1 or 2 and R 9 is alkyl or haloalkyl as defined;
R 3 is hydrogen;
R 4 is unsubstituted or substituted phenyl or unsubstituted or substituted heteroaryl which is pyridyl, pyridyl N-oxide, thienyl, furanyl, pyrrolyl, imidazolyl or triazolyl;
R 5 is hydrogen, halogen or alkyl;
R 6 and R 8 are each individually hydrogen or fluorine;
R 7 is halogen, alkyl, haloalkyl or haloalkoxy; and
X is a nitrogen atom (N) or C-R 14 in which R 14 is hyrogen, halogen, cyano, alkyl, alkylthio or alkoxy.
Particularly preferred compounds of formula (I) are those compounds of a formula (Ia) ##STR3## wherein:
R 2 is R 9 S(O) n in which n is 0, 1 or 2 and R 9 is alkyl, preferably methyl; or haloalkyl, preferably trihalomethyl or dihalomethyl; and in which halo is F, Cl or Br or combinations thereof and most preferably CF 3 , CCl 3 , CF 2 Cl, CFCl 2 , CF 2 Br, CHF 2 , CHClF or CHCl 2 ;
R 4 is unsubstituted or substituted phenyl in which the substituents are one or more: hydroxy; halogen, preferably F, Cl or Br; alkoxy, preferably methoxy or ethoxy; alkylthio, preferably methylthio; cyano; or alkyl, preferably methyl or ethyl; or combinations thereof; or R 4 is 4-pyridyl or 4-pyridyl N-oxide, optionally substituted as described for phenyl;
R 5 is: hydrogen; alkyl, preferably methyl; or halogen, preferably F, Cl or Br;
R 7 is: halogen, preferably F, Cl or Br; alkyl, preferably methyl; haloalkyl, preferably trihalomethyl and more preferably trifluoromethyl; or haloalkoxy, preferably trihalomethoxy and more preferably trifiuoromethoxy; and in which halo is F, Cl or Br or combinations thereof; and
X is a nitrogen atom or C-R 14 in which R 14 is: hydrogen; halogen, preferably F, Cl or Br; cyano; alkyl, preferably methyl or ethyl; alkylthio, preferably methylthio or ethylthio; or alkoxy, preferably methoxy or ethoxy.
For the above preferred compounds of formula (I), and particularly for (Ia), there are optimum combinations of substituent groups which optimize and maximize pesticidal activity based upon an optimum combination of chemical, physical and biological properties for each given compound. In particular those groups which function to provide particularly enhanced or unexpected and surprising pesticidal activity, as herein described, are, for example, as follows:
In the case of R 4 , preferred groups are, for example:
1. 4-hydroxy-3-methoxyphenyl;
2. 4- hydroxyphenyl;
3. 3-hydroxy-4-methoxyphenyl;
4. 3,5-dimethyl-4-hydroxyphenyl;
5. 3,5-dimethoxy-4-hydroxyphenyl;
6. 4-methylthiophenyl;
7. 2,4-dihydroxyphenyl;
8. 4-hydroxy-3-methylphenyl;
9. 3-ethoxy-4-hydroxyphenyl;
10. 3,4,5-trimethoxyphenyl;
11. phenyl;
12. 2-hydroxyphenyl;
13. 3,4-dihydroxyphenyl;
14. 2,4-dimethylphenyl;
15. 4-cyanophenyl;
16. 4-pyridyl;
17. 4-pyridyl N-oxide;
18. 3-chloro-4-hydroxyphenyl;
19. 2-chloro-4-hydroxyphenyl;
20. 5-bromo-4-hydroxy-3-methoxyphenyl;
21. 3-hydroxyphenyl;
22. 5-chloro-4-hydroxy-3-methoxyphenyl;
23. 2,4,5-trihydroxyphenyl;
24. 5-bromo-3,4-dihydroxyphenyl; or
25. 4,5-dihydroxy-3-methoxyphenyl.
Of the above R 4 groups, even more preferred are individually group No's:
A) 1-10, 12-15, or 18-25; or
B) 1-5, 7-9, 13, or 18-25; or
C) 1-4, 18 or 19.
In the case of the 1-phenyl or 1-(2-pyridyl) group comprising the substituents R 5 , R 6 , R 7 , R 8 and R 14 , preferred groups are, for example:
1. 2,6-dichloro-4-trifluoromethylphenyl;
2. 2,6-dichloro-4-trifluoromethoxyphenyl;
3. 2-chloro-4-trifluoromethoxyphenyl;
4. 2-chloro-4-trifluoromethylphenyl;
5. 2,4,6-trichlorophenyl;
6. 2,6-dichloro-4-fluorophenyl;
7. 4-bromo-2,6-dichlorophenyl;
8. 2-chloro-6-methyl-4-trifluoromethylphenyl;
9. 2-chloro-6-methylthio-4-trifluoromethylphenyl;
10. 2,4-dichlorophenyl:
11. 2-chloro-4-fluorophenyl;
12. 2-chloro-4-bromophenyl;
13. 4-bromo-2,6-difluorophenyl;
14. 3-chloro-5-trifluoromethyl-2-pyridyl;
15. 3-chloro-5-trifluoromethoxy-2-pyridyl;
16. 3-chloro-5-fluoro-2-pyridyl;
17. 3,5-dichloro-2-pyridyl;
18. 2-bromo-4-trifluoromethoxyphenyl;
19. 2-bromo-4-trifluoromethylphenyl;
20. 2-chloro-6-fluoro-4-trifluoromethoxyphenyl;
21. 2-chloro-6-fluoro-4-trifluoromethylphenyl; or
22. 2-chloro-6-cyano-4-trifluoromethylphenyl.
Of these 1-phenyl or 1-(2-pyridyl) groups, even more preferred are group No's 1, 2, 3, 4, 5, 6, 7, 8, 14, 15, 16, 17, 18, 19, 20, 21 or 22. Even further preferred are group No's 1, 2, 3, 4, 5, 7, 8, 14, 21 or 22.
Among these compounds of formula (I) and more preferably (Ia) are the following preferred compounds, which provide particularly excellent control of larval insect species by ingestion or contact:
______________________________________CMPD NO.______________________________________ 2 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(4-hydroxy-3- methoxyphenyl)methylideneimino]pyrazole; 3 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfonyl-5-[(4-hydroxy-3- methoxyphenyl)methylideneimino]pyrazole; 4 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(4-hydroxyphenyl)- methylideneimino]pyrazole; 6 1-(2,6-dichloro-4-trifluoromethoxyphenyl)-3-cyano- 4-dichlorofluoromethylsulfenyl-5-[(4-hydroxy-3- methoxyphenyl)methylideneimino]pyrazole; 9 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- dichlorofluoromethylsulfenyl-5-[(4-hydroxy-3- methoxyphenyl)methylideneimino]pyrazole;10 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfinyl-5-[(4-hydroxy-3- methoxyphenyl)methylideneimino]pyrazole;13 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(3,5-dimethoxy-4- hydroxyphenyl)methylideneimino]pyrazole;15 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(3-hydroxy-4- methoxyphenyl)methylideneimino]pyrazole;16 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(4-pyridyl)- methylideneimino]pyrazole;17 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(2,4-dihydroxyphenyl)- methylideneimino]pyrazole;18 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(4-pyridyl-N- oxide)methylideneimino]pyrazole;19 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(4-hydroxy-3- methylphenyl)methylideneimino]pyrazole;22 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(4-methylthiophenyl)- methylideneimino] pyrazole;23 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfinyl-5-[(4-hydroxy-3- methylphenyl)methylideneimino]pyrazole;24 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(3,5-dimethyl-4- hydroxyphenyl)methylideneimino]pyrazole;26 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfinyl-5-[(3,5-dimethoxy-4- hydroxyphenyl)methylideneimino]pyrazole;29 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(3-ethoxy-4- hydroxyphenyl)methylideneimino]pyrazole;30 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(3,4,5-trimethoxyphenyl)- methylideneimino]pyrazole;37 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(2-chloro-4- hydroxyphenyl)methylideneimino]pyrazole;38 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4- trifluoromethylsulfenyl-5-[(3-chloro-4- hydroxyphenyl)methylideneimino]pyrazole; or76 1-(2,6-dichloro-4-trifluoromethoxyphenyl)-3-cyano- 4-dichlorofluoromethylsulfenyl-5-[(4-hydroxy- phenyl)-methylideneimino]pyrazole.______________________________________
Of these specific named compounds, there are more preferred CMPD No's 2, 3, 4, 6, 9, 10, 13, 15, 17, 19, 23, 24, 26, 29, 37, 38 or 76 and especially preferred CMPD No's 2, 3, 10, 15, 24, 37, 38 or 76.
There are additionally other more specific categories of compounds that are specially preferred compounds of formula (I) or (Ia), which are compounds of the invention, wherein the R 4 group is a phenyl radical, which is at least substituted by 3-hydroxy or 4-hydroxy and the other phenyl radical substituents are as described by any of the independent definitions of the invention. These 3-hydroxy or 4-hydroxy compounds thus form separate and distinct subclasses independently within each of the above already indicated preferences and additional preferences, indicated as follows, which are further meant to be independent from each other. Furthermore, individual R 4 moieties, individual 1-phenyl or 1-(2-pyridyl) moieties, or individual compounds (CMPD No), within preferences C-L below, are each individually hereby meant to be separate independent preferences of the invention.
A) Compounds of formula (I);
B) Compounds of formula (Ia):
C) Preferred R 4 groups 1-25;
D) Preferred R 4 groups 1-10, 12-15 or 18-25;
E) Preferred R 4 groups 1-5, 7-9, 13 or 18-25;
F) Preferred R 4 groups 1-4, 18 or 19;
G) 1-Phenyl or 1-(2-pyridyl) groups 1-22;
H) 1-Phenyl or 1-(2-pyridyl) groups 1-8 or 14-22;
I) 1-Phenyl or 1-(2-pyridyl) groups 1-5, 7, 8, 14, 21 or 22:
J) CMPD No's 2, 3, 4, 6, 9, 10, 13, 15, 16, 17, 18, 19, 22, 23, 24, 26, 29, 30, 37, 38 or 76;
K) CMPD No's 2, 3, 4, 6, 9, 10, 13, 15, 17, 19, 23, 24, 26, 29, 37, 38 or 76; or
L) CMPD No's 2, 3, 10, 15, 24, 37, 38 or 76.
It is an object of the present invention to provide pesticidal new compounds of the 1-aryl-5-(substituted alkylideneimino)pyrazole family together with processes for their preparation.
A second object of the present invention is to provide compounds with a rather simple chemical formula that are readily prepared from known and/or readily available and frequently inexpensive intermediates and starting materials.
A third object of the present invention is to provide pesticidal compositions and pesticidal methods of use of the pesticidal pyrazole compounds against arthropods, especially insects, plant nematodes, or helminth or protozoan pests, particularly in agricultural or horticultural crops, forestry, veterinary medicine or livestock husbandry, or in public health.
A forth object of the present invention is to provide very active compounds, with broad spectrum pesticidal activity, as well as compounds with selective special activity, e.g., aphicidal, miticidal, foliar insecticidal, soil insecticidal and nematicidal, systemic, antifeeding, or pesticidal activity via seed treatment.
A fifth object of the present invention is to provide compounds with substantially enhanced and more rapid activity, especially against insects and more particularly insects in their larval stages, especially by contact action.
A sixth object of the present invention is to provide compounds with greatly improved (greater and faster) penetration into pest species when topically applied and thus provide enhanced movement of the compounds to the pesticidal site(s) of action within the pest.
Another object of the present invention is to provide compounds with high activity and improved safety to the user and the environment, which are obtained by optimization of chemical, physical and biological properties such as solubility, melting point, stability, electronic and steric parameters, and the like.
These and other objects of the invention shall become readily apparent from the detailed description of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Methods or Processes of Synthesis
The compounds of general formula (I) can be prepared by the application or adaptation of known methods (i.e. methods heretofore used or described in the chemical literature): e.g. an intermediate 5-aminopyrazole compound of a formula (II), initially prepared by known procedures, is subsequently condensed by well-known methods 1) with an appropriately substituted aldehyde or ketone to give compounds wherein R 3 is hydrogen or alkyl, respectively, or 2) with an orthoester to give compounds wherein R 3 is alkoxy, which optionally are reacted with an alkylthiol or dialkylamine, in the presence of a base such as NaH, K 2 CO 3 and Na 2 CO 3 , to give compounds wherein R 3 is alkylthio or dialkylamino.
The intermediate 5-amino-1-phenylpyrazole intermediates of formula (II) are known or can be prepared by methods or processes as described in EP 295, 117, published Dec. 14, 1988; EP 295, 118, published Dec. 14, 1988; EP 234,119, published Sep. 2, 1987 (also corresponding to WO 87/03781, published Jul. 2, 1987); and EP 350,311, published Jan. 10, 1990; all of which are incorporated herein by reference.
In an analogous manner for the preparation of the 5-amino-1-phenylpyrazole intermediates, the 5-amino-1-(2-pyridyl)pyrazole intermediates can be prepared by a variety of similar methods. According to a preferred synthetic method, these compounds can be obtained from an intermediate 1-(substituted-2-pyridyl)-3-alkoxycarbonyl-5-aminopyrazole compound followed by further substitution or derivatization using analogous procedures to these described for the 5-amino-1-phenylpyrazole compounds. The 5-amino-1-(2-pyridyl)pyrazole intermediate is initially obtained by cyclizing, in the presence of a base, an alkyl 2-oxo-3-cyanopropionate, obtained by acid neutralization of its corresponding metal enolate salt, with an appropriately substituted 2-pyridylhydrazine. The hydrazine is either commercially available or is generally a known compound of organic chemistry, prepared by known literature procedures familiar to one skilled in the art.
The aldehydes, ketones, ortho esters, alkylthiols and dialkylamines are also generally known compounds of organic chemistry and usually commercially available or can be prepared from such available compounds by known methods.
The compounds of formula (I), chemically described as Schiff bases, are prepared in a condensation reaction, for example, of an aldehyde or ketone of formula (III) with an aminopyrazole of formula (II), according to the following reaction: ##STR4## wherein the substituents R 1 through R 8 are as hereinabove defined.
In the reaction shown above, the aldehyde or ketone is optionally replaced by the above described ortho ester, R 4 C(O-C 1-4 alkyl) 3 , and removal of the formed alcohol, to provide compounds wherein R 3 is alkoxy, which is optionally converted to R 3 is alkylthio or dialkylamino.
The proper conditions for formation of the Schiff base will depend upon the nature of the starting materials and the product formed, that is to say solubility, reactivity, stability, etc. While such conditions may be required to be individually selected, in general, the compounds of formula (I) can readily be prepared by known condensation methods such as those described by J. March in "Advanced Organic Chemistry", McGraw-Hill, publ. (1985), p. 1165 and references cited therein.
REPRESENTATIVE COMPOUNDS OF THE INVENTION
The compounds of TABLE 1 are illustrative of some of the preferred compounds or subgroups of compounds within the purview of the above general formula (I) and can be prepared by the herein described methods or processes of synthesis, by the appropriate selection of reactants, conditions and procedures, which are commonly known and apparent to one skilled in the art.
TABLE 1__________________________________________________________________________REPRESENTATIVE 1-ARYL-5-(SUBSTITUTEDALKYLIDENEIMINO)PYRAZOLES OF FORMULA (I): (Ph = PHENYL)NO. R.sup.1 R.sup.2 R.sup.3 R.sup.4__________________________________________________________________________A) Wherein: R.sup.5 = C1, R.sup.6 & R.sup.8 = H, R.sup.7 = CF.sub.3, andX = CClA-1) 1 CN SCF.sub.3 CH.sub.3 4-OHPh 2 CN SCF.sub.3 H 2-pyrrolyl 3 CN SCF.sub.3 H NCH.sub.3 -2-pyrrolyl 4 CN SCCl.sub.2 F H 3,4-(OH).sub.2 Ph 5 CN SCCl.sub.2 F H 4-OHPh 6 CN SCCl.sub.2 F H 3-OH-4-OCH.sub.3 Ph 7 CN SCCl.sub.2 F H 2,4-(OH).sub.2 Ph 8 CN SCCl.sub.2 F H 3,5-(OCH.sub.3).sub.2 -4-OHPh 9 CN SCClF.sub.2 H 4-OH-3-OCH.sub.3 Ph10 CN SCClF.sub.2 H 3,5-(CH.sub.3).sub.2 -4-OHPhA-2)11 Cl SCF.sub.3 H 4-OH-3-OCH.sub.3 Ph12 Cl SO.sub.2 CF.sub.3 H 4-OHPh13 Cl SCCl.sub.2 F H 3-OHPh14 Cl SCCl.sub.2 F H 4-OH-3-OCH.sub.3 Ph15 Br SCF.sub.3 H 3,5-(CH.sub.3).sub.2 -4-OHPhA-3)16 Br NO.sub.2 H 4-OH-3-OCH.sub.3 Ph17 Br NO.sub.2 H 3,5-(CH.sub.3).sub.2 -4-OHPh18 Br NO.sub.2 H 3,5-(OCH.sub.3).sub.2 -4-OHPh19 Br NO.sub.2 H 3-OH-4-OCH.sub.3 PhB) Wherein: R.sup.5 = Cl, R.sup.6 & R.sup.8 = H, R.sup.7 = CF.sub.3, andX = CF20 CN SCF.sub.3 H 4-OH-3-OCH.sub.3 Ph21 CN SCF.sub.3 H 3,5-(CH.sub.3).sub.2 -4-OHPh22 CN SCF.sub.3 H 4-OH-3-CH.sub.3 Ph23 CN SCF.sub.3 H 4-OHPh24 CN SCF.sub.3 H 3,5-(OCH.sub.3).sub.2 -4-OHPh25 CN SCCl.sub.2 F H 4-OH-3-OCH.sub.3 Ph26 CN SCClF.sub.2 H 4-OH-3-OCH.sub.3 PhC) Wherein: R.sup.5 = Cl, R.sup.6 & R.sup.8 = H, R.sup.7 = OCF.sub.3, andX = CCl27 CN SCF.sub.3 H 4-OH-3-OCH.sub.3 Ph28 CN SCF.sub.3 H 4-OHPh29 CN SCF.sub.3 H 3-OH-4-OCH.sub.3 Ph30 CN SCF.sub.3 H 3,5-(CH.sub.3).sub.2 -4-OHPh31 CN SCF.sub.3 H 3-OHPh32 CN SOCF.sub.3 H 4-OH-3-CH.sub.3 Ph33 CN SOCF.sub.3 H 3,5-(CH.sub.3).sub.2 -4-OHPh34 CN SO.sub.2 CF.sub.3 H 4-OH-3-OCH.sub.3 Ph35 CN SCCl.sub.2 F H 3,4-(OH).sub.2 Ph36 CN SCCl.sub.2 F H 4-OHPh37 CN SCCl.sub.2 F H 3-OH-4-OCH.sub.3 Ph38 CN SCCl.sub.2 F H 2,4-(OH).sub.2 Ph39 CN SCCl.sub.2 F H 4-pyridyl NOD) Wherein: R.sup.5, R.sup.6 & R.sup.8 = H, R.sup.7 = CF.sub.3, and X =CBr or CCl40 CN SCF.sub.3 H 4-OH-3-OCH.sub.3 Ph41 CN SCF.sub.3 H 3,5-(CH.sub.3).sub.2 -4-OHPh42 CN SCF.sub.3 H 4-OHPh43 CN SCF.sub.3 H 3-OH-4-OCH.sub. 3 Ph44 CN SCF.sub.3 H 4-OH-3-CH.sub.3 Ph45 CN SO.sub.2 CF.sub.3 H 4-OH-3-CH.sub.3 Ph46 CN SCCl.sub.2 F H 3,5-(CH.sub.3).sub.2 -4-OHPh47 CN SCCl.sub.2 F H 4-OHPh48 CN SCCl.sub.2 F H 3,5-(OCH.sub.3).sub.2 -4-OHPh49 CN SCCl.sub.2 F H 3-OH-4-OCH.sub.3 Ph50 CN SCClF.sub.2 H 4-OH-3-OCH.sub.3 PhE) Wherein: R.sup.5, R.sup.6 & R.sup.8 = H, R.sup.7 = OCF.sub.3, and X =CBr or CCl51 CN SCF.sub.3 H 4-OH-3-OCH.sub.3 Ph52 CN SOCF.sub.3 H 4-OH-3-OCH.sub.3 Ph53 CN SOCF.sub.3 H 4-OH-3-CH.sub.3 Ph54 CN SO.sub.2 CF.sub.3 H 4-OH-3-CH.sub.3 Ph55 CN SCF.sub.3 H 3,5-(CH.sub.3).sub.2 -4-OHPh56 CN SCF.sub.3 H 3-OH-4-OCH.sub.3 Ph57 CN SCF.sub.3 H 4-OHPh58 CN SCCl.sub.2 F H 3,5-(CH.sub.3).sub.2 -4-OHPh59 CN SCCl.sub.2 F H 4-OHPh60 CN SCCl.sub.2 F H 3,5-(OCH.sub.3).sub.2 -4-OHPh61 CN SCCl.sub.2 F H 3-OH-4-OCH.sub.3 Ph62 CN SCClF.sub.2 H 4-OH-3-OCH.sub.3 PhF) Wherein: R.sup.5 = Cl, R.sup.6 & R.sup.8 = H, R.sup.7 = Br, and X =CCl63 CN SOCF.sub.3 H 4-OH-3-OCH.sub.3 Ph64 CN SO.sub.2 CF.sub.3 H 4-OH-3-OCH.sub.3 Ph65 CN SCCl.sub.2 F H 3,4-(OH).sub.2 Ph66 CN SCF.sub.3 H 4-pyridyl NO67 CN SCF.sub.3 H 3-OH-4-OCH.sub.3 Ph68 CN SCF.sub.3 H 3,5-(CH.sub.3).sub.2 -4-OHPh69 CN SCF.sub.3 H 4-OHPh70 CN SCF.sub.3 H 3,5-(OCH.sub.3).sub.2 -4-OHPhG) Wherein: R.sup.5 = Cl, R.sup.6 & R.sup.8 = H, R.sup.7 = Cl, and X =CCl71 CN SCCl.sub.2 F H 4-OHPh72 CN SCCl.sub.2 F H 4-OH-3-OCH.sub.3 Ph73 CN SCF.sub.3 H 4-OH-3-CH.sub.3 Ph74 CN SCF.sub.3 H 4-OH-3-OCH.sub.3 PhH) Wherein: R.sup.5 = Cl, R.sup.6 & R.sup.8 = H, R.sup.7 = F, and X =CCl75 CN SCCl.sub.2 F H 4-OH-3-OCH.sub.3 Ph76 CN SCF.sub.3 H 4-OHPh77 CN SCF.sub.3 H 4-OH-3-OCH.sub.3 PhI) Wherein: R.sup.5 = Cl, R.sup.6 & R.sup.8 = H, R.sup.7 = CF.sub.3, andX = N78 CN SCF.sub.3 H 3,5-(CH.sub.3 O).sub.2 -4-OHPh79 CN SCCl.sub.2 F H 4-OH-3-OCH.sub.3 Ph80 CN SCF.sub.3 H 4-OH-3-OCH.sub.3 Ph81 CN SOCF.sub.3 H 4-OH-3-OCH.sub.3 Ph82 CN SO.sub.2 CF.sub.3 H 4-OH-3-OCH.sub.3 Ph83 CN SCCl.sub.2 F H 3-OH-4-OCH.sub.3 Ph84 CN SCCl.sub.2 F H 4-OHPh85 CN SCF.sub.3 H 3,5-(OCH.sub.3).sub.2 -4-OHPhJ) Wherein: R.sup.5 = Cl, R.sup. 6 & R.sup.8 = H, R.sup.7 = CF.sub.3,OCF.sub.3, Br or Cl,and X = CCl86 Cl Cl CH.sub.3 4-ClPh87 CHO CH.sub.3 H 4-CNPh88 CH.sub.3 CO NO.sub.2 H 4-NO.sub.2 Ph89##STR5## OCH.sub.3 H 4-OHPh90 CN CF.sub.3 CH.sub.3 4-OH-3-OCH.sub.3 Ph91 CN OCF.sub.3 H 2,4-(OH).sub.2 Ph92 NO.sub.2 CH.sub.3 CH.sub.3 3,4-(OH).sub.2 Ph93 Br SCN H 3-OHPh94 CN SO.sub.2 NH.sub.2 H 4-OH-3-OCH.sub.3 Ph95 Cl CONHCH.sub.3 H 2-OHPh96 NO.sub.2 COOCH.sub.3 CH.sub.3 2,4-(CH.sub.3).sub.2 Ph97 CN SO.sub.2 CH.sub.3 H 3-OH-4-OCH.sub.3 Ph98 CN SCF.sub.3 H 4-CF.sub.3 -3-OHPh99 Cl SOCF.sub.3 CH.sub.3 3-OCF.sub.3 Ph100 CN NO.sub.2 H 4-O.sub.2 CCH.sub.3 Ph101 NO.sub.2 Cl CH.sub.3 4-OPhPh102 CN SCF.sub. 3 H 4-PhPh103 CN SCCl.sub.2 F H 3-SO.sub.2 CH.sub.3 Ph104 CN SCF.sub.3 H 3-SCF.sub.3 Ph105 Br SCF.sub.3 H 4-N(CH.sub.3).sub.2 Ph106 Cl NO.sub.2 CH.sub.3 4-COOCH.sub.3 Ph107 CN SCF.sub.3 H 3-SO.sub.3 CH.sub.3 Ph108 CN SCF.sub.3 SCH.sub.3 4-OH-3-OCH.sub.3 Ph109 CN SOCF.sub.3 N(CH.sub.3).sub.2 4-OH-3-OCH.sub.3 Ph110 CN SCF.sub.3 OC.sub.2 H.sub.5 4-OHPh111 CN SCF.sub.3 H 3-OCH.sub.3 -4-OSi(CH.sub.3).sub.3 PhK) Wherein: R.sup.5 = Cl, R.sup.6 & R.sup.8 = H, R.sup.7 = CH.sub.3,OCH.sub.3, CN, NO.sub.2,COCH.sub.3, COCF.sub.3, SOCH.sub.3, SO.sub.2 CH.sub.3, SOCF.sub.3 orSO.sub.2 CF.sub.3, and X = CCl112 CN SCF.sub.3 H 4-OHPh113 Cl NO.sub.2 CH.sub.3 3-OH-4-CH.sub.3 Ph114 CN SOCF.sub.3 SC.sub.2 H.sub.5 3-OHPh115 CN SCF.sub.3 OC.sub.4 H.sub.9 2,4-(OH).sub.2 Ph116 CN Cl N(C.sub.2 H.sub.5).sub.2 4-OHPhL) Wherein: R.sup.5 = CH.sub.3, R.sup.6 & R.sup.8 = F, R.sup.7= CF.sub.3, and X =CCH.sub.3, CH, CCN, CNO.sub.2, COCH.sub.3 or CSCH.sub.3117 Cl NO.sub.2 H 4-OHPh118 CN SCCl.sub.2 F CH.sub.3 3-OH-4-OCH.sub.3 Ph119 CN SCF.sub.3 H 2,4-(OH).sub.2 PhM) Wherein: R.sup.5 = Cl or Br, R.sup.6 & R.sup.8 = H, R.sup.7 = CF.sub.3or OCF.sub.3, andX = CH, CCH.sub.3, CCN, CNO.sub.2, COCH.sub.3 or CSCH.sub.3120 CN SCF.sub.3 H 4-OH-3-OCH.sub.3 Ph121 CN SCCl.sub.2 F H 4-OH-3-OCH.sub.3 Ph122 CN SCF.sub.3 H 4-OHPh123 CN SO.sub.2 CF.sub.3 H 4-OH-3-CH.sub.3 Ph__________________________________________________________________________
DETAILED EXAMPLES OF COMPOUND SYNTHESIS
The following EXAMPLES 1 to 5 illustrate detailed methods of synthesis and the physical properties of representative pesticidal compounds of formula (I) (and their chemical intermediates) according to the invention. These example compounds and others prepared in a similar manner, following the detailed procedures or other methods or processes herein described, are shown in Tables 2, 2A and 2B. Reported melting points for the compounds in these EXAMPLES, as well as those in Tables 2, 2A and 2B, represent the average value of an observed melting point range determined for a compound or furthermore represent the average value of a number of separate melting point determinations. Additionally, one or more spectroscopic analyses (IR, H 1 or F 19 NMR, MS, etc.) have been performed on each compound for characterization and confirmation of the chemical structure.
The condensation is preferably carried out in the presence of a suitable reaction auxiliary. Those auxiliaries which are suitable are: organic or inorganic acids, for example, sulfuric acid, hydrochloric acid, phosphoric acid, toluenesulfonic acid or methanesulfonic acid; ion exchange resin catalysts; and/or water-removing agents, for example, sodium (or magnesium) sulfate or molecular sieves. It is also possible to optionally remove reaction water from the reaction mixture by azotropic distillation to facilitate the reaction.
Particularly preferred reaction auxiliaries are ion exchange resins of the commercial type sold by Dow Chemical Company under the trademark "DOWEX®" or by Bio-Rad Chemical Division under the trademark "AG®", "BIO-REX®" or "CHELEX®". These latter Bio-Rad resins, their properties and uses are extensively described in "Bio-Rad Guide to Ion Exchange" catalog Number 140-997 (and references described therein), Bio-Rad Chemical Division, 1414 Harbour Way South, Richmond, Calif. 94804. The resins of this type are also described in "The Chemist's Companion", Gorden, A. J. and Ford, R. A., page 386, John Wiley and Sons.
Particularly preferred are acidic cationic exchange resins, for example, as follows:
______________________________________1. Strong sulfonic acid "BIO-REX ®" 40 (RCH.sub.2 SO.sub.3 H) phenolic type resin2. Strong sulfonic acid (φSO.sub.3 H) "AGO ®" 50W (X Series) polystyrene type resin ("DOWEX ®" 50 (X Series)3. Intermediate phosphonic acid "BIO-REX ®" 63 (φPO.sub.3 Na) polystyrene type resin4. Weak Acid (RCOONa) "BIO-REX ®" 70 acrylic type resin5. Weak Acid Chelating "CHELEX ®" 100 (φCH.sub.2 N(CH.sub.2 COOH).sub.2 polystyrene type resin______________________________________
These commercial resins maybe in protonic acid form or as salts. In the event they are salts, it may be necessary to appropriately convert them to a proper acid form for best catalysis of the condensation reaction.
The use of these ion exchange resin catalysts is especially advantageous or beneficial since:
a) they can be readily removed, for example, by simple filtration;
b) they avoid aqueous basic washes of the reaction product when typical organic or inorganic acid catalysts are used;
c) they avoid hydrolysis of the desired product;
d) they are more efficient/effective in providing higher yields, higher purities and faster reaction rates;
e) they are available in very small to large particle sizes which allows better reaction results/control;
f) they provide more precise catalytic acidity range and control;
g) they are more reproducible in their results;
h) they are more economical since they can be used, then reused/recycled numerous times; and
i) they are more flexible in their use in batch, semi-continuous or continuous reaction processes.
The reaction temperatures for the condensation reaction can be varied within a relatively wide range. In general, the reaction is carried out at temperatures between about 70° C. and about 160° C., preferably at temperatures between about 100° C. and about 130° C.
For carrying out the process according to the invention, 1.0 to 5.0 equivalents, preferably 1.0 to 1.5 equivalents, of aldehyde or ketone of the formula (III) and 0.01 to 2.0 equivalents, preferably 0.01 to 0.5 equivalents, of the reaction auxiliary are generally employed. In the case of ionic resin catalysts as reaction auxiliaries, they may be used at lower as well as higher equivalencies. The reaction is carried out and the reaction products are worked up and isolated by generally customary methods.
Suitable diluents, which in some cases may be optional, for carrying out the process are inert, typically aprotic, organic solvents, which include aliphatic, alicyclic or aromatic, or optionally halogenated hydrocarbons, for example, benzene, chlorobenzene, toluene or xylene.
EXAMPLE 1
Preparation of: 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifluoromethylsulfenyl-5-[(4-hydroxy-3-methoxyphenyl)methylideneimino]pyrazole; CMPD No. 2
A mixture of 5-amino-1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifluoromethylsulfenylpyrazole (2.5 g, 5.9 mmol), 4-hydroxy-3-methoxybenzaldehyde (1.1 g, 1.3 equivalents), p-toluenesulfonic acid (0.15 g, 0.13 equivalents) and toluene (750 mL) was heated at reflux with a Dean-Stark trap to remove water for 40 hours. Toluene was removed in vacuo. The residue was dissolved with ethyl acetate. The organic solution was washed once with saturated aqueous Na 2 CO 3 , then water, dried over MgSO 4 , filtered and concentrated in vacuo. The desired product (2.8 g. 85% of theory) was obtained as a light yellow solid, mp 132.5° C. H 1 and F 19 NMR spectral data indicated it to be pure.
EXAMPLE 2
Preparation of: 1-(2.6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifluoromethylsulfenyl-5-[(4-nitrophenyl)methylideneimino]pyrazole; CMPD No. 33
A mixture of 5-amino-1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifluoromethylsulfenylpyrazole (2.0 g, 4.7 mmol), 4-nitrobenzaldehyde (0.87 g, 1.25 equivalents), p-toluenesulfonic acid (0.02 g, 0.02 equivalents) and toluene (200 mL) was heated at reflux with a Dean-Stark trap to remove water for 36 hours. After cooling to room temperature, the toluene solution was agitated with aqueous NaHSO 3 solution in an ice bath for five minutes. Two phases were separated. This was repeated one more time. The organic layer was then washed with water, dried over MgSO 4 , filtered and concentrated in vacuo. The crude product was recrystallized from t-butyl methyl ether and hexane to give the desired product (1.42 g,. 54.4% yield) as a yellow solid, mp 167.5° C.
EXAMPLE 3
Preparation of: 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifluoromethylsulfinyl-5-[(3,5-dimethoxy-4-hydroxyphenyl)methylideneimino]pyrazole; CMPD No. 26
A mixture of 5-amino-1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifluoromethylsulfinylpyrazole (2.0 g, 4.58 mmol), 3,5-dimethoxy-4-hydroxybenzaldehyde (1.0 g. 1.2 equivalents), p-toluenesulfonic acid (0.08 g, 0.1 equivalents) and toluene (800 mL) was heated at reflux with a Dean-Stark trap to remove water for eight days. The reaction solution was concentrated to 100 mL in vacuo and ethyl acetate was added. The organic solution was washed with saturated aqueous Na 2 CO 3 , dried over MgSO 4 , filtered and concentrated in vacuo. The residue was purified by silica gel column chromatography, eluted with hexane/ethyl acetate. The desired product (1.2 g) as a yellow solid (yield: 44%), was obtained, mp. 175° C.
EXAMPLE 4
Preparation of: 1-(2.6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifluoromethylsulfinyl-5-[(3-methoxy-4-hydroxyphenyl)-methylideneimino]pyrazole: CMPD. No. 10
A mixture of 5-amino-1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifiuoromethylsulfinylpyrazole (60 g, 0.137 mole), 3-methoxy-4-hydroxybenzaldehyde (25.6 g, 1.2 equivalents), "DOWEX®" (trademark) 50×8-400 resin (140 g) and toluene (1.5 L) was heated at reflux with a Dean-Stark tube to remove water for four days. After cooling to room temperature, the reaction mixture was filtered. The toluene filtrate was concentrated in vacuo. The solid residue was ground, and then heated at reflux with heptane (600 mL). A yellow solid was filtered while the mixture was still hot. The solid (66.5 g) was obtained as the desired product, m.p. 155° C.
EXAMPLE 5
Preparation of: 1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifluoromethylsulfenyl-5-[(3-methoxy-4-hydroxyphenyl)methylideneimino]pyrazole: CMPD. No. 2
A mixture of 5-amino-1-(2,6-dichloro-4-trifluoromethylphenyl)-3-cyano-4-trifluoromethylsulfenylpyrazo (5 g, 11.8 mmol), 3-methoxy-4-hydroxybenzaldehyde (2 g, 1.1 equivalents), "DOWEX®" (trademark) 50×8-100 resins (2 g) and toluene (400 mL) was heated at reflux with a Dean-Stark tube for 30 hours. After cooling to room temperature, the mixture was filtered through a thin layer of silica gel and celite. The filtrate was concentrated and the desired product as a white solid was obtained (6.85 g), m.p. 132.5° C.
Using similar procedures to those of EXAMPLES 1 to 5, there were obtained the following other compounds as shown in TABLES 2, 2A, and 2B.
TABLE 2__________________________________________________________________________SYNTHESIZED PYRAZOLE COMPOUNDS OF FORMUIA (I), WHEREIN:R.sup.1 IS CN AND R.sup.3, R.sup.6 AND R.sup.8 ARE H (Ph = PHENYL)CMPDNO R.sup.2 R.sup.5 R.sup.7 X R.sup.4 M.P. °C.__________________________________________________________________________ 1 SCF.sub.3 Cl CF.sub.3 CCl 2-OH--Ph 158 2 SCF.sub.3 Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 132.5 3 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 177 4 SCF.sub.3 Cl CF.sub.3 CCl 4-OH--Ph 139 5 SCF.sub.3 Cl CF.sub.3 CCl 3-OPh--Ph Oil 6 SCCl.sub.2 F Cl OCF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 172 7 SCF.sub.3 Cl CF.sub.3 CCl 2-thienyl 110 8 SCF.sub.3 Cl Br CCl 4-OH-3-OCH.sub.3 --Ph Oil 9 SCCl.sub.2 F Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 6910 SOCF.sub.3 Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 15511 SCF.sub.3 Cl CF.sub.3 CCl 3,4-(OH).sub.2 --Ph 7412 SCF.sub.3 Cl CF.sub.3 CCl 3,4-(OCH.sub.2 O)--Ph 14013 SCF.sub.3 Cl CF.sub.3 CCl 3,5-(OCH.sub.3).sub.2 -4-OH--Ph 162.514 SCF.sub.3 Cl CF.sub.3 CCl 4-N(CH.sub.3).sub.2 --Ph 144.515 SCF.sub.3 Cl CF.sub.3 CCl 3-OH-4-OCH.sub.3 --Ph 16216 SCF.sub.3 Cl CF.sub.3 CCl 4-pyridyl 15717 SCF.sub.3 Cl CF.sub.3 CCl 2,4-(OH).sub.2 --Ph 16218 SCF.sub.3 Cl CF.sub.3 CCl 4-pyridyl N--O 18919 SCF.sub.3 Cl CF.sub.3 CCl 4-OH-3-CH.sub.3 --Ph 178.520 SCF.sub.3 Cl CF.sub.3 CCl 2-furanyl 16921 SCF.sub.3 Cl CF.sub.3 CCl 4-OCH.sub.3 --Ph 95.522 SCF.sub.3 Cl CF.sub.3 CCl 4-SCH.sub.3 --Ph 11323 SOCF.sub.3 Cl CF.sub.3 CCl 4-OH-3-CH.sub.3 --Ph 17624 SCF.sub.3 Cl CF.sub.3 CCl 3,5-(CH.sub.3).sub.2 -4-OH--Ph 18325 SCF.sub.3 Cl CF.sub.3 CCl 2,6-(CH.sub.3).sub.2 -4-OH--Ph 18026 SOCF.sub.3 Cl CF.sub.3 CCl 3,5-(OCH.sub.3).sub.2 -4-OH--Ph 17527 SOCF.sub.3 Cl CF.sub.3 CCl 4-N(CH.sub.3).sub. 2 --Ph Oil28 SCF.sub.3 Cl CF.sub.3 CCl Ph 148.529 SCF.sub.3 Cl CF.sub.3 CCl 3-OC.sub.2 H.sub.5 -4-OH--Ph 15130 SCF.sub.3 Cl CF.sub.3 CCl 3,4,5-(OCH.sub.3).sub.3 --Ph 13231 SCF.sub.3 Cl CF.sub.3 CCl 2,4-(CH.sub.3).sub.2 --Ph 10832 SCF.sub.3 Cl CF.sub.3 CCl 4-CN--Ph 14233 SCF.sub.3 Cl CF.sub.3 CCl 4-NO.sub.2 --Ph 167.534 SCF.sub.3 Cl CF.sub.3 CCl 4-Cl--Ph 14035 SOCF.sub.3 Cl CF.sub.3 CCl 4-OCH.sub.3 --Ph 9736 SCF.sub.3 Cl CF.sub.3 CCl 3-Cl-4-OH-5-OCH.sub.3 --Ph 17837 SCF.sub.3 Cl CF.sub.3 CCl 2-Cl-4-OH--Ph 18038 SCF.sub.3 Cl CF.sub.3 CCl 3-Cl-4-OH--Ph 15639 SCF.sub.3 Cl CF.sub.3 CCl 2,3,5,6-F.sub.4 --Ph 12640 SCF.sub.3 Cl CF.sub.3 CCl 3,4-(OH).sub.2 -5-OCH.sub.3 --Ph 16341 SCF.sub.3 Cl CF.sub.3 CCl 3,4-(OCH.sub.3).sub.2 --Ph Oil42 SCF.sub.3 Cl CF.sub.3 CCl 3-Br-4-OH-5-OCH.sub.3 --Ph 18443 SCF.sub.3 Cl CF.sub.3 CCl 2-Cl--Ph 159.544 SCF.sub.3 Cl CF.sub.3 CCl 4-NHCOCH.sub.3 --Ph 11045 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 4-OH--Ph 20146 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 3,5-(OCH.sub.3).sub.2 -4-OH--Ph 11147 SOCF.sub.3 Cl CF.sub.3 CCl 3-OC.sub.2 H.sub.5 -4-OH--Ph 15548 SOCF.sub.3 Cl CF.sub.3 CCl 3-Cl-4-OH-5-OCH.sub.3 --Ph 129.549 SCF.sub.3 Cl CF.sub.3 CCl 4,6-(OCH.sub.3).sub.2 -2-OH--Ph 155.550 SCF.sub.3 Cl CF.sub.3 CCl 2-OH-3-OCH.sub.3 --Ph 7151 SCF.sub.3 Cl CF.sub.3 CCl 2-F--Ph 9552 SCF.sub.3 Cl CF.sub.3 CCl 3,5-Br.sub.2 -4-OH--Ph 160.553 SCF.sub.3 Cl CF.sub.3 CCl 4-O.sub.2 CCH.sub.3 --Ph 14254 SCF.sub.3 Cl CF.sub.3 CCl 3-OCH.sub.3 --Ph 99.555 SCF.sub.3 Cl CF.sub.3 CCl 2-CF.sub.3 --Ph 85.556 SCF.sub.3 Cl CF.sub.3 CCl 3-F--Ph 12557 SCF.sub.3 Cl CF.sub.3 CCl 4-F--Ph 12458 SCF.sub.3 Cl CF.sub.3 CCl 3-OH--Ph 13859 SCF.sub.3 Cl CF.sub.3 CCl 4,5-(OCH.sub.3).sub.2 -3-OH--Ph 12660 CF.sub.3 Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 17161 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 3-OC.sub.2 H.sub.5 -4-OH--Ph 18962 SCCl.sub.2 F Cl CF.sub.3 CH 4-OH-3-OCH.sub.3 --Ph 15563 SCCl.sub.2 F Br CF.sub.3 CH 4-OH-3-OCH.sub.3 --Ph 14764 SCF.sub.3 Cl CF.sub.3 CCl 3,5-(t-C.sub.4 H.sub.9).sub.2 -4-OH--Ph 18365 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 3-OH-4-OCH.sub.3 --Ph 11466 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 4-OH-3-CH.sub.3 --Ph 160d67 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 3-Cl-4-OH--Ph 6368 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 4-pyridyl N--O 197d69 SCF.sub.3 Cl CF.sub.3 CCl 3-OCH.sub.3 -4-O.sub.2 CCH.sub.3 --Ph 14870 SCF.sub.3 Cl CF.sub.3 CCl 2,6-(OCH.sub.3).sub.2 --Ph 18371 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 3,4-(OCH.sub.3).sub.2 --Ph 4472 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 2,4-(OCH.sub.3).sub.2 -6-OH--Ph 12673 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 3,5-(CH.sub.3).sub.2 -4-OH--Ph 210.5__________________________________________________________________________
TABLE 2A__________________________________________________________________________SYNTHESIZED PYRAZOLE COMPOUNDS OF FORMULA (I),WHEREIN: R.sup.1 IS CN AND R.sup.3, R.sup.6 AND R.sup.8 ARE H (Ph =PHENYL) M.P.CMPD NO. R.sup.2 R.sup.5 R.sup.7 X R.sup.4 °C.__________________________________________________________________________74 SCF.sub.3 Cl CF.sub.3 CCl 4-OH-5-OCH.sub.3 -3-NO.sub.2 --Ph 16575 SO.sub.2 CF.sub.3 Cl CF.sub.3 CCl 2-Cl-4-OH--Ph 15476 SCCl.sub.2 F Cl OCF.sub.3 CCl 4-OH--Ph 17077 SCF.sub.3 Cl CF.sub.3 CCl 2,4-(OCH.sub.3).sub.2 -3-OH--Ph 12878 SCClF.sub.2 Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 13879 SCClF.sub.2 Cl CF.sub.3 CCl 4-OH--Ph 15980 SCClF.sub.2 Cl CF.sub.3 CCl 3,5-(CH.sub.3).sub.2 -4-OH--Ph 18081 SCClF.sub.2 Cl CF.sub.3 CCl 3-OH-4-OCH.sub.3 --Ph 14782 SCCl.sub.2 F Cl OCF.sub.3 CCl 3,5-(CH.sub.3).sub.2 -4-OH--Ph 24683 SCCl.sub.2 F Cl OCF.sub.3 CCl 3-OH-4-OCH.sub.3 --Ph 17884 SCCl.sub.2 F Cl OCF.sub.3 CCl 3-Cl-4-OH--Ph 10885 SCClF.sub.2 Cl CF.sub.3 CCl 2-Cl-4-OH--Ph 20786 SCClF.sub.2 Cl CF.sub.3 CCl 3-Cl-4-OH--Ph 15287 SCF.sub.3 Cl CF.sub.3 N 4-OH-3-OCH.sub.3 --Ph 6988 SCCl.sub.2 F Cl OCF.sub.3 CCl 2-Cl-4-OH--Ph 13589 SCCl.sub.2 F Cl OCF.sub.3 CCl 2,4-(OH).sub.2 --Ph 18390 SCF.sub.3 Cl CF.sub.3 CCl 2,4-(OH).sub.2 -6-CH.sub.3 --Ph 17391 SCF.sub.3 Cl CF.sub.3 CCl 2,3,4-(OH).sub.3 --Ph 16192 SCF.sub.3 Cl CF.sub.3 CCl 2,4,5-(OH).sub.3 --Ph 16193 SCF.sub.3 Cl CF.sub.3 CCl 3,4-(OH).sub.2 -5-Br--Ph 8994 SCCl.sub.2 F Cl CF.sub.3 CCl 3-Cl-4-OH--Ph 14895 SCCl.sub.2 F Cl CF.sub.3 N 4-OH-3-OCH.sub.3 --Ph 15596 SCClF.sub.2 Cl CF.sub.3 CCl 2,4-(OH).sub.2 --Ph 15997 SCCl.sub.2 F Cl CF.sub.3 CCl 2-Cl-4-OH--Ph 20598 SCCl.sub.2 F Cl CF.sub.3 CCl 2,4-(OH).sub.2 --h 14099 SCCl.sub.2 F Cl CF.sub.3 CCl 3-OH-4-OCH.sub.3 --Ph 104100 SCF.sub.3 Cl CF.sub.3 CCl 3-Br-4-OH--Ph 132101 SCCl.sub.2 F Cl OCF.sub.3 CCl 3-Br-4-OH--Ph 146102 SCCl.sub.2 F Cl OCF.sub.3 CCl 4-OH-3-CH.sub.3 --Ph 151103 SCCl.sub.2 F Cl OCF.sub.3 CCl 3,5-(OCH.sub.3).sub.2 -4-OH--Ph 158104 SCCl.sub.2 F Cl OCF.sub.3 CCl 5-Br-4-OH-3-OCH.sub.3 --Ph 216105 SCCl.sub.2 F Cl OCF.sub.3 CCl 4,5-(OH).sub.2 -3-OCH.sub.3 --Ph 197106 SCCl.sub.2 F Cl OCF.sub.3 CCl 3-OC.sub.2 H.sub.5 -4-OH--Ph 169.5107 SO.sub.2 CH.sub.3 Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 215108* NO.sub.2 Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 125109* SOCF.sub.3 Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph 188110 SCH.sub.3 Cl CF.sub.3 CCl 4-OH-3-OCH.sub.3 --Ph Oil111 SCH.sub.3 Cl CF.sub.3 CCl 4-OH--Ph 178__________________________________________________________________________ *R.sup.1 is Cl.
TABLE 2B__________________________________________________________________________SYNTHESIZED PYRAZOLE COMPOUNDS OF FORMULA (I),WHEREIN: R.sup.1 IS CN AND R.sup.3, R.sup.6 AND R.sup.8 ARE H (Ph =PHENYL) M.P.CMPD NO. R.sup.2 R.sup.5 R.sup.7 X R.sup.4 °C.__________________________________________________________________________112 SCF.sub.3 Cl CF.sub.3 CCl 3,5-(CF.sub..sub.3).sub.2 --Ph 110113 SCF.sub.3 Cl CF.sub.3 CCl 2-OCH.sub.3 --Ph 141114 SCF.sub.3 Cl CF.sub.3 CCl 2-Cl-6-F--Ph 160115 SCF.sub.3 Cl CF.sub.3 CCl 2-imidazolyl 224116 SCF.sub.3 Cl CF.sub.3 CCl 3-CN--Ph 104117 SCF.sub.3 Cl CF.sub.3 CCl 2-OH-4-N(C.sub.2 H.sub.5).sub.2 --Ph 58118 SCF.sub.3 Cl CF.sub.3 CCl 3-OCH.sub.3 -4-OC.sub.10 H.sub.21 --Ph 123119 SCF.sub.3 Cl CF.sub.3 CCl 4-OC.sub.5 H.sub.11 --Ph 64120 SCF.sub.3 Cl CF.sub.3 CCl 3-OCH.sub.3 -4-OCH.sub.2 Ph--Ph 123121 SCF.sub.3 Cl CF.sub.3 CCl 3-OCH.sub.3 -4-O.sub.2 CC.sub.7 H.sub.15 Oilh122 SCCl.sub.2 F Cl OCF.sub.3 CCl 3,4-(OCH.sub.3).sub.2 --Ph 85123 SCCl.sub.2 F Cl OCF.sub.3 CCl 3,4,5-(OCH.sub.3).sub.3 --Ph 134124 SCCl.sub.2 F Cl OCF.sub.3 CCl 2-OH--Ph 137125 SCCl.sub.2 F Cl OCF.sub.3 CCl 2-OH-3-OCH.sub.3 --Ph 125126 SCH.sub.3 Cl CF.sub.3 CCl Ph 156__________________________________________________________________________
EXAMPLE 6
Miticide, Insecticide, Aphicide, and Nematicide Use
The following representative test procedures, using compounds of the invention, were conducted to determine the pesticidal use and activity of compounds of the invention against: mites; certain insects, including aphids, two species of caterpillar, a fly, and three species of beetle larvae (one foliar feeding and two root feeding); and nematodes. The specific species tested were as follows:
______________________________________ (ABBREV-GENUS, SPECIES COMMON NAME IATION)______________________________________Tetranychus urticae twospotted spider mite TSMAphis nasturtii buckthorn aphid BASpodoptera eridania southern armyworm SAWEpilachna varivestis Mexican bean beetle MBBMusca domestica housefly HFDiabrotica u. southern corn rootworm SCRWhowardiDiabrotica virgifera western corn rootworm WCRWMeloidogyne southern root-knot nematode SRKNincognitaAphis gossypii cotton aphid CASchizaphis graminum greenbug (aphid) GBHeliothis virescens tobacco budworm TBW______________________________________
Formulations
The test compounds were formulated for use according to the following methods used for each of the test procedures.
For mite, aphid, southern armyworm, Mexican bean beetle, and tobacco budworm tests, a solution or suspension was prepared by adding 10 mg of the test compound to a solution of 160 mg of dimethylformamide, 838 mg of acetone, 2 mg of a 3:1 ratio of Triton X-72: Triton X-152 (respectively, mainly anionic and nonionic low foam emulsifiers which are each anhydrous blends of alkylaryl polyether alcohols with organic sulfonates), and 98.99 g of water. The result was a concentration of 100 ppm of the test compound.
For housefly tests, the formulation was initially prepared in a similar manner to the above, but in 16.3 g of water with corresponding adjustment of other components, providing a 200 ppm concentration. Final dilution with an equal volume of a 20% by weight aqueous solution of sucrose provided a 100 ppm concentration of the test compound. When necessary, sonication was provided to insure complete dispersion.
For southern and western corn rootworm tests, a solution or suspension was prepared in the same manner as that used for the initial 200 ppm concentration for housefly. Aliquots of this 200 ppm formulation were then used by dilution with water according to the required test concentration.
For southern root-knot nematode and systemic tests for southern armyworm, cotton aphid, tobacco budworm and greenbug, a stock solution or suspension was prepared by adding 15 mg of the test compound to 250 mg of dimethylformamide, 1250 mg of acetone and 3 mg of the emulsifier blend referenced above. Water was then added to provide a test compound concentration of 150 ppm. When necessary, sonication was provided to insure complete dispersion.
For tobacco budworm contact tests, a stock solution was prepared by dissolving the compound in acetone and then further diluted to provide the required serial dilution concentrations.
Test Procedures
The above formulated test compounds were then evaluated for their pesticidal activity at the specified concentrations, in ppm (parts per million) by weight, according to the following test procedures:
Twospotted spider mite: Leaves infested with adult and nymphal stages of the two-spotted spider mite, obtained from a stock culture were placed on the primary leaves of two bean plants growing in a 6 cm. peat pot. A sufficient number of mites (150-200) for testing were transferred to the fresh plants within a period of twenty-four hours. The potted plants (one pot per compound) were placed on a revolving turntable and sprayed, sufficient to wet the plants to runoff, with 100 ml of the 100 ppm test compound formulation by use of a DeVilbiss spray gun set at 40 psig. air pressure. As an untreated control, 100 ml of the water-acetone-DMF-emulsifier solution, containing no test compound, were also sprayed on infested plants. A treated control with a commercial technical compound, either dicofol or hexythiazox, formulated in the same manner, was tested as a standard. The sprayed plants were held for six days, after which a mortality count of motile forms was made.
Twospotted spider mite (ovicide test): Eggs were obtained from adults of the twospotted spider mite from a stock culture. Heavily infested leaves from the stock culture were placed on uninfested bean plants. Females were allowed to oviposit for a period of about 24 hours, after which the leaves of the plant were dipped into a solution of TEPP (tetraethyl diphosphate) in order to kill the motile forms and prevent additional egg laying. This dipping procedure, which was repeated after the plants dried, did not affect the viability of the eggs. The potted plants (one pot per compound) were placed on a revolving turntable and sprayed, sufficient to wet the plants to runoff, with 100 ml of the 100 ppm test compound formulation by use of a DeVilbiss spray gun set at 40 psig. air pressure. As an untreated control, 100 ml of the water-acetone-DMF-emulsifier solution, containing no test compound, were also sprayed on infested plants. A treated control with a commercial technical compound, typically demeton, formulated in the same manner, was tested as a standard. The sprayed plants were held for seven days, after which a mortality count of egg forms was made along with notations on residual activity on hatched larvae.
Buckthorn or cotton aphid: Adult and nymphal stages of buckthorn or cotton aphid were reared on potted dwarf nasturtium or cotton plants, respectively. The potted plants (one pot per compound tested) infested with 100-150 aphids, were placed on a revolving turntable and sprayed with 100 ml of the 100 ppm test compound formulation by use of a DeVilbiss spray gun set at 40 psig air pressure. As an untreated control, 100 ml of a water-acetone-DMF-emulsifier solution, containing no test compound, were also sprayed on infested plants. A treated control with a commercial technical compound, malathion or cyhalothrin, formulated in the same manner, was tested as a standard. After spraying, the pots were stored for one day on buckthorn aphid or three days for cotton aphid, after which the dead aphids were counted.
Southern armyworm: Potted bean plants, were placed on a revolving turntable and sprayed with 100 ml of the 100 ppm test compound formulation by use of a DeVilbiss spray gun set at 40 psig air pressure. As an untreated control, 100 ml of a water-acetone-DMF-emulsifier solution, containing no test compound, were also sprayed on plants. A treated control with a commercial technical compound, either cypermethrin or sulprofos, formulated in the same manner, was tested as a standard. When dry, the leaves were placed in plastic cups lined with moistened filter paper. Five randomly selected second instar southern armyworm larvae were introduced into each cup which was closed and held for five days. Larvae which were unable to move the length of the body, even upon stimulation by prodding, were considered dead.
Tobacco budworm: Potted cotton plants were placed on a revolving turntable and sprayed with 100 ml of the 100 ppm test compound formulation by use of a DeVilbiss spray gun set at 40 psig air pressure. As an untreated control, 100 ml of a water-acetone-DMF-emulsifier solution, containing no test compound, were also sprayed on plants. A treated control with a commercial technical compound, either cypermethrin or sulprofos, formulated in the same manner, was tested as a standard. When dry, the leaves were placed in plastic dishes containing a piece of filter paper and a moistened dental wick. One randomly selected second instar tobacco budworm larva was then introduced into each cup which was closed and held for five days. Larvae unable to move the length of their body, even upon stimulation by prodding, were considered dead.
Mexican bean beetle: Potted bean plants were placed on a revolving turntable and sprayed with 100 ml of the 100 ppm test compound formulation, sufficient to wet the plants to runoff, by use of a DeVilbiss spray gun set at 40 psig air pressure. As an untreated control, 100 ml of a water-acetone-DMF-emulsifier solution, containing no test compound, were also sprayed on plants. A treated control with a commercial technical compound, either cypermethrin or sulprofos, formulated in the same manner, was tested as a standard. When dry, the leaves were placed in plastic cups lined with moistened filter paper. Five randomly selected second instar Mexican bean beetle larvae were introduced into each cup which was closed and held for five days. Larvae which were unable to move the length of the body, even upon stimulation by prodding, were considered dead.
House fly: Four to six day old adult house flies were reared according to the specifications of the Chemical Specialties Manufacturing Association (Blue Book, McNair-Dorland Co., N.Y. 1954; pages 243-244, 261) under controlled conditions. The flies were immobilized by anesthetizing with carbon dioxide and twenty five immobilized individuals, males and females, were transferred to a cage consisting of a standard food strainer and a wrapping-paper-covered surface. Ten ml of the 100 ppm test compound formulation were added to a souffle cup containing an absorbent cotton pad. As an untreated control, 10 ml of a water-acetone-DMF-emulsifier-sucrose solution, containing no test compound, were applied in a similar manner. A treated control with a commercial technical compound, malathion, formulated in the same manner, was tested as a standard. The bait cup was introduced inside the food strainer prior to admitting the anesthetized flies. After 24 hours, flies which showed no sign of movement on stimulation were considered dead.
Southern or western corn rootworm: Into a jar containing 60 g of sandy loam soft was added 1.5 ml of an aqueous formulation consisting of an aliquot of the 200 ppm test compound formulation, diluted with water as appropriate for the final soil concentration of the test compound, 3.2 ml of water and five pregerminated corn seedlings. The jar was shaken thoroughly to obtain an even distribution of the test formulation. Following this, twenty corn rootworm eggs (or optionally ten first instar larvae in the case of WCRW) were placed into a cavity, which was made in the soil. Vermiculite (1 ml), used optionally in the case of WCRW tests, and water (1.7 ml) were then added to this cavity. In a similar manner, an untreated control was prepared by application of the same size aliquot of a water-acetone-DMF-emulsifier solution, containing no test compound. Additionally, a treated control with a commercial technical compound (selected typically from terbufos, fonofos, phorate, chlorpyrifos, carbofuran, isazophos, or ethoprop), formulated in the same manner was used as needed as a test standard. After 7 days, the living rootworm larvae were counted using a well known "Berlese" funnel extraction method.
Southern root-knot nematode: Infected roots of tomato plants, containing egg masses of southern root-knot nematode, were removed from a stock culture and cleaned of soil by shaking and washing with tap water. The nematode eggs were separated from the root tissue and rinsed with water. Samples of the egg suspension were placed on a fine screen over a receiving bowl, in which the water level was adjusted to be in contact with the screen. From the bowl, juveniles were collected on a fine screen. The bottom of a cone-shaped container was plugged with coarse vermiculite and then filled to within 1.5 cm of the top with about a 200 ml volume of pasteurized soil. Then into a hole made in the center of the soil in the cone was pipetted an aliquot of the 150 ppm test compound formulation. A treated control with a commerical technical compound, fenamifos, formulated in a similar manner, was tested as a standard. As an untreated control, an aliquot of a water-acetone-DMF-emulsifier solution, containing no test compound, was applied in a similar manner. Immediately after treatment of the soil with the test compound there were added to the top of each cone 1000 second stage juvenile southern root-knot nematodes. After 3 days, a single healthy tomato seedling was then transplanted into the cone. The cone, containing the infested soil and tomato seedling, was kept in the greenhouse for 3 weeks. At the termination of the test, roots of the tomato seedling were removed from the cone and evaluated for galling on a rating scale relative to the untreated control as follows:
1--severe galling, equal to untreated control
3--light galling
4--very light galling
5--no galling, ie, complete control
These results were then converted to an ED 3 or ED 5 value (effective dose to provide a 3 or 5 gall rating).
Southern armyworm on tomato - systemic evaluation: This test was conducted in conjunction with the southern root-knot nematode evaluation (discussed below). The tomato plants, grown in the soil (at an initial compound test screening rate of 6.6 ppm soil concentration or about 150 ppm solution concentration) for nematode evaluation, were then utilized for evaluation of a compound's uptake via roots and subsequent systemic transport to the tomato foliage. At the termination of the nematode test, 21 days after treatment, the tomato foliage was excised, placed into a plastic container, and infested with second instar larvae of southern armyworm. After about 5 days, the larvae were examined for percent mortality.
Cotton aphid and tobacco budworm (on cotton) and greenbug and tobacco budworm (on Sorghum) - systemic evaluation: A 7.0 ml aliquot of the 150 ppm nematode test solution was applied to deliver the equivalent of 10.0 ppm soil concentration dose as a drench to 6 cm pots containing cotton and sorghum plants. The cotton plants were previously infested with cotton aphids about two days before treatment and greenbug one day before treatment. After holding the plants about three days, the plants were rated for aphid activity. Again at six days, the plants were rated for aphid activity and the cotton aphids and greenbugs were counted and mortality was assessed. Portions of the cotton and sorghum foliage were excised, placed in separate plastic containers, and infested with second instar larvae of tobacco budworm. The potted plants were dipped in sulfotepp to kill the remaining aphids and returned to the greenhouse for regrowth. Thirteen days after treatment, the remaining foliage was excised and fed to tobacco budworms. Mortality was assessed six days after infestation.
Cotton aphid and southern armyworm (on cotton) and greenbug and Southern armyworm (on sorghum) - systemic evaluation: A stock solution or suspension was prepared to deliver 5 ml of a 20 ppm soil concentration dose (and subsequent dilutions) as a drench to 6 cm pots containing cotton and sorghum plants. The cotton plants were previously infested with cotton aphids about two days before treatment and greenbug one day before treatment. After holding the plants about three days, the plants were rated for aphid activity. Again at six days, the plants were rated for aphid activity and the cotton aphids and greenbugs were counted and mortality was assessed. Portions of the cotton and sorghum foliage were excised, placed in separate plastic containers, and infested with second instar larvae of southern armyworms. The potted plants were dipped in sulfotepp to kill the remaining aphids and returned to the greenhouse for regrowth. Thirteen days after treatment the remaining foliage was excised and fed to southern armyworm. Mortality was assessed six days after infestation.
Cotton aphid and southern armyworm (on cotton and oats) - seed treatment evaluation: Technical material was applied to the seed of oats and cotton by placing the compound and the seed in an appropriate sized jar and rolling the jar on a ball mill. Assay of the material applied to the seed was by weight. Seed was then planted. When germinated and emerged, the plants were infested at the appropriate intervals with host insects. Mortality was assessed on those insects.
Tobacco budworm - contact evaluation: The following topical application method provides an assessment of contact toxicity of a compound to tobacco budworm larvae. The test compound solution at sequential two-fold dilution concentrations from 10 down to 0.16 μg/μl was applied by a microinjector in replicated 1 μl portions to the dorsum of approximately 20 mg tobacco budworm larvae. This is equivalent to applied doses of 500 down to 8 μg/g body weight. An acetone treated control, without any test compounds, was also applied. A treated control with a commercial technical compound, cypermethrin or thiodicarb, also in acetone was used as a standard. The treated larvae were placed, individually, in separate plastic petri dishes containing an untreated cotton leaf and a moist dental wick. The treated larvae were maintained at about 27° C. and 50% relative humidity. The percent mortality was rated 1 and 4 days after treatment.
Use Results: Typical results of miticidal, insecticidal, and nematicidal activity for some of the representative compounds of the invention are discussed below or the results of some compounds are set forth in TABLE 3 against the indicated test species (BA*/CA, SAW, MBB, HF, TBW, SCRW*/WCRW: designated by common name abbreviations) and at the indicated dosage rates. The results in TABLE 3 are presented (by an X) as compounds which provide a 70-100% mortality against the indicated test species.
Some of the compounds of the invention are also acaricides where, for example, CMPD NO's 40, 47, and 57 provided 30-70% control of mites at 100 ppm in foliar bait tests.
Some of the compounds additionally exhibit systemic control of insect larvae and aphids via root uptake at the soil concentrations specified in the above protocols. Some, for example, are as follows: 50-100% control of southern armyworm on tomato (CMPD NO's 10, 11 and 12); 30-100% control of southern armyworm at six days on cotton (CMPD NO's 69, 89, 113 and 120) and 30-100% control of southern armyworm at thirteen days (CMPD NO's 64, 65, 67, 68 and 110); 30-100% control of southern armyworm after six days on sorghum (CMPD NO's 2, 10, 69, 72, 90, 100, 115 and 121) and 70-100% control at thirteen days (CMPD NO's 65, 66, 110 and 117); 100% control of tobacco budworm after six days on sorghum (CMPD NO's 16, 17, 18, 19 and 20); 30-100% control of cotton aphid after six days on cotton (CMPD NO's 13, 16, 17, 18, 19, 107, 110, 111, 112 and 126); and 30-100% control of greenbug after six days on sorghum (CMPD NO's 4, 16, 17, 18, 19, 20, 21, 74, 87, 90, 93, 107, 110, 111, 112 and 126).
Some of the compounds also provide activity via seed treatment where, for example. CMPD NO, 2, at 1.0 wt. % on oat seeds, provided 100% control of southern armyworm after six days.
Compounds of the invention also provide surprising, unexpected and excellent control of tobacco budworm (TBW) when applied in topical or contact tests where, for example, CMPD NO's 1-6, 9-11, 13, 15-19, 21-32, 35-38, 40, 42, 44-47, 50, 52, 58, 59, 61, 65-67, 69, 71, 73-78, 80, 81, 84-89, 91-94, 96-103 and 116 provide 50-100% control at an application dose of 63 μg/g body weight.
Nematicidal activity is additionally provided by compounds of the invention where, for example, CMPD NO's 7, 10 and 89 gave ED 3 value on SRKN larvae of about 21 kg/ha and CMPD NO's 7, 9 and 11 gave ED 3 values on SRKN eggs of between about 14 to 21 kg/ha.
Furthermore, compounds of the invention exhibit reduced or antifeeding properties for some pest species, for example for foliar pests such as southern armyworm and Mexican bean beetle.
The compounds of the invention have utility against various pest species at even lower rates, for example: for foliar application, rates in the range of about 50-0.5 ppm, or less, may be useful; for bait application, rates in the range of about 50-0.05 ppm, or less, may be useful; and for soil application, rates in the range of about 1.0-0.01 ppm, or less, may be useful.
In the above discussion and the results reported in TABLE 3, compounds according to the invention are applied at various concentrations. The use of a 1 ppm (concentration of the compound in parts per million of the test solution applied) foliar solution or suspension or emulsion corresponds approximately to an application of 1 g/ha of active ingredient, based upon an approximate spray volume of 1000 liters/ha (sufficient to run off). Thus applications of foliar sprays of from about 6.25 to 500 ppm would correspond to about 6-500 g/ha. For soil applications, a 1 ppm soil concentration, on the basis of about a 7.5 cm soil depth, corresponds to an approximate 1000 g/ha broadcast field application. Or alternatively stated, a 1 ppm soil concentration as above, but as an approximate 18 cm band application corresponds to an approximate 166 g/ha. For the contact test, it is approximated that an application dose of 10 μg/μl body weight applied as a 0.2 μg/μl (200 ppm) solution to the larvae would correspond to a field use application as a broadcast spray at about 50 to about 100 g/ha.
TABLE 3__________________________________________________________________________USE EXAMPLE OF PESTICIDAL ACTIVITY OF REPRESENTATIVEPYRAZOLE COMPOUNDS OF FORMUIA (I) PROVIDING 70-100%PEST MORTALITYCMPD. Foliar or Bait Application at 100 ppm Soil conc.-.5 ppmNO. BA*/CA SAW MBB HF TBW SCRW*/WCRW__________________________________________________________________________1 X X X X X*2 X X X X3 X X X X X*4 X* X X X X X*5 X X X X*6 X X X X8 X* X X X X9 X X X X10 X* X X X X X11 X* X X X X X12 X* X X X X13 X X X X X14 X X15 X X X X X16 X X X X X17 X X X X X18 X X X X X19 X X X20 X X X X X21 X X X X X22 X X X X X23 X X X X24 X X X X25 X X26 X X X X X27 X X X28 X X X X X29 X X X X30 X X X31 X X32 X X X X X33 X X X34 X X X X35 X X X X36 X X X X37 X X X X X38 X X X X X39 X X X X X40 X X X X42 X X X X43 X X X44 X X X46 X X47 X X X X48 X X X X49 X X X50 X X X51 X X X X52 X X X X53 X X X X54 X X X X55 X X56 X X X57 X X X58 X X59 X X X60 X X X61 X X X62 X X X X63 X X X X64 X X65 X X X X X66 X X X X67 X X X X X68 X X69 X X X X70 X X71 X X X73 X X X X X74 X X X X X X75 X X X X76 X X X X77 X X X X X78 X X X X X79 X X X X80 X X X X X81 X X X X X82 X X X83 X X X X84 X X X X X85 X X X86 X X X87 X X X X88 X X X89 X X X90 X X X X91 X X X X92 X X X X93 X94 X X X X96 X X X97 X X98 X X X99 X X100 X X X X101 X X102 X X103 X X104 X X X105 X X106 X X107 X X108 X109 X X110 X111 X112 X X X X X113 X X X X X114 X X X X X115 X X X X116 X X X X X117 X X118 X X X119 X X X120 X X X121 X X X122 X X123 X X X X124 X X X125 X X126 X__________________________________________________________________________
METHODS AND COMPOSITIONS
As is evident from the foregoing pesticidal uses, the present invention provides pesticidally active compounds and methods of use of said compounds for the control of a number of pest species which includes: arthropods, especially insects or mites; plant nematodes; or helminth or protozoan pests. The compounds thus are advantageously employed in practical uses, for example, in agricultural or horticultural crops, forestry, veterinary medicine or livestock husbandry, or in public health.
A feature of the present invention therefore provides a method of control of pests at a locus which comprises the treatment of the locus (e.g., by application or administration) with an effective amount of a compound of general formula (I) and more preferably a compound of formula (Ia), wherein the substituent groups are as hereinbefore defined. The locus includes, for example, the pest itself or the place (plant, animal, person, field, structure, premises, forest, orchard, waterway, soil, plant or animal product, or the like) where the pest resides or feeds.
The compounds of this invention are preferably used to control soil insects, such as corn rootworm, termites (especially for protection of structures), root maggots, wireworms, root weevils, stalkborers, cutworms, root aphids, or grubs. They may also be used to provide activity against plant pathogenic nematodes, such as root-knot, cyst, dagger, lesion, or stem or bulb nematodes, or against mites. For the control of soil pests, for example corn rootworm, the compounds are advantageously applied to or incorporated at an effective rate into the soil in which crops are planted or to be planted or to the seeds or growing plant roots.
Furthermore, these compounds may be useful in the control via foliar application or systemic action of some arthropods, especially insects or mites, which feed on the above ground portions of plants. Control of foliar pests may additionally be provided by application to the plant roots or plant seeds with subsequent systemic translocation to the above ground portions of the plants.
In the area of public health, the compounds are especially useful in the control of many insects, especially filth flies or other Dipteran pests, such as houseflies, stableflies, soldierflies, hornflies, deerflies, horseflies, midges, punkies, blackflies, or mosquitoes.
Compounds of the invention may be used in the following applications and on the following pests including arthropods, especially insects or mites, nematodes, or helminth or protozoan pests:
In the protection of stored products, for example cereals, including grain or flour, groundnuts, animal feedstuffs, timber or household goods, e.g. carpets and textiles, compounds of the invention are useful against attack by arthropods, more especially beetles, including weevils, moths or mites, for example Ephestia spp. (flour moths), Anthrenus spp. (carpet beetles), Tribolium spp. (flour beetles), Sitophilus spp. (grain weevils) or Acarus spp. (mites).
In the control of cockroaches, ants or termites or similar arthropod pests in infested domestic or industrial premises or in the control of mosquito larvae in waterways, wells, reservoirs or other running or standing water.
For the treatment of foundations, structures or soil in the prevention of the attack on building by termites, for example, Reticulitermes spp., Heterotermes spp., Coptotermes spp..
In agriculture against adults, larvae and eggs of Lepidoptera (butterflies and moths), e.g. Heliothis spp. such as Heliothis virescens (tobacco budworm), Heliothis armigera and Heliothis zea, Spodoptera spp. such as S. exempta, S. frugiperda, S. exiqua, S. littoralis (Egyptian cotton worm), S. eridania (southern army worm), and Mamestra configurata (bertha army worm); Earias spp. e.g. E. insulana (Egyptian bollworm), Pectinophora spp. e.g. Pectinophora gossypiella (pink bollworm), Ostrinia spp. such as O. nubilalis (European cornborer), Trichoplusia ni (cabbage looper), Artogeia spp. (cabbage worms), Laphygma spp. (army worms), Agrotis and Amathes spp. (cutworms), Wiseana spp. (porina moth), Chilo spp. (rice stem borer), Tryporyza spp. and Diatraea spp. (sugar cane borers and rice borers), Sparganothis pilleriana (grape berry moth), Cydia pomonella (codling moth), Archips spp. (fruit tree tortrix moth), Plutella xylostella (diamond back moth), Bupalus piniarius, Cheimatobia brumata, Lithocolletis blancardella, Hyponomeuta padella, Plutella maculipennis, Malacosoma neustria, Euproctis chrysorrhoea, Lymantria spp. Bucculatrix thurberiella, Phyllocnistis citrella, Euxoa spp., Feltia brassicae, Panolis flammea, Prodenia litura, Carpocapsa pomonella, Pyrausta nubilalis. Ephestia kuehniella, Galleria mellonella, Tineola bisselliella, Tinea pellionella, Hofmannophila pseudospretella, Cacoecia podana, Capus reticulana, Choristoneura fumiferana, Clysia ambiguellis, Homona magnanime and Tortix viridana.
Against adults and larvae of Coleoptera (beetles) e.g. Hypothenemus hampei (coffee berry borer), Hylesinus spp. (bark beetles), Anthonomus spp. e.g. grandis (cotton boll weevil), Acalymma spp. (cucumber beetles), Lema spp., Psylliodes spp,, Leptinotarsa decemlineata (Colorado potato beetle), Diabrotica spp. (corn rootworms), Gonocephalum spp. (false wire worms), Agriotes spp., Limonius spp. (wireworms), Dermolepida spp., Popillia spp., Heteronychus spp. (white grubs), Phaedon cochleariae (mustard beetle), Epitrix spp. (flea beetles), Lissorhoptrus oryzophilus (rice water weevil), Meligethes spp. (pollen beetles), Ceutorhynchus spp., Rhynchoporus and Cosmopolites spp. (root weevils), Anobiumn punctatum, Rhizopertha dominica, Bruchidius obtectus, Acanthoscelides obtectus, Hylotrupes bajulus, Agelastica alni, Psylliodes chrysocephala, Epilachna varivestis, Atomaria spp., Oryzaephilus surinamensis, Sitophilus spp., Otiorrhynchus sulcatus, Cosmoplites sordidus, Ceuthorrhynchus assimilis, Hypera postica, Dermestes spp., Trogoderma spp., Anthrenus spp., Attagenus spp., Lyctus spp., Maligethes aeneus, Ptinus spp., Niptus hololeucrus, Gibbium psylloides, Tribolium spp., Tenebrio molitor, Conoderus spp., Melolontha melolontha, Amphimallon solststialis and Costelytra zealandica.
Against Heteroptera (Hemiptera and Homoptera) e.g. Psylla spp., Bemisia spp., Trialeurodes spp., Aphis spp., Myzus spp., Megoura viciae, Phylloxera spp., Adelges spp., Phorodon humuli (hop damson aphid), Aeneolamia spp., Nephotettix spp. (rice leaf hoppers), Empoasca spp., Nilaparvata spp., Perkinsiella spp., Pyrilla spp., Aonidiella spp. (red scales), Coccus spp., Pseucoccus spp., Helopeltis spp. (mosquito bugs), Lygus spp., Dysdercus spp., Oxycarenus spp., Nezara spp., Eurygaster spp., Piesma quadrata, Cimex lectularius, Rhodnius prolixus and Triatoma spp. Aspidiotus hederae, Aeurodes brassicae, Brevicoryne brassicae, Cryptomyzus ribis, Doralis fabae, Doralis pomi., Eriosoma lanigerum, Hyalopterus arundinis, Macrosiphum avenae, Phorodon humuli, Rhopalosiphum padi, Euscelis bilobatus, Nephotettix cincticeps, Lecanium corni, Saissetia oleae, Laodelphax striatellus.
Against Hymenoptera e.g. Athalia spp. and Cephus spp. (saw flies), Atta spp. (leaf cutting ants), Diprion spp., Hopolocampa spp., Lasius spp., Monomorium spp., Polistes spp., Vespa spp., Vespula spp., and Solenopsis spp..
Against Diptera e.g. Delia spp. (root maggots), Atherigona spp. and Chlorops spp., Sarcophaga spp., Musca spp, Phormia spp., Aedes spp., Anopheles spp., Simulium spp., (shoot flies), Phytomyza spp. (leaf miners), Ceratitis spp. (fruit flies), Culex spp., Drosophila melanogaster, Ceratitis capitata, Dacus oleae, Tipula paludosa, Calliphora erythrocephala, Lucilia spp.. Chrysomyia spp., Cuterebra spp., Gastrophilus spp., Hyppobosca spp., Stomoxys spp., Oestrus spp., Hypoderma spp., Tabanus spp., Fannia spp., Bibio hortulanus, Oscinella frit, Phorbia spp., Pegomyia hyoscyani.
Against Thysanoptera such as Thrips tabaci, Hercinothrips femoralis, and Frankliniella spp..
Against Orthoptera such as Locusta and Schistocerca spp., (locusts and crickets) e.g. Gryllus spp., and Acheta spp. for example, Blatta orientalis, Periplaneta americana, Leucophaea maderae, Blatella germanica, Acheta domesticus, Gryllotalpa spp., Locusta migratoria migratorioides, Melanoplus differentialis and Schistocerca gregaria.
Against Collembola e.g. Sminthurus spp. and Onychiurus spp. (springtails); Periplaneta spp. and Blattela spp. (roaches).
Against Isoptera e.g. Odontotermes spp., Reticuletermes spp., Coptotermes spp. (termites).
Against Dermaptera e.g. Forticula sp. (earwigs).
Against arthropods of agricultural significance such as Acari (mites) e.g. Tetranychus spp., Panonychus spp., Bryobia spp. (spider mites), Ornithonyssus spp. (fowl mites), Eriophyes spp. (gall mites), and Polyphadotarsonemus supp..
Against Thysanura, for example Lepisma saccharia.
Against Anoplura for example, Phylloxera vastatrix, Pemphigus spp., Pediculus humanus corporis, Haematopinus spp. and Linognathus spp..
Against Mallophaga, for example, Trichodectes spp. and Damalinea spp..
Against Siphonoptera, for example, Xenopsylla cheopis and Ceratophyllus spp..
Against other arthopods, such as Blaniulus spp. (millipedes), Scutigerella spp. (symphilids), Oniscus spp. (woodlice) and Triops spp. (crustacea).
Against Isopoda, for example, Oniseus asellus, Armadillidium vulgare and Porcellio scaber.
Against Chilopoda, for example, Geophilus carpophagus and Scutigera spex..
Against nematodes which attack plants or trees of importance to agriculture, forestry or horticulture either directly or by spreading bacterial, viral, mycoplasma or fungal diseases of the plants. For example root-knot nematodes such as Meloidogyne spp. (e.g. M. incognita); cyst nematodes such as Globodera spp. (e.g. G. rostochiensis); Heterodera spp. (e.g. H. avenae); Radopholus spp. (e.g. R. similis; lesion nematodes such as Pratylenchus spp. (e.g. P. pratensis); Belonolaimus spp. (eg, B. gracilis); Tylenchulus spp. (e.g. T. semipenetrans); Rotylenchulus spp. (e.g. R. reniformis); Rotylenchus spp. (R. robustus); Helicotylenchus spp. (e.g. H. multicinctus); Hemicycliophora spp. (e.g. H. gracilis); Criconemoides spp. (e.g. C. similis); Trichodorus spp. (e.g. T. primitivus); dagger nematodes such as Xiphinema spp. (e.g. X. diversicaudatum), Longidorus spp. (e.g. L. elongatus); Hoplolaimus spp. (e.g. H. coronatus): Aphelenchoides spp. (e.g A. ritzema-bosi, A. besseyi); stem and bulb eelworm such as Ditylenchus spp. (e.g. D. dipsaci).
In the field of veterinary medicine or livestock husbandry or in the maintenance of public health against arthropods, helminths or protozoa which are parasitic internally or externally upon vertebrates, particularly warm-blooded vertebrates, for example man or domestic animals, e.g. cattle, sheep, goats, equines, swine, poultry, dogs or cats, for example Acarina, including ticks (e.g. Ixodes spp., Boophilus spp. e.g. Boophilus microplus, Amblyomma spp., Hyalomma spp., Rhipicephalus spp. e.g. Rhipicephalus appendiculatus, Haemaphysalis spp., Dermacentor spp., Ornithodorus spp. (e.g. Ornithodorus moubata) and mites (e.g. Damalinia spp., Dermahyssus gallinae, Sarcoptes spp. e.g. Sarcoptes scabiei, Psoroptes spp., Chorioptes spp;, Demodex spp., Eutrombicula spp.,); Diptera (e.g. Aedes spp., Anopheles spp., Musca spp., Hypoderma spp., Gasterophilus spp., Simulium spp); Hemiptera (e.g. Triatoma spp); Phthirapter (e.g. Damalinia spp., Linognathus spp.); Siphonaptera (e.g. Ctenocephalides spp.); Dictyoptera (e.g. Periplaneta spp., Blatella spp.); Hymenoptera (e.g. Monomorium pharaonis); for example against infections of the gastro-intestinal tract caused by parasitic nematode worms, for example members of the family Trichostrongylidae, Nippostrongylus brasiliensis, Trichinella spiralis, Haemonchus contortus, Trichostrongylus colubriformis, Nematodirus batus, Ostertagis circumcincta, Trichostrongylus axei, Cooperia spp. and Hymenolepis nana; in the control and treatment of protozoal diseases caused by, for example, Eimeria spp. e.g. Eimeria tenella, Eimeria acervulina, Eimeria brunetti, Eimeria maxima and Eimeria necatrix, Tryanosoms cruzi, Leishaminia spp., Plasmodium spp., Babesis spp., Trichomonadidae spp., Histomanas spp., Giardia spp., Toxoplasma spp., Entamoeba histolytica and Theileria spp..
The invention, as previously described, provides methods of control of pests via application or administration of an effective amount of compounds of formula (I) or (Ia) at a locus which composes treatment of the locus.
In practical use for the control of arthropods, especially insects or mites, or nematode pests of plants, a method, for example, comprises applying to the plants or to the medium in which they grow an effective amount of a compound of the invention. For such a method, the active compound is generally applied to the locus in which the arthropod or nematode infestation is to be controlled at an effective rate in the range of about 0.005 kg to about 15 kg of the active compound per hectare of locus treated. Under ideal conditions, depending on the pest to be controlled, a lower rate may offer adequate protection. On the other hand, adverse weather conditions, resistance of the pest or other factors may require that the active ingredient be used at higher rates. The optimum rate depends usually upon a number of factors, for example, the type of pest being controlled. the type or the growth stage of the infested plant, the row spacing or also the method of application. More preferably an effective rate range of the active compound is from about 0.01 kg/ha to about 2 kg/ha.
When a pest is soil-borne, the active compound generally in a formulated composition, is distributed evenly over the area to be treated (ie, for example broadcast or band treatment) in any convenient manner. Application may be made, if desired, to the field or crop-growing area generally or in close proximity to the seed or plant to be protected from attack. The active component can be washed into the soil by spraying with water over the area or can be left to the natural action of rainfall. During or after application, the formulated compound can, if desired, be distributed mechanically in the soil, for example by ploughing, disking, or use of drag chains. Application can be prior to planting, at planting, after planting but before sprouting has taken place, or after sprouting. Additionally, a method of control may also comprise treatment of the seed prior to planting with subsequent control effected after planting the seed.
Methods of control of pests also consist of application to or treatment of the foliage of plants to control arthropods, especially insects or mites, or nematodes attacking the aerial parts of the plants. In addition, methods of control of pests by the invention compounds are provided to control pests which feed on parts of the plant remote from the point of application. e.g., leaf feeding insects which are controlled via systemic action of the active compound when applied for example to the roots of a plant or to the plant seed prior to planting. Furthermore, the compounds of the invention may reduce attacks on a plant by means of antifeeding or repellent effects.
The compounds of the invention and methods of control of pests therewith are of particular value in the protection of field, forage, plantation, glasshouse, orchard or vineyard crops, of ornamentals, or of plantation or forest trees, for example: cereals (such as maize, wheat, rice, or sorghum), cotton, tobacco, vegetables (such as beans, cole crops, curcurbits, lettuce, onions, tomatoes or peppers), field crops (such as potatoes, sugar beets, ground nuts, soybeans, or oil seed rape), sugar cane, grassland or forage crops (such as maize, sorghum, or lucerne), plantations (such as tea, coffee, cocoa, banana, palm oil, coconut, rubber, or spices), orchards or groves (such as of stone or pit fruit, citrus, kiwifruit, avocado, mango, olives or walnuts), vineyards, ornamental plants, flowers or vegetables or shrubs under glass or in gardens or parks, or forest trees (both deciduous and evergreen) in forests, plantations or nurseries.
They are also valuable in the protection of timber (standing, felled, converted, stored or structural) from attack, for example, by sawflies or beetles or termites.
They have applications in the protection of stored products such as grains, fruits, nuts, spices or tobacco, whether whole, milled or compounded into products, from moth, beetle, mite or grain weevil attack. Also protected are stored animal products such as skins, hair, wool or feathers in natural or converted form (e.g. as carpets or textiles) from moth or beetle attack as well as stored meat, fish or grains from beetle, mite or fly attack.
Additionally, the compounds of the invention and methods of use thereof are of particular value in the control of arthropods, helminths or protozoa which are injurious to, or spread or act as vectors of diseases in man and domestic animals, for example those hereinbefore mentioned, and more especially in the control of ticks, mites, lice, fleas, midges, or biting, nuisance or myiasis flies. The compounds of the invention are particularly useful in controlling arthropods, helminths or protozoa which are present inside domestic host animals or which feed in or on the skin or suck the blood of the animal, for which purpose they may be administered orally, parenterally, percutaneously or topically.
Furthermore, compounds of the invention may be useful for coccidiosis, a disease caused by infections from protozoan parasites of the genus Eimeria. It is an important potential cause of economic loss in domestic animals and birds, particularly those raised or kept under intensive conditions. For example, cattle, sheep, pigs or rabbits may be affected, but the disease is especially important in poultry, particularly in chickens. Administration of a small-amount of a compound of the invention, preferably by a combination with feed is effective in preventing or greatly reducing the incidence of coccidiosis. The compounds are effective against both the cecal form and the intestinal forms. Furthermore, the compounds of the invention may also exert an inhibiting effect on oocytes by greatly reducing the number and sporulation of those produced. The poultry disease is generally spread by the birds picking up the infectious organism in droppings in or on contaminated litter, ground, food, or drinking water. The disease is manifested by hemorrhage, accumulation of blood in the ceca, passage of blood to the droppings, weakness and digestive disturbances. The disease often terminates in the death of the animal, but the fowl which survive severe infections have had their market value subtantially reduced as a result of the infection.
The compositions hereinafter described for application to growing crops or crop growing loci or as a seed dressing may, in general, alteratively be employed for topical application to man or animals or in the protection of stored products, household goods, property or areas of the general environment. Suitable means of applying the compounds of the invention include:
to growing crops as foliar sprays, dusts, granules, fogs or foams or also as suspensions of finely divided or encapsulated compositions as soil or root treatments by liquid drenches, dusts, granules, smokes or foams; to seeds of crops via application as seed dressings by liquid slurries or dusts;
to persons or animals infested by or exposed to infestation by arthropods, helminths or protozoa, by parenteral, oral or topical application of compositions in which the active ingredient exhibits an immediate and/or prolonged action over a period of time against the arthropods, helminths or protozoa, for example by incorporation in feed or suitable orally-ingestible pharmaceutical formulations, edible baits, salt licks, dietary supplements, pour-on formulations, sprays, baths, dips, showers, jets, dusts, greases, shampoos, creams, wax smears or livestock self-treatment systems;
to the environment in general or to specific locations where pests may lurk, including stored products, timber, household goods, or domestic or industrial premises, as sprays, fogs, dusts, smokes, wax-smears, lacquers, granules or baits, or in tricklefeeds to waterways, wells, reservoirs or other running or standing water;
to domestic animals in feed to control fly larvae feeding in their feces;
In practice, the compounds of the invention most frequently form parts of compositions. These compositions can be employed to control: arthopods, especially insects or mites; nematodes; or helminth or protozoan pests. The compositions may be of any type known in the art suitable for application to the desired pest in any premises or indoor or outdoor area or by internal or external administration to vertebrates. These compositions contain at least one compound of the invention, such as described earlier, as the active ingredient in combination or association with one or more other compatible components which are for example, solid or liquid carriers or diluents, adjuvants, surface-active-agents, or the like appropriate for the intended use and which are agronomically or medicinally acceptable. These compositions, which may be prepared by any manner known in the art, likewise form a part of this invention.
These compositions may also contain other kinds of ingredients such as protective colloids, adhesives, thickeners, thixotropic agents, penetrating agents, spray oils (especially for acaridical use), stabilizers, preservative agents (especially mold preservatives), sequestering agents, or the like, as well as other known active ingredients with pesticidal properties (particularly insecticidal, miticidal, nematicidal, or fungicidal) or with properties regulating the growth of plants. More generally, the compounds employed in the invention may be combined with all the solid or liquid additives corresponding to the usual techniques of formulation.
Compositions, suitable for applications in agriculture, horticulture, or the like include formulations suitable for use as, for example, sprays, dusts, granules, fogs, foams, emulsions, or the like.
Compositions suitable for administration to vertebrates or man, include preparations suitable for oral, parenteral, percutaneous, e.g. pour-on, or topical administration.
Compositions for oral administration comprise one or more of the compounds of general formula(I) in association with pharmaceutically acceptable carriers or coatings and include, for example, tablets, pills, capsules, pastes, gels, drenches, medicated feeds, medicated drinking water, medicated dietary supplements, slow-release boluses or other slow-release devices intended to be retained within the gastro-intestinal tract. Any of these may incorporate the active ingredient contained within microcapsules or coated with acid-labile or alkali-labile or other pharmaceutically acceptable enteric coatings. Feed premixes or concentrates containing compounds of the present invention for use in preparation of medicated diets, drinking water or other materials for consumption by animals may also be used.
Compositions for parenteral administration include solutions, emulsions or suspensions in any suitable pharmaceutically acceptable vehicle or solid or semisolid subcutaneous implants or pellets designed to release the active ingredient over a protracted period of time and may be prepared and made sterile in any appropriate manner known to the art.
Compositions for percutaneous and topical administration include sprays, dusts, baths, dips, showers, jets, greases, shampoos, creams, wax-smears, or pour-on preparations or devices (e.g. ear tags attached externally to animals in such a way as to provide local or systemic arthropod control).
Solid or liquid baits, suitable for controlling arthropods, comprise one or more compounds of general formula(I) and a carrier or diluent which may include a food substance or some other substance to induce consumption by the arthropod.
The effective use doses of the compounds employed in the invention can vary within wide limits, particularly depending on the nature of the pest to be eliminated or degree of infestation, for example, of crops with these pests. In general, the compositions according to the invention usually contain about 0.05 to about 95% (by weight) of one or more active ingredients according to the invention, about 1 to about 95% of one or more solid or liquid carriers and, optionally, about 0.1 to about 50% of one or more other compatible components, such as surface-active agents or the like.
In the present account, the term "carrier" denotes an organic or inorganic ingredient, natural or synthetic, with which the active ingredient is combined to facilitate its application, for example, to the plant, to seeds or to the soil. This carrier is therefore generally inert and it must be acceptable (for example, agronomically acceptable, particularly to the treated plant).
The carrier may be a solid, for example, clays, natural or synthetic silicates, silica, resins, waxes, solid fertilizers (for example ammonium salts), ground natural minerals, such as kaolins, clays, talc, chalk, quartz, attapulgite, montmorillonite, bentonite or diatomaceous earth, or ground synthetic minerals, such as silica, alumina, or silicates especially aluminium or magnesium silicates. As solid carriers for granules the following are suitable: crushed or fractionated natural rocks such as calcite, marble, pumice, sepiolite and dolomite; synthetic granules of inorganic or organic meals; granules of organic material such as sawdust, coconut shells, corn cobs, corn husks or tobacco stalks; kieselguhr, tricalcium phosphate, powdered cork, or absorbent carbon black; water soluble polymers, resins, waxes; or solid fertilizers. Such solid compositions may, if desired, contain one or more compatible wetting, dispersing, emulsifying or colouring agents which, when solid, may also serve as a diluent.
The carrier may also be liquid, for example: water; alcohols, particularly butanol or glycol, as well as their ethers or esters, particularly methylglycol acetate; ketones, particularly acetone, cyclohexanone, methylethyl ketone, methylisobutylketone, or isophorone; petroleum fractions such as paraffinic or aromatic hydrocarbons, particularly xylenes or alkyl naphthalenes; mineral or vegetable oils; aliphatic chlorinated hydrocarbons, particularly trichloroethane or methylene chloride; aromatic chlorinated hydrocarbons, particularly chlorobenzenes; water-soluble or strongly polar solvents such-as dimethylformamide, dimethyl sulphoxide, or N-methylpyrrolidone; liquefied gases; or the like or a mixture thereof.
The surface-active agent may be an emulsifying agent, dispersing agent or wetting agent of the ionic or non-ionic type or a mixture of such surface-active agents. Amongst these are e.g., salts of polyacrylic acids, salts of lignosulphonic acids, salts of phenolsulphonic or naphthalenesulphonic acids, polycondensates of ethylene oxide with fatty alcohols or fatty acids or fatty esters or fatty amines, substituted phenols (particularly alkylphenols or arylphenols), salts of sulphosuccinic acid esters, taurine derivatives (particularly alkyltaurates), phosphoric esters of alcohols or of polycondensates of ethylene oxide with phenols, esters of fatty acids with polyols, or sulphate, sulphonate or phosphate functional derivatives of the above compounds. The presence of at least one surface-active agent is generally essential when the active ingredient and/or the inert carrier are only slightly water soluble or are not water soluble and the carrier agent of the con, position for application is water.
Compositions of the invention may further contain other additives such as adhesives or colorants. Adhesives such as carboxymethylcellulose or natural or synthetic polymers in the form of powders, granules or lattices, such as arabic gum, polyvinyl alcohol or polyvinyl acetate, natural phospholipids, such as cephalins or lecithins, or synthetic phospholipids can be used in the formulations. It is possible to use colorants such as inorganic pigments, for example: iron oxides, titanium oxides or Prussian Blue; organic dyestuffs, such as alizarin dyestuffs, azo dyestuffs or metal phthalocyanine dyestuffs; or trace nutrients such as salts of iron, manganese, boron, copper, cobalt, molybdenum or zinc.
Compositions containing compounds of general formula (I) which may be applied to control arthropod, plant nematode, helminth or protozoan pests, may also contain synergists (e.g. piperonyl butoxide or sesamex), stabilizing substances, other insecticides, acaricides, plant nematocides, anthelmintics or anticoccidials, fungicides (agricultural or veterinary as appropriate, e.g. benomyl and iprodione), bactericides, arthropod or vertebrate attractants or repellents or pheromones, deodorants, flavouring agents, dyes, or auxiliary therapeutic agents, e.g. trace elements. These may be designed to improve potency, persistence, safety, uptake where desired, spectrum of pests controlled or to enable the composition to perform other useful functions in the same animal or area treated.
Examples of other pesticidally-active compounds which may be included in, or used in conjunction with the compositions of the present invention are: acephate, chlorpyrifos, demeton-S-methyl, disulfoton, ethoprofos, fenitrothion, fenamiphos, fonofos, isazophos, isofenphos, malathion, monocrotophos, parathion, phorate, phosalone, pirimiphosmethyl, terbufos, triazophos, cyfluthrin, cypermethrin, deltamethrin, fenpropathrin, fenvalerate, permethrin, tefluthrin, aldicarb, carbosulfan, methomyl, oxamyl, pirimicarb, bendiocarb, teflubenzuron, dicofol, endosulfan, lindane, benzoximate, cartap, cyhexatin, tetradifon, avermectins, ivermectins, milbemycins, thiophanate, trichlorfon, dichlorvos, diaveridine or dimetriadazole.
For their agricultural application, the compounds of the formula(I) are therefore generally in the form of compositions, which are in various solid or liquid forms.
Solid forms of compositions which can be used are dusting powders (with a content of the compound of formula(I) ranging up to 80%), wettable powders or granules (including water dispersible granules), particularly those obtained by extrusion, compacting, impregnation of a granular carrier, or granulation starting from a powder (the content of the compound of formula(I) in these wettable powders or granules being between about 0.5 and about 80%). Solid homogenous or heterogenous compositions containing one or more compounds of general formula(I) for example granules, pellets, briquettes or capsules, may be used to treat standing or running water over a period of time. A similar effect may be achieved using trickle or intermittent feeds of water dispersible concentrates as described herein.
Liquid compositions, for example, include aqueous or non-aqueous solutions or suspensions (such as emulsifiable concentrates, emulsions, flowables, dispersions, or solutions) or aerosols. Liquid compositions also include, in particular, emulsifiable concentrates, dispersions, emulsions, flowables, aerosols, wettable powders (or powder for spraying), dry flowables or pastes as forms of compositions which are liquid or intended to form liquid compositions when applied, for example as aqueous sprays (including low and ultra-low volume) or as fogs or aerosols.
Liquid compositions, for example, in the form of emulsifiable or soluble concentrates most frequently comprise about 5 to about 80% by weight of the active ingredient, while the emulsions or solutions which are ready for application contain, in their case, about 0.01 to about 20% of the active ingredient. Besides the solvent, the emulsifiable or soluble concentrates may contain, when required, about 2 to about 50% of suitable additives, such as stabilizers, surface-active agents, penetrating agents, corrosion inhibitors, colorants or adhesives. Emulsions of any required concentration, which are particularly suitable for application, for example, to plants, may be obtained from these concentrates by dilution with water. These compositions are included within the scope of the compositions which may be employed in the present invention. The emulsions may be in the form of water-in-oil or oil-in-water type and they may have a thick consistency.
The liquid compositions of this invention may, in addition to normal agricultural use applications be used for example to treat substrates or sites infested or liable to infestation by arthropods (or other pests controlled by compounds of this invention) including premises, outdoor or indoor storage or processing areas, containers or equipment or standing or running water.
All these aqueous dispersions or emulsions or spraying mixtures can be applied, for example, to crops by any suitable means, chiefly by spraying, at rates which are generally of the order of about 100 to about 1,200 liters of spraying mixture per hectare, but may be higher or lower (eg. low or ultra-low volume) depending upon the need or application technique. The compounds or compositions according to the invention are conveniently applied to vegetation and in particular to roots or leaves having pests to be eliminated. Another method of application of the compounds or compositions according to the invention is by chemigation, that is to say, the addition of a formulation containing the active ingredient to irrigation water. This irrigation may be sprinkler irrigation for foliar pesticides or it can be ground irrigation or underground irrigation for soil or for systemic pesticides.
The concentrated suspensions, which can be applied by spraying, are prepared so as to produce a stable fluid product which does not settle (fine grinding) and usually contain from about 10 to about 75% by weight of active ingredient, from about 0.5 to about 30% of surface-active agents, from about 0.1 to about 10% of thixotropic agents, from about 0 to about 30% of suitable additives, such as anti-foaming agents, corrosion inhibitors, stabilizers, penetrating agents, adhesives and, as the carrier, water or an organic liquid in which the active ingredient is poorly soluble or insoluble. Some organic solids or inorganic salts may be dissolved in the carrier to help prevent settling or as antifreezes for water.
The wettable powers (or powder for spraying) are usually prepared so that they contain from about 10 to about 80% by weight of active ingredient, from about 20 to about 90% of a solid carrier, from about 0 to about 5% of a wetting agent, from about 3 to about 10% of a dispersing agent and, when necessary, from about 0 to about 80% of one or more stabilizers and/or other additives, such as penetrating agents, adhesives, anti-caking agents, colorants, or the like. To obtain these wettable powders, the active ingredient(s) is(are) thoroughly mixed in a suitable blender with additional substances which may be impregnated on the porous filler and is(are) ground using a mill or other suitable grinder. This produces wettable powders, the wettability and the suspendability of which are advantageous. They may be suspended in water to give any desired concentration and this suspension can be employed very advantageously in particular for application to plant foliage.
The "water dispersible granules (WG)" (granules which are readily dispersible in water) have compositions which are substantially close to that of the wettable powders. They may be prepared by granulation of formulations described for the wettable powders, either by a wet route (contacting finely divided active ingredient with the inert filler and a little water, e.g. 1 to 20% by weight, or with an aqueous solution of a dispersing agent or binder, followed by drying and screening), or by a dry route (compacting followed by grinding and screening).
The application dose (effective dose) of active ingredient, also as a formulated composition, is generally between about 0.005 and about 15 kg/ha, preferably between about 0.01 and about 2 kg/ha. Therefore, the rates and concentrations of the formulated compositions may vary according to the method of application or the nature of the compositions or use thereof. Generally speaking, the compositions for application to control arthropod, plant nematode, helminth or protozoan pests usually contain from about 0.00001% to about 95%, more particularly from about 0.0005% to about 50% by weight of one or more compounds of general formula(I) or of total active ingredients (that is to say the compound(s) of general formula(I) together with: other substances toxic to arthropods or plant nematodes, anthelmintics, anticoccidials, synergists, trace elements or stabilizers). The actual compositions employed and their rate of application will be selected to achieve the desired effect(s) by the farmer, livestock producer, medical or veterinary practitioner, pest control operator or other person skilled in the art.
Solid or liquid compositions for application topically to animals, timber, stored products or household goods usually contain from about 0.00005% to about 90%, more particularly from about 0.001% to about 10%, by weight of one or more compounds of general formula(I). For administration to animals orally or parenterally, including percutaneously solid or liquid compositions, these normally contain from about 0.1% to about 90% by weight of one or more compounds of general formula(I). Medicated feedstuffs normally contain from about 0.001% to about 3% by weight of one or more compounds of general formula(I). Concentrates or supplements for mixing with feedstuffs normally contain from about 5% to about 90%, preferably from about 5% to about 50%, by weight of one or more compounds of general formula(I). Mineral salt licks normally contain from about 0.1% to about 10% by weight of one or more compounds of general formula(I).
Dusts or liquid compositions for application to livestock, persons, goods, premises or outdoor areas may contain from about 0.0001% to about 15%, more especially from about 0.005% to about 2.0%, by weight, of one or more compounds of general formula(I). Suitable concentrations in treated waters are between about 0.0001 ppm and about 20 ppm, more particularly about 0.001 ppm to about 5.0 ppm. of one or more compounds of general formula(I) and may be used therapeutically in fish farming with appropriate exposure times. Edible baits may contain from about 0.01% to about 5%, preferably from about 0.01% to about 1.0%, by weight, of one or more compounds of general formula(I).
When administered to vertebrates parenterally, orally or by percutaneous or other means, the dosage of compounds of general formula(I) will depend upon the species, age, or health of the vertebrate and upon the nature and degree of its actual or potential infestation by arthropod, helminth or protozoan pests. A single dose of about 0.1 to about 100 mg, preferably about 2.0 to about 20.0 mg, per kg body weight of the animal or doses of about 0.01 to about 20.0 mg, preferably about 0.1 to about 5.0 mg, per kg body weight of the animal per day, for sustained medication, are generally suitable by oral or parenteral administration. By use of sustained release formulations or devices, the daily doses required over a period of months may be combined and administered to animals on a single occasion.
The following composition EXAMPLES 7A-7L illustrate compositions for use against arthropods, especially mites or insects, plant nematodes, or helminth or protozoan pests which comprise, as active ingredient, compounds of general formula (I), especially compounds according to formula (Ia), such as those described in preparative examples. The compositions described in EXAMPLES 7A-7F can each be diluted in water to give a sprayable compositon at concentrations suitable for use in the field. Generic chemical descriptions of the ingredients (for which all of the following percentages are in weight percent), used in the composition EXAMPLES 7A-7L exemplified below, are as follows:
______________________________________Trade Name Chemical Description______________________________________Ethylan BCP Nonylphenol ethylene oxide condensateSoprophor BSU Tristyrylphenol ethylene oxide condensateArylan CA A 70% w/v solution of calcium dodecylbenzenesulfonateSolvesso 150 LightC.sub.10 aromatic solventArylan S Sodium dodecylbenzenesulfonateDarvan No2 Sodium lignosulphonateCelite PF Synthetic magnesium silicate carrierSopropon T36 Sodium salts of polycarboxylic acidsRhodigel 23 Polysaccharide xanthan gumBentone 38 Organic derivative of magnesium montmorilloniteAerosil Microfine silicon dioxide______________________________________
EXAMPLE 7A
A water soluble concentrate is prepared with the composition as follows:
______________________________________Active ingredient 7%Ethylan BCP 10%N-methylpyrrolidone 83%______________________________________
To a solution of Ethylan BCP dissolved in a portion of N-methylpyrrolidone is added the active ingredient with heating and stirring until dissolved. The resulting solution is made up to volume with the remainder of the solvent.
EXAMPLE 7B
An emulsifiable concentrate (EC) is prepared with the composition as follows:
______________________________________Active ingredient 7%Soprophor BSU 4%Arylan CA 4%N-methylpyrrolidone 50%Solvesso 150 35%______________________________________
The first three composition are dissolved in N-methylpyrrolidone and to this is then added the Solvesso 150 to give the final volume.
EXAMPLE 7C
A wettable powder (WP) is prepared with the composition as follows:
______________________________________Active ingredient 40%Arylan S 2%Darvan No 2 5%Celite PF 53%______________________________________
The ingredients are mixed and ground in a hammer-mill to a powder with a particle size of less than 50 microns.
EXAMPLE 7D
An aqueous-flowable formulation is prepared with the composition as follows:
______________________________________Active ingredient 40.00%Ethylan BCP 1.00%Sopropon T360. 0.20%Ethylene glycol 5.00%Rhodigel 230. 0.15%Water 53.65%______________________________________
The ingredients are intimately mixed and are ground in a bead mill until a mean particle size of less than 3 microns is obtained.
EXAMPLE 7E
An emulsifiable suspension concentrate is prepared with the composition as follows:
______________________________________Active ingredient 30.0%Ethylan BCP 10.0%Bentone 38 0.5%Solvesso 150 59.5%______________________________________
The ingredients are intimately mixed and ground in a beadmill until a mean particle size of less than 3 microns is obtained.
EXAMPLE 7F
A water dispersible granule is prepared with the composition as follows:
______________________________________Active ingredient 30%Darvan No 2 15%Arylan S 8%Celite PF 47%______________________________________
The ingredients are mixed, micronized in a fluid-energy mill and then granulated in a rotating pelletizer by spraying with water (up to 10%). The resulting granules are dried in a fluid-bed drier to remove excess water.
EXAMPLE 7G
A dusting powder is prepared with the composition as follows:
______________________________________Active ingredient 1 to 10%Tale powder-superfine 99 to 90%______________________________________
The ingredients are intimately mixed and further ground as necessary to achieve a fine powder. This powder may be appplied to a locus of arthropod infestation, for example refuse dumps, stored products or household goods or animals infested by, or at risk of infestation by, arthropods to control the arthropods by oral ingestion. Suitable means for distributing the dusting powder to the locus of arthropod infestation include mechanical blowers, handshakers or livestock self treatment devices.
EXAMPLE 7H
An edible bait is prepared with the composition as follows:
______________________________________Active ingredient 0.1 to 1.0%Wheat flour 80%Molasses 19.9 to 19%______________________________________
The ingredients are intimately mixed and formed as required into a bait form. This edible bait may be distributed at a locus, for example domestic or industrial premises, e.g. kitchens, hospitals or stores, or outdoor areas, infested by arthropods, for example ants, locusts, cockroaches or flies, to control the arthropods by oral ingestion.
EXAMPLE 7I
A solution formulation is prepared with a composition as follows:
______________________________________Active ingredient 15%Dimethyl sulfoxide 85%______________________________________
The active ingredient is dissolved in dimethyl sulfoxide with mixing and or heating as required. This solution may be applied percutaneously as a pour-on application to domestic animals infested by arthropods or, after sterilization by filtration through a polytetrafluoroethylene membrane (0.22 micrometer pore size), by parenteral injection, at a rate of application of from 1.2 to 12 ml of solution per 100 kg of animal body weight.
EXAMPLE 7J
A wettable powder is prepared with the composition as follows:
______________________________________Active ingredient 50%Ethylan BCP 5%Aerosil 5%Celite PF 40%______________________________________
The Ethylan BCP is absorbed onto the Aerosil which is then mixed with the other ingredients and ground in a hammer-mill to give a wettable powder, which may be diluted with water to a concentration of from 0.001% to 2% by weight of the active compound and applied to a locus of infestation by arthropods, for example, dipterous larvae or plant nematodes, by spraying, or to domestic animals infested by, or at risk of infection by arthropods, helminths or protozoa, by spraying or dipping, or by oral administration in drinking water, to control the arthropods, helminths or protozoa.
EXAMPLE 7K
A slow release bolus composition is formed from granules containing the following components in varying percentages(similar to those described for the previous compositions) depending upon need:
Active ingredient
Density agent
Slow-release agent
Binder
The intimately mixed ingredients are formed into granules which are compressed into a bolus with a specific gravity of 2 or more. This can be administered orally to ruminant domestic animals for retention within the reticulo-rumen to give a continual slow release of active compound over an extended period of time to control infestation of the ruminant domestic animals by arthropods, helminths or protozoa.
EXAMPLE 7L
A slow release composition in the form of granules, pellets, brickettes or the like can be prepared with compositions as follows:
______________________________________Active ingredient 0.5 to 25%Polyvinyl chloride 75 to 99.5%Dioctyl phthalate (plasticizer) catalytic amount______________________________________
The components are blended and then formed into suitable shapes by melt-extrusion or molding. These composition are useful, for example, for addition to standing water or for fabrication into collars or eartags for attachment to domestic animals to control pests by slow release.
While the present invention has been set forth in specific and illustrative details and described with preferred particularity, it is susceptible to changes, modifications or alternations, obvious to one of ordinary skill in the art, without departing from the scope and spirit of the invention, which is defined by the claims appended hereto.
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The invention describes novel 1-aryl-5-(substituted alkylideneimino)pyrazoles of formula (I) ##STR1## wherein typically preferred substituents are: R 1 is cyano, nitro, or halogen;
R 2 is R 9 S(O) n in which n is 0, 1 or 2 and R 9 is alkyl, preferably methyl which is substituted by halogen atoms which are the same or different up to full substitution of the alkyl moiety;
R 3 is hydrogen or alkyl;
R 4 is phenyl or heteroaryl, optionally substituted by one or more hydroxy, halogen, alkoxy, alkylthio, cyano or alkyl or combinations thereof; preferably R 4 is phenyl, which is at least substituted by 3-hydroxy or 4-hydroxy;
R 5 is hydrogen, alkyl or halogen;
R 6 and R 8 are hydrogen;
R 7 is halogen, alkyl, haloalkyl or haloalkoxy; and
X is a nitrogen atom or CR 14 in which R 14 is hydrogen, halogen, cyano, alkyl, alkylthio or alkoxy.
The invention further describes processes to make the compounds, compositions of the compounds, and methods of use of the compounds for the control of arthropods (mites, aphids or insects), nematodes, helminths, or protozoa.
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FIELD OF THE INVENTION
The present invention relates to a control system for a startup shift element of an automatic motor vehicle transmission capable of electro-hydraulic or electro-pneumatic actuation with an electronic transmission control device, whereby the startup shift element may be shifted hydraulically or pneumatically to an emergency-operation mode even if the electronic control device fails.
BACKGROUND OF THE INVENTION
Automated motor vehicle manual transmissions and automatic transmissions whose startup element is in the form of a friction clutch have long been known. Actuation of such a startup shift element is usually electro-hydraulic, electro-pneumatic, or even electro-mechanical, whereby the actuators of the actuation device of the startup shift element are controlled via An electronic transmission control device. In order to provide a high degree of shifting smoothness when the vehicle begins to move, the transmission startup element is usually regulated, taking into account the RPM of the shifting element, and the torque to be transmitted, using a correspondingly executed regulation process that is implemented within the electronic control device.
When the motor vehicle transmission electronic control device fails, problems arise during the startup process. Since the startup shift element may no longer be brought into a regulated state, the internal-combustion engine powering the vehicle stalls, as a result of the more or less violent engagement of the startup device.
To solve this problem, a hydraulically controlled startup device that is capable of electro-hydraulic operation, such as is known from the constantly-variable-ratio “Honda Multimatic” automatic transmission, is provided in which at least the minimum information regarding the transmission input RPM necessary for proper engagement of the startup clutch is determined hydraulically by means of an additionally-installed pitot tube. This RPM-proportional pressure is passed via the control lines of the electro-hydraulic transmission control device operating the transmission exclusively hydraulically, in emergency mode. The control valves of the electro-hydraulic transmission control device which controls the startup shift element, are so configured, that the startup shift element may be shifted based on RPM in emergency mode as an alternative to the normal electronic control.
The entire startup control device of the startup clutch is correspondingly expensive, including the pitot tube as a hydraulic RPM sensor.
In another automatic transmission, the “AUDI Multitronic”, with an integrated startup clutch capable of electro-hydraulic operation, an expensive startup clutch control device is obviated, with the result that the motor vehicle becomes immobile and without power upon failure of the electronic transmission control device.
It is the task of the invention to present a control system for an automated motor vehicle transmission or automatic transmission capable of electro-hydraulic or electro-pneumatic actuation with an electronic transmission control device with which the startup shift element may be smoothly actuated in an emergency mode of the transmission, even if the electronic transmission control device, without additional sensor devices, fails.
SUMMARY OF THE INVENTION
The present invention is preferably based on a known automated transmission or automatic transmission for a motor vehicle, in which a startup element of the transmission is capable of electro-hydraulic or electro-pneumatic actuation, by means of an electronic transmission control device. The startup shift element may be integrated into the transmission, and may be in the form of a clutch or brake. The startup shift element may, however, be implemented as a separate component that is positioned in the drive train between the drive motor and the transmission input shaft or between the transmission output shaft and the drive shaft along the direction of power flow. In normal operating mode, the electronic transmission control device controls or regulates the electro-hydraulic or electro-pneumatic triggering of the startup shift element via suitably-configured actuators. When the electronic transmission control device fails, a hydraulic or pneumatic triggering option of the startup shift element is present during operation in emergency transmission mode.
Further, the invention is preferably based on a conventional electrical connection of the transmission, and its electronic transmission control device, to the motor vehicle electrical power circuit and to other motor vehicle systems, particularly to an electronic engine control system of the internal-combustion engine powering the motor vehicle, as well as to vehicle braking systems, such as to an electronic brake control device, for example. For this, signals from other vehicle control devices that are required for the control or regulation of the startup shift element, e.g. engine RPM, engine torque, or a performance demand by the driver, may be transmitted to the electronic transmission control device via a data bus system, for example (e.g., CAN), or conventionally via a fixed electrical line.
In accordance with the invention, the control system for the startup shift element includes an emergency shift valve capable of being triggered electrically, that is assigned to the hydraulic or startup shift element pneumatic control device, as well as a transmission-independent electronic control module, by means of which the above-mentioned emergency-operation-mode shift valve may be actuated.
In an advantageous embodiment of the invention, the emergency shift valve capable of being triggered electrically, is integrated into the hydraulic or pneumatic electronic transmission control device. In another advantageous embodiment of the invention, the transmission-independent electronic control module is integrated into the electronic engine control device. The transmission-independent control module may be a programmable device, having program instructions stored in a computer readable medium, such as a read only memory or reprogrammable memory. The control algorithm according to the present invention may thus be provided in the form of a series of program steps executed by a microcontroller in the transmission-independent control module.
When the electronic control module fails, the startup shift element based on the present invention may be shifted by means of an electrical triggering of an emergency-operation-mode shift valve, via a transmission-independent electronic control module. Such a failure of the electronic transmission control device may be indicated, for example, by an active setting of the emergency-mode bit (“electronic transmission control device defective”) from the electronic transmission control device itself, or from the transmission-independent electronic control module by disruption of the communications (“electronic transmission control device active”) from the electronic transmission control device.
The transmission-independent electronic control module recognizes a startup condition from a driver by evaluating signals already present in the motor vehicle, that are made available via a data bus. For example, by evaluating signals from existing sensors and/or other vehicle control devices to the transmission-independent electronic control module, or signals from the engine control device and the brake control device. In a simple embodiment, release of a vehicles' brakes and a subsequent or simultaneous actuation of the accelerator pedal may be interpreted as a desire to start driving a vehicle that is at rest. The corresponding signals for this are, for example, a brake light signal or brake pressure, the accelerator pedal angle or desired engine torque, wheel speed, or vehicle speed. If the transmission-independent electronic control module is to determine whether the vehicle brakes have actually been released based only on the existence of a brake light signal, it is desirable to link the brake light signal with a vehicle-speed signal.
If the transmission-independent electronic control module has recognized the desire to start driving a vehicle that is at rest, it triggers the emergency-operation-mode shift valve. The emergency-operation-mode shift valve again opens a channel of the hydraulic or pneumatic actuation device affecting the startup shift element, whereby the previously-disengaged startup shift element is engaged hydraulically or pneumatically.
In an advantageous embodiment of this control system, the startup shift element receives pressure via a baffle when the emergency-operation-mode shift valve is triggered. Switching of the emergency-operation-mode shift valve thus causes a ramp-shaped pressure buildup in the startup shift element actuation device, up to a maximum pressure determined by the system, for example, by a system pressure already established by a transmission pump and determined by the baffle. Such a baffle system could be suitably combined with a conventional spring-/volume damper system.
Of course, several shifting elements can be actuated by the emergency-operation-mode shift valve at the same time, or in sequence, if required for transmission of power within the transmission corresponding to the overall transmission concept. Also, the control system may be so configured that a forward or reverse startup procedure may be performed in spite of electronic transmission control device failure.
After the synchronizing point is achieved, at the conclusion of the startup shift element shift process, or in consideration of a tolerance value, the transmission-independent electronic control module monitors whether the vehicle is to be stopped again. The startup shift element must be disengaged at the proper moment in order to prevent the engine from stalling. In an advantageous embodiment, it is therefore proposed that the emergency-operation-mode shift valve of the transmission-independent electronic control module is again electrically disengaged, when values fall short of a vehicle-speed or engine-speed threshold.
Functionality of the control system during rapid repetitive shifting or at low temperatures may be ensured by means of correspondingly-large emptying cross-sectional areas at the emergency-operation-mode shift valve.
It is desirable for safety reasons to configure such a control system for the startup shift element as described above, so that the emergency-operation mode shift valve is electrically controlled only when the a drive ratio is selected that corresponds to the direction of vehicular travel when the startup shift element is engaged. If the above-described control system is implemented in a transmission that includes a mechanical link between the gear-selection device and the gear-shift valve (gear “pusher”) for hydraulic or pneumatic actuation of the startup shift element, the emergency-operation mode shift valve may be functionally coupled to the existing hydraulic or pneumatic position valve. If the above-described control system is implemented in a transmission with pure electrical connection between the gear-selection device and the hydraulic or pneumatic startup shift element actuation device, the vehicle direction desired by the driver must be determined purely electrically from the vehicle, preferably from the gear-selection device, and must be transmitted to the transmission-independent electronic control module.
In one embodiment of the invention, the startup shift element control system is implemented such that the emergency-operation mode shift valve is capable of electrical operation when the electrical voltage releases the pressure channel for hydraulic or pneumatic actuation of the startup shift element. In this embodiment version, the electronic transmission control device has the same priority regarding the capability of the emergency-operation mode shift valve to being triggered. As long as the electronic transmission control device is functional, a faulty control signal from the transmission-independent electronic control module cannot lead to undesired engagement of the startup shift element.
In a further embodiment example of the invention, the engagement of the startup shift element, upon a failed electronic transmission control device, is supported by engine-related measures. Thus, upper and lower tolerance values for engine speed gradients during the shifting process are calculated by the active transmission-independent electronic control module, preferably as a function of current engine speed, current vehicle speed, and the load imposed by the driver. When a value exceeds or falls short of these calculated tolerance values, the transmission-independent electronic control module undertakes regulation of engine speed via engine-related measures, such as torque limitation, to a value within the calculated tolerance values. Thus, on the one hand, an excessive speed differential of the startup shift element, and thus excessive friction wear, may be avoided, and on the other hand, a great decline of engine speed, and thereby an unsmooth shift and excessive friction wear of the startup shift element, can be avoided.
As a safety function for the transmission and the startup shift element a general limitation of engine torque and/or or engine speed gradient and/or vehicle speed may be provided that functions when the transmission-independent electronic control module is active The various engine-related features may be combined and subcombined together in a useful manner.
BRIEF DESCRIPTION OF THE DRAWINGS
A function progression within the transmission-independent electronic control module is described using the following FIGS. 1 through 4 , as an example for integration of this transmission-independent electronic control module into the control sequence of the transmission control device. For this, FIGS. 1 through 4 show individual flowcharts of control sequences of a sample interactive startup diagram, based on which a vehicle startup process may be controlled by the transmission-independent electronic control module with failed electronic transmission control device.
FIG. 1 shows a flowchart of a sample control sequence to initiate the startup function of the transmission-independent electronic control module.
FIG. 2 shows a flowchart of a sample control sequence to engage the startup shift element after successful initiation of the startup function of the transmission-independent electronic control module, until the achievement of synchronization speed for the shift process.
FIG. 3 shows a flowchart of a sample control sequence after the achievement of synchronization speed for the startup shift element shift process, and for the transition of the startup function of the transmission-independent electronic control module to a “Vehicle is stopping” mode.
FIG. 4 shows a flowchart of a sample exit function for rapid conclusion of the startup function of the transmission-independent electronic control module, when the electrical emergency-operation mode of the electronic transmission control device is cancelled during an active startup process of the transmission-independent electronic control module, and the electronic transmission control device is again fully functional.
FIG. 5 shows a schematic drawing of the system according to the present invention, with the startup element placed between the engine and the transmission. The transmission independent control module responds to a number of inputs and generates a number of outputs, as schematically shown.
Finally, FIG. 6 shows a schematic drawing of the system according to the present invention, with the startup element placed between the transmission and the drive axle. The transmission independent control module responds to a number of inputs and generates a number of outputs, as schematically shown.
OBJECTS OF THE INVENTION
It is therefore an object of the present invention to provide a control system for a startup shift element of a motor vehicle transmission, the startup shift element being capable of electro-hydraulic or electro-pneumatic actuation, and whereby the startup shift element, upon failure of an electronic transmission control device, may be shifted hydraulically or pneumatically in an emergency-operation mode, comprising an emergency-operation mode shift valve receiving an electrical signal for controlling the hydraulic or pneumatic actuation device of the startup shift element, the electrical triggering signal being initiated by a transmission-independent control module, to control a startup procedure of the motor vehicle, upon a failure of the electronic transmission control device.
It is a further object of the invention to provide a control system for a startup shift element of a transmission wherein, upon failure of the electronic transmission control device, the startup shift element may be actuated by the transmission-independent control module in dependence on a control input from a motor vehicle driver, whereby the transmission-independent control module determines a desired startup condition by means of an evaluation of sensor or control signals already present in the motor vehicle. A release of a vehicle brake and a simultaneous or subsequent actuation of an accelerator pedal, while the motor vehicle is at rest, may be interpreted by the transmission-independent control module as a desired startup condition. Further, the transmission-independent control module determines the release of the vehicle brake by means of an evaluation of a brake pressure signal of a vehicle brake system. The transmission-independent control module may determine the release of the vehicle brakes by means of evaluation of a brake-light signal of a vehicle brake system, dependent on a vehicle speed or a signal based on the vehicle speed. The transmission-independent control module may further determine the release of the vehicle brake by means of an evaluation of at least one of a brake pressure signal of a vehicle brake system and a brake-light of a vehicle brake system, dependent on a vehicle speed or a signal based on the vehicle speed.
The startup shift element may be engaged hydraulically or pneumatically by means of the electrical actuation of the emergency-operation mode shift valve via a baffle damper system or via a spring-volume damper system.
Another object of the invention is to provide a control system for a startup shift element of a transmission, having a transmission-independent control module which calculates a synchronization point during an engagement process of the startup shift element. The transmission-independent control module may monitor a vehicle speed, a transmission speed, and/or an engine speed with the startup shift element engaged, whereby the startup shift element is re-engaged below a vehicle speed and/or an engine speed threshold by means of switching off the electrical actuation of the emergency-operation mode shift valve by the transmission-independent control module. An engagement process of the startup shift element, may, for example, be controlled in conjunction with a vehicle engine speed gradient. Further, the engine speed gradient may be adjusted within a tolerance range calculated and specified by the transmission-independent control module. The transmission-independent control module may recognize a failure of the electronic transmission control device by means of a transmission signal from the electronic transmission control device, and/or by means of a missing signal from the electronic transmission control device. In one embodiment, the transmission-independent control module preferably actuates at least two shift elements of the motor vehicle transmission.
The emergency-operation mode shift valve of the startup shift element may be triggered electrically, only when a motor-vehicle driving direction specified by a selector device operated by the driver actually corresponds to an actual driving direction with engaged startup shift element.
It is another object of the invention to provide a control system for a startup shift element of a transmission wherein an emergency-operation mode shift valve capable of electrical actuation is integrated into a hydraulic or pneumatic control device of the motor vehicle transmission. The transmission-independent control module, in turn, may be integrated into an electronic motor-vehicle engine control device. The startup shift element may be configured, for example, as a clutch integrated into the motor vehicle transmission, or as a separate clutch positioned in the power train between the engine and a transmission input shaft or as a separate clutch positioned in the power train between the transmission output shaft and the drive axle of the motor vehicle.
A further object of the invention provides that an engagement process of the startup shift element is controlled in conjunction with a vehicle engine torque, vehicle engine speed gradient and/or other vehicle engine operating characteristic.
It is another object of the invention to provide a method for controlling a startup shift element of a motor vehicle transmission, having a normal mode receiving an electro-hydraulic or electro-pneumatic actuation signal, and an emergency mode receiving a hydraulic or pneumatic control signal, comprising the steps of detecting an electronic transmission control failure by a transmission-independent control module; upon detection of an electronic transmission control failure, electrically controlling an emergency-operation mode shift valve; and controlling the motor vehicle transmission hydraulically or pneumatically by operation of the emergency-operation mode shift valve. The motor vehicle engine may be limited to protect transmission during an emergency mode. The transmission-independent control device may determine the existence of a startup condition and control the emergency-operation mode shift valve in accordance therewith. The transmission-independent control device may proportionally control the emergency-operation mode shift valve, and likewise, the emergency-operation mode shift valve may also be proportionally controlled. Both the engine system and brake system may be monitored, and the startup shift element controlled consistently therewith. A plurality of transmission elements may be controlled in an emergency mode with the transmission-independent control module, after detection of electronic transmission control failure.
It is also an object of the invention top provide a computer readable program storage device, storing therein instructions for controlling a programmable motor vehicle transmission-independent control module to perform the following steps: detecting an emergency mode, wherein failure of an electronic transmission control is presumed; and producing an electrical control signal for an emergency-operation mode shift valve in event of presumed electronic transmission control failure, wherein a startup element of the motor vehicle transmission is operative in dependence on a hydraulic or pneumatic control signal from the emergency-operation mode shift valve, to permit the motor vehicle to startup in event of electronic transmission control failure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
During a first function, “Entry” 10 , of the transmission-independent electronic control module. FIG. 1 shows the checking of whether the electronic transmission control device that controls or regulates the startup shift element during normal transmission operation is functional 11 . For this, the transmission-independent electronic control module queries an EMERGENCY-OPERATION MODE control bit of the electronic transmission control device. During this the transmission electronic control device may set this EMERGENCY-OPERATION MODE control bit to active mode (ON) to indicate a disruption of function. The system may also be configured so that the transmission-independent electronic control module recognizes a missing signal of the electronic transmission control device that is sent from the electronic transmission control device in normal transmission operating mode, as an EMERGENCY-OPERATION MODE control bit. If the EMERGENCY-OPERATION MODE condition is fulfilled, a control bit NOT_G is set to “ON” 12 within the function progression of the transmission-independent electronic control module, and general transmission safety measures are implemented. These types of protective functions are intentionally effective as long as the transmission is in emergency-operation mode. Examples of transmission-protection functions are a permanent limitation of torque to be transferred to the startup shift element, a permanent limitation of an engine speed gradient dn_mot/dt, or a permanent limitation of vehicle speed v/Fzg, for example as a function of the current RPM relationship v or the current slip of the startup shift element. Only then is the program continued with Program Step 1 . If the EMERGENCY-OPERATION MODE condition is not fulfilled, the control bit NOT_G is set to “OFF” 13 , and the program is directly continued with Program Step 1 .
As is visible from FIG. 1 , a Program Step 4 , from which the “Entry” function module 10 is invoked, links the “Entry” function module 10 to a closed loop functional progression to trigger the startup shift element. This Program Step 4 will be explained later in connection with FIG. 4 .
FIG. 2 further explains the subsequent functional progressions that engage the startup shift element to the point that a synchronizing speed is achieved. Program Step 1 shows the transition between the “Entry” function module 10 and an “Engage startup shift element” 20 function module 20 of the transmission-independent electronic control module. The “Engage startup shift element” function module 20 , first checks whether the control bit NOT_G is set 21 . If the control bit NOT_G is not “ON”, e.g., it is “OFF”, the “Engage startup shift element” function module is immediately abandoned and the program continues with Program Step 3 . This Program Step 3 will later be described by FIG. 4 . If the control bit NOT_G is “ON”, the transmission-independent electronic control molecule initiates a calculation of the synchronization point for the startup shift element 22 . During this, a synchronization RPM n_synchron that is supposed to be present at the output of the startup shift element of the engaged startup shift element may be calculated in the conventional tanner, via an engine speed n_mot and a power takeoff speed n_ab of the transmission or speed of the vehicle, with consideration of a known drive ratio i_not of the transmission or of the vehicle power train in emergency-mode operation. If the transmission emergency-mode program possesses several (known) gear ratios i_gang_not, these must be correspondingly taken into account, whereby the actual effective emergency-mode program conversion may be recognized during the transition from normal mode to emergency mode, dependent on the actual vehicle speed, for example. Also, pre-determined tolerances may be taken into account when calculating the synchronization speed n_synchron such as, for example, those that take into account inaccuracies during the determination of the actual current RPM's in the power-flow path before and after the startup shift element, or also as an additional safety feature for the “startup shift element engaged” status. Of course, the synchronization speed n_synchron is adapted to changes in the startup RPM's n_ab of the transmission or of the vehicle speed v_Fzg.
Upon inception of the calculation of the synchronization point, the transmission-independent electronic control module also electrically controls an emergency-mode shift valve capable of electrical operation that is assigned to a conventional hydraulic or pneumatic actuation device. As a result of the flow through this emergency-mode shift valve, the startup shift element is then engaged by means of its hydraulic or pneumatic actuation device, e.g., by means of a conventional hydraulic or pneumatic baffle control or volume damper control.
Subsequent program steps check to see whether the calculated synchronization speed n_synchron has been achieved at the startup shift element output 23 . If this is the case, then the “Engage startup shift element” function module 20 is immediately abandoned and the program continues with Program Step 2 , which will be explained in connection with FIG. 3 . If the synchronization speed n_synchron has not been achieved, then the transmission-independent control module sets a control bit NOT_M to a value of “ON” 24 . As long as this control bit NOT_M is active. i.e., is “ON,” then the following engine-related measures described in the following become effective to support the startup shift element shift process. The transmission-independent control module calculates upper and lower tolerance values dn_mot_o/dt and dn_mot_u/dt for a permissible gradient dn_mot/dt of the engine speed n_mot, preferably as a function of the current values from the engine speed n_mot, takeoff speed n_ab, or vehicle speed v_Fzg, accelerator-pedal or throttle-plate positional angle dki, and RPM ratio v or differential speed at the startup shift element 25 .
If the current engine speed gradient dn_mot/dt is greater than the upper tolerance value dn_mot_o/dt or less than the lower tolerance value dn_mot_u/dt 26 , then the engine speed gradient dn_mot/dt is adjusted to fall between the upper and lower tolerance values dn_mot_o/dt and dn_mot_u/dt using engine-related measures 27 . Such engine-related measures include, for example, ignition timing angle access or fuel-supply access via an electronic engine control device. In the subsequent program progression, the program loops 28 directly after Program Step 1 to the beginning of the “Engage startup shift element” function module 20 , and then the control bit NOT_G is checked to see if it is still set 21 .
If the value of the current engine speed gradient dn_mot/dt lies within the tolerance range defined by the limits dn_mot_o/dt and dn_mot_u/dt, the program is immediately continued with a jump 29 back to a point directly after Program Step 1 , the beginning of the “Engage startup shift element” function module 20 .
The function progression shown in FIG. 3 concerns the program progression after the synchronization speed n_synchron has been achieved, i.e., after successful engagement of the startup shift element, and begins with Program Step 2 . Since the startup shift element is not completely engaged, a previously-effective limitation of engine torque may be removed so that a performance maneuver desired by the driver from the engine (normally via the accelerator positional angle) may be performed, in order to provide effective protection to the transmission in the emergency-mode program against overload, within the limits of the transmission protection functions activated in the “Entry” function module 10 . A comfort-oriented function removes an engine torque limitation in a regulated, ramped, manner 31 . Finally, the control bit NOT_M is set to a value of “OFF”.
During subsequent program progression, the transmission-independent control module checks during an “Exit because of condition Vehicle is stopping” function module 30 as to whether the motor vehicle is (again) to be stopped, preferably via the signals of available engine-speed sensors and/or vehicle speed sensors (wheel RPM sensors). For this, the check as to whether the motor vehicle is to be stopped is continued until the values fall short of predetermined threshold values for engine speed n_mot or vehicle speed v_Fzg 33 , or in other words, until normal vehicle operation occurs. In order to take into account the fact that the emergency-mode operation of the transmission remains unaltered, the program progression contains a jump back to the beginning of the “Entry” function module 10 , Program Step 4 .
If the current engine speed n_mot falls short of a predetermined threshold, or if the current vehicle speed v_Fzg falls short of a predetermined threshold, then the transmission-independent control module switches off the electrical initiation of the emergency-operation mode shift valve, whereby the conventional hydraulic or pneumatic emergency-operation mode shift valve is so controlled that the startup shift element is disengaged 34 . After successful exit, the subsequent program progression also contains a jump back to the beginning of the “Entry” function module 10 , Program Step 4 .
The functional progression shown in FIG. 4 concerns the program steps of an exit function 43 , to rapidly conclude the startup function of the transmission-independent control module, when the electrical emergency operation of the electronic transmission control device is reset during active startup function of the transmission-independent control module, i.e. when electronic transmission control is normally functional again. As may be seen in FIG. 2 , this “Exit by resetting transmission emergency-mode operation” function module 40 shown in FIG. 4 is invoked from the “Engage startup shift element” function module 20 if the control bit NOT_G is not set with the value “ON” 21 .
Within the “Exit by resetting transmission emergency-mode operation” function module 40 started with Program Step 3 , all potentially active limiting functions of the transmission-independent control module are reset 41 . This includes both transmission-protective functions and measures to support the engagement process of the startup shift element. The release of any torque-limitation preferably occurs using a rapid, ramped regulation in order to ensure the highest possible motor-vehicle mobility. Removal of limitations to the engine speed gradient dn_mot/dt and/or the vehicle speed v_Fzg may also be via a slow, ramped regulation for reasons of smoothness.
Further, a potentially still-active electrical triggering of the emergency-operation mode shift valve of the startup shift element is switched off within the “Exit by resetting transmission emergency-mode operations” function module 40 , whereby a hydraulic or pneumatic actuation device of the startup shift element comes under the complete control of the electronic transmission control device. During subsequent program progression, the control bit NOT_M is set with the value “OFF” 42 , and the program is finally continued with a jump back to the beginning of the “Entry” function module 10 . The pertinent Program Step is designated with 4 consistent with FIG. 3 .
While the above detailed description has shown, described and pointed out the fundamental novel features of the invention as applied to various embodiments, it will be understood that various omissions and substitutions and changes in the form and details of the system and method illustrated may be made by those skilled in the art, without departing from the spirit of the invention. Consequently, the full scope of the invention should be ascertained by the appended claims.
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A control system, method for control, and control software for operating a startup shift element of an automated motor vehicle transmission or automatic transmission capable of electro-hydraulic or electro-pneumatic actuation with an electronic transmission control device, whereby the startup shift element may be shifted hydraulically or pneumatically in emergency mode even if the electronic control device fails. The control system includes a transmission-independent control module, and a emergency-operation mode shift valve capable of electrical triggering, that controls the hydraulic or pneumatic actuation device of the startup shift element. If the transmission-independent control module fails during transmission emergency-mode operation, the startup shift element is capable of actuation by means of the electrical triggering of the emergency-operation mode shift valve via the transmission-independent control module. This may particularly control a motor-vehicle startup procedure.
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RELATED APPLICATION
This application claims priority to U.S. Provisional Application No. 61/740,836, filing date Dec. 21, 2012, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present disclosure relates to rotary shear valves and associated methods and, in particular, to rotary selector valves, which include an internal bladder and, in some embodiments, include a diaphragm.
BACKGROUND
Rotary valves are generally used in process industries for directing fluids from one or more sources to one or more destinations in a repeatable or cyclic process. For example, CO 2 based chromatography systems or UHPLC systems can generally utilize rotary shear valves which include a rotor and a stator as the two interacting sealing surfaces to alter the flow path directions of mobile phase constituents (e.g., solvents, modifiers, and the like) within the valve. Current high pressure chromatography shear valves typically employ a stator comprising a metallic element and a rotor device composed of a polymer material that forms a fluid-tight seal at a rotor/stator interface. While this combination has been found useful, it can be limited in pressure rating and/or valve lifetime.
Rotor materials can include high strength and solvent resistant polymers, such as polyether ether ketone (PEEK) or polyimide. However, both PEEK and polyimide have compressive strength limitations that can prevent the valve from safely operating above 20,000 psi. To increase the operating conditions of the valve beyond 20,000 psi, higher strength materials, such as stainless steels, have been considered. In particular, stainless steels have a significantly higher modulus than polymers, e.g., approximately 28 million psi versus approximately 2 million psi. However, the higher modulus can make it more difficult to achieve uniform contact stresses for the sealing surface between the rotor and stator. In particular, uniform contact stresses are important to allow for uniform wear and to seal the fluidic paths.
SUMMARY
In general, embodiments of the present disclosure are directed to rotary shear valves that create substantially uniform contact stresses between the rotor and stator, thereby promoting uniform wear and sealing of the fluidic paths. Specifically, the exemplary rotary shear valves utilize a three piece design including a diaphragm and bladder which allows for more uniform contact stresses between the rotor and stator and allows operation of the valve beyond 20,000 psi.
In accordance with embodiments of the present disclosure, exemplary rotary shear valves are provided that include a rotor, a stator and a bladder. The rotor defines a cavity extending at least partially therethrough and is rotatably mounted relative to the stator to create at least one fluidic path therebetween. The bladder comprises a polymer disposed inside the cavity.
The rotor generally includes at least one rotor groove and the stator includes at least one stator port for the at least one fluidic path. The polymer forming the bladder can be a low compressive yield strength polymer and generally exhibits fluid-like properties under a compressive stress. The bladder can be disposed inside the cavity such that, when compressed, the bladder substantially distributes contact stresses in at least two directions between the rotor and the stator. The exemplary rotary shear valves can include at least one diaphragm coupled to the rotor. The diaphragm can be, e.g., an integrated diaphragm, a separate diaphragm, and the like. The separate diaphragm can be coupled to the rotor using at least one of, e.g., electron beam welding, laser beam welding, friction welding, and the like. The integrated diaphragm is coupled to the rotor by being formed from a portion of the rotor. The exemplary rotary shear valves can include at least one relief slot for increased flexure of the integrated diaphragm.
The stator can define a flat stator face and at least one of the rotor and the at least one diaphragm can define a flat face complementary to the flat stator face. The diaphragm can be fabricated from at least one of, e.g., a stainless steel alloy, such as a UNS S21800 stainless steel, a cobalt alloy, a nickel alloy, a nickel-cobalt alloy, such as UNS R30035 nickel-cobal alloy (e.g., MP35N®available from SPS Technologies, Inc. of PA), and the like. The stator can he fabricated from at least one of e,g., a titanium alloy, a 316 stainless steel, an MP35N® alloy, and the like. The stator can include a coating, e.g., a diamond-like coating, and in some embodiments, a nanofilm diamond-like coating (e.g., having a thickness of 5,000 nm or less). The polymer can be at least one of, e.g., a polytetrafluoroethylene (PTFE), an ultra-high-molecular-weight polyethylene (UHMWPE), and the like.
The exemplary rotary shear valves can include a spacer disposed at least partially inside the cavity which transmits a load into the bladder. The spacer can be fabricated from, e.g., a 316 stainless steel, and the like. The bladder can transmit the load into at least one of the rotor and at least one diaphragm through uniform contact stresses. That is, in some embodiments the bladder transmits the load into the rotor. In certain embodiments, the bladder transmits the load in both the rotor and a first diaphragm. In other embodiments, the bladder transmits the load into the rotor, and two or more diaphragms. In some embodiments, the uniform contact stress reduces wear of at least one of the rotor, the stator, the bladder, and the at least one diaphragm. In certain embodiments, the uniform contact stress seals the at least one fluidic path. In embodiments, the uniform contact stress seals the at least one fluidic path as well as reduces wear of one or more of the rotor, stator, bladder, and at least one diaphragm.
In accordance with embodiments of the present disclosure, exemplary methods of operating a rotary shear valve are provided that include providing a valve body that includes a rotor, a stator and a bladder. The exemplary methods generally include providing a stator and providing a rotor defining a cavity extending at least partially therethrough rotatably mounted relative to the stator to create at least one fluidic path therebetween. The exemplary methods include positioning a bladder comprising a polymer inside the cavity of the rotor. The exemplary methods further include transmitting a compressive stress into the bladder. Transmitting the compressive stress into the bladder generally distributes contact stresses between the rotor and the stator.
In general, the exemplary methods include providing at least one diaphragm coupled to the rotor and providing a spacer disposed at least partially inside the cavity. The exemplary methods can include transmitting a compressive stress into the bladder via the spacer such that the bladder exhibits fluid-like properties and substantially distributes the compressive stress in at least two directions. The exemplary methods can include transmitting the compressive stress into at least one of the rotor and the at least one diaphragm via the bladder through uniform contact stresses.
The above exemplary embodiments in accordance with the present disclosure provide many advantages. For example, one or more embodiments described herein create substantially uniform contact stresses between the rotor and stator to promote uniform wear and/or sealing of the fluidic paths. As a result, the exemplary rotary shear valves can be implemented in a variety of operating conditions, including those beyond about 20,000 psi.
Other advantages and features will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
To assist those of skill in the art in making and using the disclosed rotary shear valves and associated methods, reference is made to the accompanying figures (which are not necessarily to scale), wherein:
FIG. 1 shows a side view of a rotary shear valve of the prior art;
FIG. 2 shows a cross-sectional view of an exemplary rotary shear valve;
FIG. 3 shows a cross-sectional view of an exemplary rotary shear valve with an integrated diaphragm;
FIG. 4 shows a cross-sectional view of an exemplary rotary shear valve with two separate diaphragms;
FIG. 5 shows a cross-sectional view of an exemplary rotary shear valve with an integrated diaphragm and a separate diaphragm; and
FIG. 6 shows a cross-sectional view of an exemplary rotary shear valve with an integrated diaphragm.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
With reference to FIG. 1 , a traditional rotary shear valve 10 is illustrated with a one-piece rotor 12 and a stator 14 having a sealing surface 16 . A preload 18 of, e.g., approximately 650 lbs, can generally be applied to the rotor 12 to maintain contact between the rotor 12 and the stator 14 at the sealing surface 16 . However, due to the one-piece rotor 12 in contact with the flat sealing surface 16 of the stator 14 , the traditional rotary shear valve 10 can exhibit non-uniform contact stresses 20 at the sealing surface 16 . In particular, the contact stresses 20 can generally be lowest at the center and gradually increase from the center in the direction of the edges of the stator 14 sealing surface 16 . As discussed above, the non-uniform contact stresses 20 at the sealing surface 16 between the rotor 12 and the stator 14 can cause non-uniform wear of the rotor 12 and/or the stator 14 and can fail to properly seal the fluidic paths 22 between the rotor 12 and stator 14 .
The relationship between stress and strain can be determined by utilizing Hooke's Law as shown by Equation 1 below:
σ= E×ε (1)
where σ represents stress, E represents Young's Modulus and ε represents strain. As an example, a traditional rotor 12 may have a thickness of approximately 0.140 inches, a modulus of approximately 28 million psi for a stainless steel, a rotor thickness variation of approximately 0.000050 inches, and a stress of approximately 10,000 psi. To fluidically seal at approximately 25,000 psi, the contact stresses 20 must exceed the fluid pressure and be near approximately 28,000 psi. Having a potentially 10,000 psi variation in contact stresses 20 can lead to uneven and excessive wear of the rotor 12 .
Turning now to FIG. 2 , a cross-sectional view of an exemplary (i.e., in accordance with an embodiment of the present technology) rotary shear valve 100 , e.g., a rotary selector valve such as a rotary injector valve with three rotor grooves, a rotary vent valve with two rotor grooves, and a rotary column selection valve with one radial groove, is provided which includes a three-piece rotor 102 and a stator 104 . The rotor 102 and the stator 104 can be aligned along a central vertical axis A 1 . The rotor 102 and the stator 104 can further rotate relative to each other about the central vertical axis A 1 . The rotor 102 generally defines a rotor groove (not shown) and the stator 104 generally defines at least one stator port 105 for creation of fluidic paths between the rotor 102 and stator 104 . In some embodiments, the stator 104 can be fabricated from, e.g., a titanium alloy, a 316 stainless steel, an MP35N alloy, and the like. In some embodiments, the stator 104 can include a coating, e.g., a nanofilm diamond-like coating (DLC), and the like. The material of fabrication for the stator 104 , e.g., a titanium alloy with a modulus of approximately 14,000,000 psi, and the like, can exhibit a lower modulus and be more compliant or compatible with the material of fabrication for the rotor 102 to improve the sealing capability against the rotor 102 . The coating on the stator 104 generally reduces the amount of friction between the stator 104 and other components of the rotary shear valve 100 . In some embodiments, the stator 104 can be fabricated from a material containing iron content and the DLC coating can act to prevent the iron content from rusting after being exposed due to wear.
The rotary shear valve 100 includes a ram shaft 110 including a shaft 109 and a shaft/rotor interface 111 . The shaft 109 can extend from the shaft/rotor interface 111 along the central vertical axis A 1 and engage with a mechanism configured to rotatably drive the shaft 109 about the central vertical axis A 1 . The shaft/rotor interface 111 can include two or more apertures 113 configured and dimensioned to receive pins 112 for engaging complementary apertures 115 in the rotor 102 . When inserted in the respective apertures, the pins 112 can detachably interlock the ram shaft 110 with the rotor 102 . Thus, as the ram shaft 110 axially rotates about the central vertical axis A 1 , the pins 112 engage the apertures 115 in the rotor 102 to simultaneously axially rotate the rotor 102 relative to the stator 104 .
In some embodiments, the ram shaft 110 can include a cavity 117 , e.g., a groove, centrally positioned on the face of the shaft/rotor interface 111 adjacent to the rotor 102 . The cavity 117 can be configured to receive a ball bearing 114 for supporting the rotor 102 . The ball bearing 114 can define a substantially circular top face for mating relative to the complementary cavity 117 surface and a substantially planar bottom face for mating relative to the rotor 102 or components of the rotor 102 . In some embodiments, the cavity 117 can further include a grease well 116 configured and dimensioned to receive a lubricant for lubricating the contact area in the cavity 117 between the ball bearing 114 and the shaft/rotor interface 111 of the ram shaft 110 . In some embodiments, a spacer 120 can be positioned between the substantially planar bottom face of the ball bearing 114 and the components of the rotor 102 . The spacer 120 can be fabricated from, e.g., a 316 stainless steel, and the like. In some exemplary embodiments, the spacer 120 can be fabricated from alternative heat-treated stainless steel materials in order to strengthen the spacer 120 for transfer of forces against a bladder 126 . The rotary shear valve 100 assembly can be surrounded by a bushing 118 .
The exemplary three-piece rotor 102 generally includes a rotor body 122 which defines a cavity 124 axially centered along the central vertical axis A 1 . The cavity 124 can extend at least partially through the rotor body 122 . In some embodiments, the cavity 124 can be configured as substantially cylindrical. However, it should be understood that in some embodiments, the cavity 124 can be configured in a variety of shapes. In the exemplary embodiment illustrated in FIG. 2 , the rotor body 122 defines cavity 124 extending through the entire rotor 102 , e.g., extending from a top surface to the bottom surface of the rotor body 122 along the central vertical axis A 1 .
In some embodiments, the rotor 102 can be fabricated from a non-stainless steel material to reduce or prevent rust formation and can have a thickness of, e.g., approximately 0.140 inches. Steel alloys generally include a significant percentage of iron. As the rotor 102 begins to wear due to interaction with the stator 104 , the passive chromium oxide layer of stainless steel materials which provides corrosion resistance can be penetrated. Once penetrated, the iron underneath the layer, if exposed to air and/or water, can begin to rust. Rust can thereby enter the chromatographic mobile phase (e.g., CO 2 flowstream), a contamination which cannot be tolerated. Thus, in some embodiments, the rotor 102 can be fabricated from a non-stainless steel material, e.g., a cobalt alloy, a nickel alloy, and the like, with no iron content to reduce or prevent rust formation.
The cavity 124 of the rotor body 122 can be configured and dimensioned to receive a bladder 126 therein. For example, FIG. 2 illustrates the rotor 102 including the bladder 126 positioned within the cavity 124 such that the bladder 126 does not extend outside of the cavity 124 . The bladder 126 can be fabricated from a low compressive yield strength polymer, e.g., a polytetrafluoroethylene (PTFE), an ultra-high-molecular-weight polyethylene (UHMWPE), and the like. As will be discussed in greater detail below, upon transmission of a compression stress against the bladder 126 with the bearing 114 and/or the spacer 120 , the bladder 126 can exhibit substantially fluid-like properties.
In the exemplary embodiment of FIG. 2 , the rotor 102 includes a diaphragm 128 , e.g., a separate membrane, coupled to the bottom surface of the rotor body 122 by coupling means such as welding, e.g., electron beam welding, laser beam welding, friction welding and the like, with or without filler materials. The diaphragm 128 can be fabricated from a metal material, e.g., a stainless steel alloy, such as a UNS S21800 stainless steel, a cobalt alloy, a nickel alloy, and the like. The diaphragm 128 can act to hermetically seal the rotor 102 such that the fully-constrained compliant backing, e.g., the bladder 126 , can be contained therein. Thus, when the diaphragm 128 has been secured to the rotor body 122 , the rotor body 122 and the diaphragm 128 can essentially become integral parts. It should be understood that the coupling means for securing or coupling the diaphragm 128 to the rotor body 122 should be sufficiently strong to resist the torque created by the rotating ram shaft 110 between the stator 104 substrate and the rotor 102 .
A preload 108 , e.g., a compressive stress, axially applied to a shaft/rotor interface 111 of the ram shaft 110 in a direction parallel to the central vertical axis A 1 can transfer through the ball bearing 114 (into the optional spacer 120 ) and further into the bladder 126 . Upon transmission of the preload 108 against the bladder 126 , the bladder 126 can exhibit substantially fluid-like properties within the cavity 124 . The bladder 126 can thereby evenly transfer the compressive forces from the preload 108 against the inner walls of the cavity 124 , the spacer 120 and the diaphragm 128 . Further, the compressive forces of the preload 108 can be evenly distributed by the diaphragm 128 against the sealing surface 106 of the stator 104 . The alignment of the ram shaft 110 , the ball bearing 114 , the spacer 120 and the diaphragm 128 along the central vertical axis A 1 ensures a self-aligned loading and transfer of the preload 108 .
In some embodiments, the diaphragm 128 can measure approximately 0.024 inches in thickness. In some exemplary embodiments, the diaphragm 128 thickness can be thinner or thicker than 0.024 inches. In general, the diaphragm 128 is sized to adequately absorb and uniformly transfer the compressive forces created by the bladder 126 against the sealing surface 106 of the stator 102 . In particular, during operating conditions of the rotary shear valve 100 , the pressure applied against the bladder 126 can cause the bladder 126 to yield and exhibit substantially fluid-like properties such that the bladder 126 substantially evenly distributes the forces against the inner walls of the cavity 124 , the spacer 120 and the diaphragm 128 . As would be understood by those of ordinary skill in the art, since the bladder 126 is fully constrained within the cavity 124 of the rotor 102 at all surfaces, (e.g., by the spacer 120 , the walls of the cavity 124 and the diaphragm 128 ) substantially all of the stresses created by the preload 108 can be sustained. Substantially uniform stresses are therefore applied to the thin diaphragm 128 and further transferred against the sealing surface 106 of the stator 104 .
The uniform stresses distributed by the bladder 126 against the diaphragm 128 ensure that, rather than increasing from the center to the edges of the sealing surface 106 , the contact stresses are uniformly distributed along the sealing surface 106 . In some embodiments, the uniform contact stresses promote even wear of the rotor 102 and/or the stator 104 . In some embodiments, the uniform contact stresses create the desired sealing pressure of the fluidic paths at the sealing surface 106 . In some embodiments, the sealing surface 106 , e.g., the sealing interface, can be substantially flat or planar rather than having a complex form in order to uniformly mate with the rotor 102 and/or the diaphragm 128 and to simplify the manufacturing process of the stator 104 . In some exemplary embodiments, the sealing surface 106 diameter can be approximately 0.170 inches and can withstand, e.g., approximately 25,000 psi, 28,000 psi, and the like, in contact stresses.
FIG. 3 illustrates an exemplary assembly of a stator 104 of FIG. 2 with an exemplary embodiment of a rotor 202 . The rotor 202 and the stator 104 can be aligned along the central vertical axis A 2 . The rotor 202 can include a rotor body 222 which defines a cavity 224 passing only partially therethrough, e.g., passing from the top surface of the rotor body 222 and extending only partially through the rotor body 222 in the direction of the bottom surface of the rotor body 222 along the central vertical axis A 2 . It should be understood that in some embodiments, the cavity 224 can pass from the bottom surface of the rotor body 222 and extend only partially through the rotor body 222 in the direction of the top surface of the rotor body 222 along the central vertical axis A 2 . In particular, the cavity 224 can extend partially through the rotor body 222 such that an integrated diaphragm 232 is formed at either the top and/or bottom surface of the rotor body 222 . The integrated diaphragm 232 can be configured to function substantially similarly to the separate diaphragm 128 discussed with respect to the embodiment of FIG. 2 . Thus, rather than coupling the diaphragm 128 to the rotor 102 such that the diaphragm 128 is substantially integral with the rotor 102 , the integrated diaphragm 232 can be formed from the rotor body 222 by creating a cavity 224 partially therethrough.
Similar to the rotor 102 of FIG. 2 , in some embodiments, the rotor 202 can include a spacer 220 which transfers a preload 208 against the bladder 226 which is disposed in the cavity 224 and positioned against the integrated diaphragm 232 . The fluid-like property of the bladder 226 upon application of the compressive preload 208 forces from the spacer 220 allows the bladder 226 to evenly distribute the preload 208 force against the inner surfaces of the cavity 224 , the spacer 220 and the integrated diaphragm 232 . The diaphragm 232 , in turn, evenly transfers the compressive forces against the sealing surface 106 of the stator 104 . Substantially uniform contact stresses 230 are thereby created between the diaphragm 232 and the sealing surface 106 of the stator 104 . In particular, the integrated diaphragm 232 can be dimensioned such that the bladder 226 can evenly transmit the preload 208 forces through the integrated diaphragm 232 and against the sealing surface 106 . For example, the integrated diaphragm 232 can have a thickness of approximately 0.024 inches. However, it should be understood that the thickness of the integrated diaphragm 232 can be dimensioned greater or less than 0.024 inches in other embodiments such that the integrated diaphragm 232 is capable of evenly transferring the compressive forces imparted upon the diaphragm 232 by the bladder 226 .
With reference to FIG. 4 , an exemplary rotor 302 having a cavity 324 extending through the entire rotor body 322 is provided. In particular, the cavity 324 can centrally extend from the top surface to the bottom surface of the rotor body 322 along the central vertical axis A 3 . The rotor 302 includes two separate diaphragms 328 a and 328 b coupled to the rotor body 322 at the cavity 324 openings such that the two diaphragms 328 a and 328 b are essentially integral with the rotor body 322 . In some embodiments, the rotor body 322 can include a circumferential step or groove surrounding the cavity 324 openings configured and dimensioned to receive one of the two diaphragms 328 a and 328 b . The bladder 326 can be disposed and sealed within the cavity 324 between the two diaphragms 328 a and 328 b by coupling the diaphragms 328 a and 328 b to the top and bottom surfaces of the rotor body 322 . Although illustrated as being offset from the planar surface of the rotor body 322 , in some embodiments, one or both of the diaphragms 328 a and 328 b can be substantially aligned and planar with the surface of the rotor body 322 .
In some embodiments, the top diaphragm 328 a can be positioned against the planar bottom surface of the ball bearing 114 and/or a spacer 120 of FIG. 2 such that a preload, e.g., a compressive force, can be transferred into the bladder 326 and the bottom diaphragm 328 b . In particular, the top diaphragm 328 a can receive the preload and transfer the preload to the bladder 326 contained within the cavity 324 . As discussed previously, the fluid-like property of the bladder 326 during operating conditions, e.g., application of a compressive stress against the bladder 326 , results in substantially uniform forces being transmitted to the inner walls of the cavity 324 and the two diaphragms 328 a and 328 b . Substantially uniform contact stresses are thereby created by the bottom diaphragm 328 b against the sealing surface of the stator 104 .
With reference to FIG. 5 , an exemplary rotor 402 having a cavity 424 extending partially through the rotor body 422 is provided. In particular, the cavity 424 can centrally and partially extend from the bottom surface of the rotor body 422 in the direction of the top surface of the rotor body 422 along the central vertical axis A 4 . In particular, the partially extending cavity 424 can form an integrated diaphragm 432 in top surface of the rotor body 422 . The cavity 424 opening at the bottom surface of the rotor body 422 can include a circumferential step or groove configured and dimensioned to receive a separate diaphragm 428 for coupling to the rotor body 422 . A bladder 426 can be positioned and sealed within the cavity 424 between the integrated diaphragm 432 and the separate diaphragm 428 . Although illustrated as being offset from the planar surface of the rotor body 422 , in some embodiments, the separate diaphragm 428 can be substantially aligned and planar with the surface of the rotor body 422 .
In some exemplary embodiments, the integrated diaphragm 432 can include a relief slot 434 or groove circumferentially surrounding the integrated diaphragm 432 about the central vertical axis A 4 to allow for increased flexure of the integrated diaphragm 432 (as indicated by the dashed lines), thereby permitting additional and/or improved transmission of preload forces to the bladder 426 . For example, the relief slot 434 can increase the flexibility of the integrated diaphragm 432 such that the integrated diaphragm 432 can bend in the direction of the bladder 426 to more effectively transfer preload forces applied to the rotor 402 .
FIG. 6 illustrates an exemplary rotor 502 having a cavity 524 extending partially through the rotor body 522 . In particular, the cavity 524 can centrally and partially extend from the top surface of the rotor body 522 in the direction of the bottom surface of the rotor body 522 along the central vertical axis A 5 . In particular, the partially extending cavity 524 can form an integrated diaphragm 532 along the bottom surface of the rotor body 522 . A bladder 526 can be disposed within the cavity 524 and positioned against the integrated diaphragm 532 . A spacer 520 can be positioned at least partially within the cavity 524 and against the bladder 526 to transfer a preload to the bladder 526 , the integrated diaphragm 532 and the sealing surface of the stator. Translation of the spacer 520 along the central vertical axis A 5 can be aligned by partially translating the spacer 520 within the cavity 524 as a preload is applied to maintain a substantially even distribution of preload forces against the bladder 526 .
In operation, the valves discussed herein are configured to receive a compressive stress into a bladder positioned within a cavity such that the bladder distributes substantially uniform contact stresses between the rotor and the stator. The substantially uniform contact stresses created between the rotor and the stator promote uniform wear and sealing of the fluidic paths. The substantially uniform contact stresses between the rotor and the stator also allow operation of the valve beyond 20,000 psi.
While exemplary embodiments have been described herein, it is expressly noted that these embodiments should not be construed as limiting, but rather that additions and modifications to what is expressly described herein also are included within the scope of the invention. Moreover, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations, even if such combinations or permutations are not made express herein, without departing from the spirit and scope of the invention.
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Exemplary embodiments are directed to rotary shear valves which include a stator, a rotor defining a cavity extending at least partially therethrough, and a bladder. The rotor is rotatably mounted relative to the stator to create at least one fluidic path therebetween. The bladder comprises a polymer disposed inside the cavity. Exemplary embodiments are also directed to methods of operating a rotary shear valve.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a primary carpet backing mat and more particularly, to a mat wherein the mat fibers have a coating that changes state during a post process carried out after a tufting operation, whereby the coating acts as an adhesive that bonds and retains tufted carpet fibers in the primary carpet backing, thereby eliminating or reducing the need for the application of a latex adhesive layer or use of a secondary backing.
[0003] 2. Description of the Prior Art
[0004] Carpets are conventionally manufactured by tufting fibrous yarns into a primary backing mat using a needling operation. The fibrous yarns that undergo tufting may be in the form of a continuous yarn or as previously cut yarns. These yarn(s) may be fed to a needle-punching machine for the tufting process. The characteristics of the primary backing mat fibers determine how the tufted fibers are held in place by the primary backing mat. A latex adhesive layer is applied to the underside of the carpet in order to hold the tufted fibers in place. In addition, a secondary backing mat is used below the latex adhesive layer, retaining the latex adhesive. After the tufting process, but before the latex adhesive has been applied, the tufts are susceptible to dislodgment from the primary backing. Rework is often necessary between these steps to insert any of the dislodged or absent tufts before the latex adhesive is applied. Traditionally, the latex application process is burdensome since the latex adhesive must first be compounded. Then latex water must be driven off and the latex adhesive must be cured. Finally, after the latex adhesive is cured it must be cooled. In addition, carpet manufacturers have traditionally required a secondary backing to be applied after the application of the latex adhesive. The secondary backing is usually required to protect the latex from damage and thereby hold the tufts more securely in their proper position within the primary backing and provide a non-abrasive surface that provides appropriate friction coefficient against the sub flooring over which the carpet is installed. These additional steps of applying a latex adhesive followed by a secondary backing mat are not only burdensome, but also drive up the overall carpet manufacturing costs. Increased transportation costs also result, as the carpet is heavier due to the latex adhesive and secondary backing. This heavier carpet is also less flexible.
[0005] It would be extremely desirable if a carpet could be constructed that did not require the use of a latex adhesive or to reduce its usage or the need for a secondary backing mat. It would also be desirable if the latex and secondary backing free carpet construction facilitated enhanced bonding of the tufted carpet yarns so that they would be held securely in place. Furthermore, it would be advantageous if the constructed carpet had readily bendable and flexible properties that were lacking in carpets heretofore devised and utilized, so that the constructed carpet could be more easily installed around tight corners, such as stairs.
[0006] U.S. Pat. No. 4,439,476 to Guild discloses a tufted pile fabric. A separate fiber layer of “Grilon” is disposed underneath the primary backing, which comprises a polyamide fiber layer having a melting point of 115° C. The carpet pile is tufted through the primary backing, together with the “Grilon” layer and the “Grilon” layer is melted to affect a bond between the tufted pile and the primary backing material. Most polyamides melt in the range of 225° C. to 250° C. and this melting point of 115° C. for “Grilon” appears low for a polyamide fiber layer. The melting of the “Grilon” fiber layer tends to drip down rather than form a bond to the needled tuft pile unless the fusing is carried out upside down, in which case, the melted layer reduces the flexibility of the carpet formed.
[0007] U.S. Pat. No. 4,579,763 to Mitman discloses a process for forming densified tufted carpet tiles by shrinking the primary backing. The backing is made from polyolefin and is tufted with carpet yarn pile. The structure is heated to a temperature not less than 300° F. to heat shrink the primary backing so that the carpet yarn pile is captured. Since the backing contracts by as much as 130 percent, the overall dimension of the carpet is not preserved. Furthermore, shrinkage along various directions is dependent on thermal cycles during processing and thus produces non-uniform carpets. The capturing of tufted carpet pile yarn is not reliable, and a secondary backing is needed to assure that the tufted carpet yarn is held in place.
[0008] U.S. Pat. No. 4,705,706 to Avery discloses a tufted carpeting having stitches thermally bonded to a backing. The back-loops of the stitches of tufted carpet pile yarn are fastened to the backing by thermal bonding thereby obviating the need for the application of an adhesive coating to the underside of the backing. The tufted pile yarn incorporates a low melting polymer such as polyethylene and the underside of the tufted carpet is heated to melt the low melting polymer in the yarn pile. The melting of the low melting polymer creates a bond between the carpet yarn pile and the primary backing. This requires the incorporation of a large quantity of the low melting polymer in the tufted carpet fiber yarn, and only those low melting polymer fibers present on the surface of the tufted carpet yarn contribute to the bonding process. Disadvantageously, the presence of unmelted polyethylene fiber in the carpet yarn reduces its carpet feel and spring back characteristics.
[0009] U.S. Pat. Nos. 5,532,035 and 5,630,896 to Corbin et al. (herein the '035 and '896 patents) disclose a recyclable thermoplastic tufted fabric and a method of making recyclable tufted carpets, respectively. The recyclable thermoplastic tufted fabric is made of a partially meltable primary backing and tufts of yarn tufted into the primary backing. The tufts are bonded to the backing by partially melting the primary backing to bond the tufts. A secondary backing having a similar composition to the primary backing is applied so that the carpet can be recycled. The '035 and '896 patents teach away from the use of dissimilar polymeric materials for bonding a carpet pile yarn to the primary backing. Also, it is the primary backing fibers that melt to create a bond, but such melting creates holes surrounding the tufted fibers with only localized bonding and this bond cannot effectively secure the tufted yarn. The disclosure addresses use of polyester carpet fiber yarn tufted into a primary backing that includes polyester yarn with a low melting polyester composition of heterofil or homofil polyester binder fiber that can be melted during a heating cycle to create a bond between tufted carpet yarn and the primary backing. No low melting backing compositions are provided in the disclosure for nylon-based carpet or a polypropylene based carpet.
[0010] U.S. Pat. No. 5,536,551 to Woosley discloses a method for binding tufts using a mixture of high melting and low melting fibers in the backing and the tufted carpet pile yarn. The high-melt filaments are preferably polyester or nylon and the low-melt filaments are preferably polypropylene or polyethylene. Heating the carpet melts the low melting fiber in the primary backing as well as the tufted caret pile, creating a bond between the primary backing and the tufted carpet yarn. Unfortunately, heating the carpet completely bonds the tufted carpet yarn at the face of the carpet thereby making the carpet fibers stiff, and reducing or eliminating the soft pliable characteristics of the carpet produced. The drawing shows bonding of the carpet fibers approaching about one-third of its pile length.
[0011] U.S. Pat. No. 5,538,776 to Corbin et al. (herein the '776 patent) discloses a carpet containing a hot melt polyester layer. Specifically, the '776 patent discloses a thermoplastic tufted carpet made of a polyester primary backing. Polyester fibers are tufted into the primary backing and secured through application of a poly(butylene terephthalate) polyester hot melt adhesive followed by a polyester secondary backing. As a result, the tufted fibers are disposed between the primary and secondary backing. The carpet is comprised entirely of polyester. Such a carpet can be recycled through processes known to recycle polyester including glycolysis or methanolysis. The recyclable carpet is comprised of polyester fibers tufted into a polyester primary backing, a polyester secondary backing and a poly(butylene terephthalate) hot melt adhesive, effectively adhering the polyester tufted primary backing and the polyester secondary backing. This approach does not eliminate the secondary backing, and results in a stiff, difficult to bend carpet. In addition, the '776 patent teaches away from the use of dissimilar polymeric materials for bonding a carpet pile yarn to the primary backing.
[0012] U.S. Pat. No. 5,604,009 to Long et al. discloses a non-adhesive bonded tufted carpet and method for making the same. The non-wet processed tufted carpet includes a plurality of face yarns. These face yarns are tufted into and through a primary backing fabric. A secondary backing fabric is applied to more securely hold the yarns in place. However, no adhesive binder is used. The secondary backing fabric locks the face yarns in place upon the application of heat to a non-wet surface of the secondary backing fabric non-adjacent to the primary backing fabric. Preferably, the carpet uses mixtures of high and low melting polymers, including nylon and polypropylene, for the tufted yarns, the primary backing, and the secondary backing. As a result, the tufted yarn is trapped and secured within the primary and the secondary backing when the tufted carpet is processed through a heating cycle that melts the low melting polymer. This process does not eliminate the need for a secondary backing. Furthermore, the melting of the tufted yarns, the primary backing, and the secondary backing fibers results in a substantially rigid carpet with limited flexibility. Moreover, the melting of the tufted carpet yarn face fibers results in a poor carpet feel, since the fibers become stiff.
[0013] U.S. Pat. No. 5,660,911 to Tesch discloses a tufted carpet and a process for producing the same. The tufted carpet yarn is passed through sections of a polyethylene sheet placed behind the primary backing. Thereafter tufting, heat is applied in the form of warm rolling. This heat melts the polyethylene sheet, bonding the back ends of the tufted carpet yarn to the primary backing. A secondary backing sheet may also be employed in order to retain the tufted carpet fiber. Where the secondary backing sheet is used the sections of the polyethylene sheet are bonded to the secondary and the primary backing, thereby entrapping the back ends of the tufted yarn. The bond is only created between the very back end of the tufted yarn and the primary backing mat since the polyethylene sheet is placed on the underside of the primary mat. As a result, the adhesive is not present between the tufted yarn and the primary mat yarn, creating a very weak bond between the tufted yarn and the primary backing. A secondary backing is relied on to secure the tufted yarn, thereby reducing the flexibility of the carpet.
[0014] U.S. Pat. No. 5,925,434 to Phillips et al. discloses tuftable backing and carpet construction. Serrated tuftable backing material is coated with a thin layer of polyethylene so that the tufted fibers can be bonded to the serrated backing tape by thermal processing, which melts the thin polyethylene layer. The thermoplastic serrated tape yarn comprises at least 85 weight percent polypropylene, wherein at least 50 percent of the yarns in the woven fabric are serrated with a thermoplastic polymeric layer adhered to the fabric. The thermoplastic serrated tape yarn of the backing material with a melted adhesive layer limits the flexibility of the carpet. The adhesive is only present between the back ends of the yarn and the serrated tape and it is not between the backing and the tufted fiber. As a result, the bond strength of the tufted fiber is limited.
[0015] U.S. Pat. Nos. 6,060,145 and 6,344,254 to Smith et al. (herein the '145 and '254 patents) discloses a modified secondary backing fabric, a method for the manufacture thereof and a carpet containing the same. A primary backing is bonded using latex to bond the tufted carpet yarn and to attach the modified secondary backing. The use of scrim in the secondary backing provides a softer back and improved flexibility. The '145 and '254 patent disclosures eliminate neither the latex bonding procedure nor the secondary backing material.
[0016] U.S. Published Patent Application No. US 2003/0211280 to Brumbelow et al. discloses a carpet, carpet backings and methods of making them. The contemplated carpet tile includes a primary backing, a plurality of fibers attached to the primary backing and extending into the back surface of the primary backing, an adhesive backing placed at the back surface of the primary backing, and an optional secondary backing adjacent to the adhesive backing. The adhesive backing is made from a homogeneously branched linear ethylene polymer. The method includes extrusion coating of the homogeneously branched linear ethylene polymer onto the back surface of a primary backing to provide an adhesive backing. The method of making the carpet comprises attaching tufted yarn to a primary backing material with an adhesive backing material. The adhesive backing material is composed of a first ethylene polymer layer with a higher melt index that is in intimate contact with the back surface of the primary backing material. This layer substantially penetrates and consolidates the yarn. An optional second ethylene polymer layer with a lower melt index may be applied to the first ethylene polymer layer directly onto the back side of the primary backing material. This second ethylene polymer layer is applied, together with an optional secondary backing, and is heated to fabricate a carpet tile. The adhesive polymer is a maleic anhydride grafted ethylene copolymer. The carpet is heated to melt the first, and optionally the second adhesive layer. This is a construction method for manufacture of carpet tile, not a carpet. The adhesive layer of meltable polymeric material is present below the underside of the primary backing and, as a result, any bonding between the tufted yarn and the primary backing only occurs at the backside of the tufted yarn. No adhesive is present between the primary backing yarn and the tufted fiber. As a result, a secondary backing mat is used to firmly anchor the tufted yarns in the carpet tile.
[0017] Notwithstanding the advances in the field of primary backing mats and related carpet manufacturing methods, there remains a need in the art for a readily bendable, flexible, light weight carpet that retains tufted carpet yarn effectively with superior tufted yarn pull out resistance.
SUMMARY OF THE DISCLOSURE
[0018] The present invention provides a primary backing mat, woven or non-woven, having individual mat fibers that are substantially coated with particles of a thermoplastic polymer material that has a melting point lower than that of the mat fibers. This coating process may be accomplished by spraying an aqueous dispersion of thermoplastic polymer particles onto the woven or non-woven primary backing mat and drying the mat to form the coating. Alternatively, the coating process may be accomplished by electrostatic coating. The thermoplastic polymer particles cover substantially the exterior surface of the mat fibers and are bonded in place by electrostatic charge or Van der Waal forces. This bond can be enhanced by subjecting the coated primary backing mat to a temperature sufficient to soften the thermoplastic polymer particles and make them tacky. The coated primary mat is supplied to carpet tufting machines wherein carpet yarn having a melting temperature greater than that of the thermoplastic polymer particles is needled into the openings or apertures between the primary backing mat fibers. The tufted primary backing mat is then subject to a post needling process wherein it is heated to a temperature sufficient to change the state of or melt the thermoplastic polymer particles. As a result of the melting of the polymer particles, a permanent bond is created between the tufted carpet yarn and the fibers of the primary backing mat. Since the fibers of the primary backing mat carry the thermoplastic polymer particles on the surface, these thermoplastic polymer particles are present between the tufted carpet yarn and the mat fiber. This intimate presence provides a complete bond that encircles the primary backing mat fiber, providing high pull out strength for tufted carpet fibers. The single step heating operation provides a carpet that does not require any or only a reduced quantity of a latex adhesive or secondary backing on the underside of the carpet. As a result, the carpet is lightweight and is highly bendable and is capable of being installed with ease around tight corners and stairways. The melted and solidified thermoplastic polymer is only present between the tufted carpet yarns and the mat fiber is free to bend in between the tufted carpet yarns.
[0019] Key requirements are that the mat fibers and the carpet tufted yarn have a higher melting temperature than that of the thermoplastic polymer particles that are applied as a coating to the primary backing mat fibers. Several combinations satisfy this requirement. Polyethylene thermoplastic polymer particles can be applied on primary backing mat fibers selected from one or more of nylon 6, nylon 6,6, nylon 6,10, nylon 6,11, polyester, polypropylene, and jute. The molecular weights of the thermoplastic polymer particles are selected so as to well facilitate melt flow upon the application of heat. The carpet yarn fibers may be selected from a list comprising nylon 6, nylon 6,6, polyester, polypropylene, wool, or combinations of these. However, when polypropylene thermoplastic polymer particles are used to coat the primary backing mat fibers, all fiber combinations recited above may be used, except polypropylene mat and polypropylene carpet tufting yarns cannot be used.
[0020] A unique method and means are thereby provided for constructing a carpet without the use of a latex adhesive or a second backing mat or through the use of a latex adhesive in a reduced quantity. The carpet construction facilitates enhanced bonding of the tufted carpet yarns so that they are held securely in place. Carpet constructed in accordance with the present invention has readily bendable and flexible properties that are lacking in carpets heretofore devised and utilized. As a result, carpet constructed using the method and means of the invention can be more easily installed around tight corners, such as stairs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention will be more fully understood and further advantages will become apparent when reference is had to the following detailed description of preferred embodiments of the invention and the accompanying drawings, in which:
[0022] FIG. 1 is a schematic diagram depicting a conventional carpet construction;
[0023] FIG. 2 is a schematic diagram depicting a carpet construction in accordance with the invention; and
[0024] FIG. 3 is a schematic diagram depicting a carpet construction showing a carpet primary backing having enhanced tufting and tuft securing characteristics immediately after post heat treatment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] Carpets are routinely manufactured by tufting carpet yarn through the interstices of a woven or non-woven primary backing mat. The needling operation passes continuous or discontinuous staple yarn through the interstices of the backing mat, creating the carpet facing. The ability of the tufted yarns to be held within the primary backing mat is strongly related to the spring back characteristics of the primary backing mat. The spring back properties are a strong function of the primary backing mat's yarn type and weave pattern. The carpet is moved from the tufting station to a second station that applies an adhesive latex layer on the underside of the tufted primary mat. Frequently, after the tufting process, but before the latex adhesive has been applied, the tufts are susceptible to dislodgment from the primary backing. In such cases, rework is required between these steps to reinsert any tufts that were dislodged before the latex adhesive is applied. Traditionally, the latex application is burdensome, since it requires compounding, removing water, curing, and finally cooling. A secondary backing mat is generally applied under the primary mat to contain the latex adhesive and to securely trap the tufted carpet yarn. The use of the latex adhesive and the secondary backing mat increases the cost to manufacture the carpet. Furthermore, the use of the latex adhesive and the secondary backing mat results in a heavier carpet that is reflected in the cost of transporting the carpet. Lastly, the use of the latex and secondary backing yields a less bendable carpet that cannot be easily installed on stairs or around tight corners.
[0026] The present invention addresses the problems and costs associated with requiring the application of a substantial quantity of separate latex adhesive and the use of a secondary backing mat during carpet manufacturing. The present invention provides a primary backing for a carpet, which changes state via a post process and becomes an adhesive layer that permanently bonds the carpet fibers in place. Generally stated, the invention relates to a primary backing for a carpet that provides good gripping of the carpet fibers without the need of a substantial quantity of an adhesive layer, such as latex, or use of a secondary backing mat. The primary backing mat is constructed with high melting mat fibers that are bonded with lower melting polymeric particulate matter incorporated on its surface. The primary backing mat is tufted with carpet yarn, whereby the lower melting polymeric particles are placed in between the tufted carpet yarn and the primary backing mat fiber. During the post thermal heating process the underside of the carpet is heated to a temperature sufficient to change the state of the low melting polymeric particles. The low melting polymeric particles melt and completely surround the primary backing mat fiber, thereby capturing the tufted carpet yarn. When the carpet is cooled, the low melting polymer solidifies and thereby acts as an adhesive, providing complete contact of the tufted yarn loop with the primary backing mat fiber. This bond strength is sufficient to provide pull out resistance of the tufted carpet yarn, avoiding or reducing the need for a latex adhesive or a second backing mat. Since the adhesive is only present between the primary backing mat yarn and the tufted carpet yarn, the fabricated carpet is thin, lightweight, and is highly flexible.
[0027] The low melting polymeric particulate coating may be selected from a number of polymeric types. Low density polyethylene melts at a temperature of approximately 115° C. (e.g., approximately 115 to 120° C.) while high density polyethylene melts at a temperature of approximately 135° C. (e.g., approximately 135 to 140° C.). Polypropylene melts at temperatures of approximately 160° C. (e.g., approximately 160 to 175° C.). Nylon 6 has a melting temperature of approximately 210 to 220° C., while nylon 6,6 has a melting temperature of approximately 225 to 265° C. Also, jute fibers do not readily melt. Therefore, there are a number of combinations of high melting backing fibers that may be coated with the lower melting polymeric particulate matter. For example, a polypropylene backing fiber may be coated with particles of low or high-density polyethylene. Nylon 6 or 6,6 backing fibers may be coated with low or high-density polyethylene particles or polypropylene particles. A jute backing fiber may be coated with low- or high-density polyethylene particles or polypropylene particles or nylon 6 or 6,6 particles. The post heat treatment temperature must be chosen so that the coated polymeric particles melt to create a bonding adhesive. Also, the tuft fiber must be chosen so that it does not melt at the post heat treatment temperature. The tufted fiber yarn may be wool, cotton, nylon 6 or nylon 6,6 or polypropylene, and combinations of these. The lower melting polymeric particulate coating may be readily chosen based on the selection of the post heat treatment temperature. One of the unique characteristics of low or high-density polyethylene particles is that they readily bond to nylon 6 or nylon 6,6 fibers when melted. This unique characteristic defines a preferred combination of nylon backing fibers coated with low- or high-density polyethylene particulate matter tufted with nylon pile yarn. When polyethylene is used, the post heat temperature can be at approximately 115° C. or 135° C., depending on whether the polyethylene is low- or high-density.
[0028] The lower melting polymeric matter may be coated on the high melting primary backing fibers using processing steps selected from a number of options. The high melting fibers may be woven, knitted, or non-woven to define a backing mat and the lower melting polymeric particulate matter may be dispersed as a suspension in a liquid carrier and sprayed to coat the backing. The liquid carrier may be evaporated by heating. Alternatively, a dry powder coating of the low melting polymeric powder may be applied using an electrically charged sprayer. In this embodiment the woven or non-woven mat of fibers are charged with an electrostatic charge, and the thermoplastic particles are charged with an opposite charge and are distributed in an air stream that passes adjacent the charged mat so as to deposit the thermoplastic particles on the mat. In a second embodiment, the coated primary backing fiber mat may be heated to tack the lower melting polymeric particles to the high melting fiber. The resultant primary backing mat may be supplied as a roll for tufting of pile fibers to form a carpet.
[0029] The following advantages are made possible by the present invention: (i) elimination or reduction of the wet latex adhesive application process; (ii) immediate in-line adhesion of tufted yarn fibers to the backing after post heat treatment, resulting in less defects and need to rework; (iii) reduction of energy costs customarily needed to drive off a substantial quantity of latex water and cure; and (iv) overall improvement of process speeds that can be increased to the speed of the tufting machines. The end result provides the desired advantages of a lightweight, flexible carpet, while avoiding the undesired defect/re-work characteristics of the current carpet manufacturing process.
[0030] The key features associated with the enhanced carpet primary backing include, in combination: (i) a high melting carpet primary backing mat; (ii) the high melting backing mat fibers is covered with a coating of lower melting thermoplastic polymer particles; (iii) the carpet tufting yarn is needled into openings in between fibers of the primary backing mat; (iv) the resulting construction is subjected to a post process that melts the lower melting thermoplastic polymer particle coating of the primary backing mat to form an adhesive that bonds the tufted yarn with the backing; (v) the resulting construction is cooled; (vi) the adhesive forms a permanent bond between the carpet yarn and the primary backing; (vii) the need for a separate latex adhesive is reduced or is obviated, and (viii) the need for a carpet secondary backing is reduced or is completely obviated.
[0031] The primary backing mat may be made from a single polymeric composition or mixtures of polymeric compositions including weave patterns that use dissimilar yarns in the weaving process or use twisted or braided yarns of different polymeric compositions.
[0032] Referring to FIG. 1 of the drawings, there is shown generally at 10 a schematic diagram depicting a conventional carpet construction. Carpet 10 consists of: (i) a primary backing; (ii) carpet fibers tufted into the primary backing; (iii) an additional latex adhesive wet-applied to the back side of the primary backing; and (iv) a secondary backing. The carpet yarns 12 are tufted into the primary backing 11 , wherein the cross-sections of the individual fibers of the primary backing are shown as darkened circles. The tufted yarn carpet forms a loop at 15 . The backing is coated with an adhesive layer 14 and is held by a secondary backing 13 .
[0033] Referring to FIG. 2 there is shown generally at 20 a schematic diagram depicting the carpet primary backing having enhanced tufting and tuft securing characteristics immediately after tufting. At this stage of the carpet manufacturing process, the construction comprises: (1) a primary backing created with high melting fibers that are coated with lower melting polymeric particulate matter; and (ii) carpet fibers tufted into the primary backing with the lower melting polymeric particulate matter resident in between the tufted yarn and the high melting fibers of the backing. A carpet primary backing having enhanced tufting and tuft securing characteristics, in the as-tufted condition, is shown at 20 . Carpet yarns 12 are tufted into the primary backing 11 , wherein the cross-sections of the individual fibers of the primary backing 11 are shown as darkened circles. Primary backing 11 is coated with lower melting polymeric particles, shown at 17 . Tufted carpet yarns 12 form a loop 15 , which may encircle the primary backing 11 , coated with low melting polymeric particles 17 as shown. Alternatively, the tufted carpet yarns 12 may be a free dangling loop (not shown). After the carpet yarns 12 are tufted into the primary baking 11 , coated with lower melting polymeric particles 17 , the resultant carpet is taken to a post heat treatment station. The post heat treatment station may be in line or off line, and is set at the required temperature to melt the lower melting polymeric particles 17 . As the low melting polymeric particles 17 melt, an adhesive is formed, which permanently bonds the tufted carpet yarns 12 to the primary backing 11 . The heating may be conveniently applied at 18 , as shown.
[0034] Referring to FIG. 3 there is shown generally at 30 a schematic diagram depicting the carpet primary backing having enhanced tufting and tuft securing characteristics immediately after post heat treatment. At this process stage, the construction consists of: (i) a primary backing with high melting fibers coated with melted lower melting polymeric particulate matter; and (ii) carpet fibers tufted and permanently bonded into the primary backing. The carpet primary backing having enhanced tufting and tuft securing characteristics is shown in the as tufted and post heat treated condition 30 . Carpet yarns 12 are tufted into the primary backing 11 , wherein the cross-sections of the individual fibers of the primary backing are represented by darkened circles. Primary backing 11 is coated with melted lower melting polymeric particles, shown at 17 . Tufted carpet yarns 12 form a loop at 15 , which may encircle the primary backing 11 coated with lower melting polymeric particles 17 , as shown. Alternatively, the tufted carpet yarns 12 may be a free dangling loop (not shown). The melted lower melting polymeric particles 17 form a permanent bond between the tufted carpet yarns 12 and the primary backing 11 . The entire loop 15 of the tufted carpet yarns 12 encircles the primary backing 11 with melted and solidified lower melting polymeric particles 17 therein between.
[0035] The carpet primary backing having enhanced tufting and tuft securing characteristics is produced by a method comprising the steps of (i) selecting fibers for a primary backing mat that are higher melting polymeric materials; (ii) manufacturing the primary backing mat either by weaving or using non-woven mat preparation processes; and (iii) coating each mat fiber with lower melting polymeric particles. The lower melting polymeric particles may be bonded to the primary backing mat by electrostatic forces or Van der Waal type forces. The bond between the lower melting polymeric particles and the primary backing mat fibers may be improved by subjecting the coated primary backing mat to a temperature sufficient to make the particles sticky and tacks the particles without melting. The primary backing is subjected to carpet yarn tufting followed by a post heat treatment. The post heat treatment changes the state of the lower melting polymeric particles, causing the particles to adhere and permanently bond the tufted carpet yarns to the primary backing mat.
[0036] Having thus described the invention it is to be understood that such detail need not be strictly adhered to, but that additional changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the following claims.
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A primary carpet backing is provided for use in the formation of a tufted carpet which eliminates or reduces the need for a latex adhesive layer or the use of a secondary backing. The external surfaces of a woven or non-woven fibrous mat are coated with thermoplastic polymer particles having a lower melting temperature than the fibers of the mat. The mat possesses sufficient openings between fibers to be capable of undergoing tufting. Following tufting the tufted mat is heat treated so as to melt the thermoplastic polymer particles and to create a bond between the tufted carpet yarn fibers and the primary backing mat.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/434,669, filed Jan. 20, 2011.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to oral hygiene devices, and more particularly to an orthodontic flosser for flossing teeth and/or teeth with braces with relative ease.
[0004] 2. Description of the Related Art
[0005] Oral hygiene is a vital component in maintaining strong and healthy teeth. Lack thereof can lead to gingivitis, periodontal disease, demineralization and fracturing of the teeth enamel.
[0006] The above effects are more susceptible in orthodontic patients who have dental appliances such as braces. The metal wires and brackets of the orthodontic appliance traps food debris, plaque and biofilm, which thereby build up on teeth and under the gum line, causing tooth decay and gingivitis. Flossing is one method that helps reduce such an occurrence, but majority of the available flossing devices are not user-friendly for those with orthodontic appliances. It would be a benefit in the art of orthodontic devices to provide a flossing device that may be easily used by both orthodontic patients and others.
[0007] Thus, an orthodontia flosser solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0008] The orthodontia flosser includes a floss head integrally attached to an elongate handle. The handle includes a finger depression at the attachment juncture to facilitate ergonomic gripping of the orthodontia flosser for use thereof. The floss head includes a pair of arms extending perpendicular to the handle. A recess in each arm supports floss therebetween and maintains the floss in a taut condition. The arms are of a size to reach under the wires of braces.
[0009] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an environmental, perspective view of an orthodontia flosser according to the present invention.
[0011] FIG. 2 is a perspective view of the orthodontia flosser according to the present invention.
[0012] FIG. 3 is a side view of the orthodontia flosser according to the present invention.
[0013] FIG. 4 is a partial side view of the orthodontia flosser of FIG. 3 , the head being broken away and partially in section to show details thereof.
[0014] FIG. 5 is a perspective view of an alternative embodiment of an orthodontia flosser according to the present invention.
[0015] FIG. 6 is a rear view of the orthodontia flosser shown in FIG. 5 .
[0016] FIG. 7 is a top view of the orthodontia flosser shown in FIG. 5 .
[0017] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The present invention relates to an orthodontia flosser, generally referred to in the drawings by reference number 10 , for flossing teeth with relative ease. Initially, it is noted that the orthodontia flosser 10 has been configured to assist orthodontia patients to floss in a manner that overcomes the encumbrance of dental appliances such as braces. However, anyone can use the orthodontia flosser 10 with similar ease.
[0019] As shown in FIGS. 1-4 , the orthodontia flosser 10 includes an elongated handle 12 attached to a floss head 16 . The handle 12 is preferably integral with the floss head 16 . However, the orthodontia flosser 10 may be configured so that the floss head 16 is detachable. In this manner, the floss head 16 may be easily disposed and replaced with a new one and vice versa with respect to the handle 12 .
[0020] The handle 12 is long and slightly curved so as to be comfortably grasped by the user. The handle 12 is substantially rectangular in cross section that gradually flattens out towards the bottom half of the handle 12 . The flattened area provides an ergonomic area where the palm of the user can rest while gripping the handle 12 . The top of the handle 12 also includes an elongate finger depression 14 at a corner thereof, which extends from the juncture between the head 16 and the handle 12 a short distance clown towards the distal end. The finger depression 14 is ideally located to permit the user to place a finger or thumb thereon. This ergonomic feature permits the user to maneuver the floss head 16 into operative position and floss between the teeth T with relative ease.
[0021] The floss head 16 may be a substantially U-shaped body having a base 18 and a pair of arms 20 extending therefrom. The floss head 16 is attached to the handle 12 at the base 18 , and the arms 20 extend perpendicularly therefrom. Each arm 20 includes a recess, notch, or depression 22 at its free or distal end upon which floss 24 may be internally threaded and supported thereon in a similar manner to a bow. In fact, the floss 24 may be manufactured so that a substantial portion of the ends of the floss 24 is embedded inside the respective arms 20 . In this manner, the floss 24 is stretched between the arms 20 to keep the same taut for use.
[0022] The following describes how to use the orthodontia flosser 10 . The handle 12 is placed comfortably in the hand of the user. The floss head 16 is guided to enter between the teeth T from the lingual or tongue side. One of the arms 20 should be placed over and on the bracket side or the outer side of the tooth at the interproximal junction. The floss head 16 is pushed downward and upward to gently slide the floss 24 between the teeth T and under the gum. Backward and forward and an upward and downward motion is used against the edge of the teeth T to remove food debris and plaque from the teeth T and gums. When finished, the used floss or contaminated orthodontia flosser 10 can be properly disposed of. If desired, the orthodontia flosser 10 can be reused by disposing of contaminated floss, then washing the used flosser with water and mild soap and allowed to dry prior to reuse. The ease of handling and use permitted by the orientation of the head 16 and the finger depression 14 helps to reduce and prevent dental caries, enamel fractures and gingivitis.
[0023] An alternative embodiment of the orthodontia flosser 100 is shown in FIGS. 5-7 . In this embodiment, the orthodontia flosser 100 includes additional ergonomic features for ease of preparation and use. Moreover, the orthodontia flosser 100 is configured to be reusable, if desired.
[0024] As shown, the orthodontia flosser 100 includes an elongated handle 112 attached to a floss head 116 . The handle 112 is preferably integral with the floss head 116 . However, the orthodontia flosser 100 may be configured so that the floss head 16 is detachable. In this manner, the floss head 116 may be easily disposed and replaced with a new one and vice versa with respect to the handle 112 .
[0025] The handle 112 is long and slightly curved with an enlarged area near the floss head 116 so that the handle 112 may be comfortably grasped by the user. The handle 112 is substantially rectangular in cross section and gradually flattens out towards the bottom half of the handle 112 . The flattened area provides an ergonomic area where the palm of the user can rest while gripping the handle 112 . The top of the handle 112 also includes an elongate depression where a plurality of finger ridges or protrusions 114 are formed thereon. These finger ridges 114 form a gripping means that enhance grip for the user's finger or thumb during the course of using the orthodontia flosser 100 . The depression is formed at the juncture between the head 116 and the handle 112 and extends a short distance down towards the distal end. The finger ridges 114 are ideally located to permit the user to place a finger or thumb thereon.
[0026] The floss head 116 may be a substantially U-shaped body having a yoke or bifurcated base 118 and a pair of arms 120 extending therefrom. The floss head 116 extends from the handle 112 at the base 118 , and the arms 120 extend perpendicularly therefrom. Each arm 120 includes an L-shaped groove or channel 122 upon which floss 124 may be threaded and supported thereon in a similar manner to a string on a bow. The portion of the groove 122 extending to the tip end of each arm 120 forms prongs, ensuring that the floss 124 threaded thereon will not slip.
[0027] To facilitate winding of the floss 124 , each arm 120 includes a recess or depression 128 , and a binding post 126 extends outwardly from the recess 128 . One end of the floss 124 is wound on one of the binding posts 126 and threaded through the groove 122 on the respective arm 120 . The rest of the floss 124 is threaded through the groove 122 on the other arm 120 , and the other end of the floss 124 is secured to the other binding post 126 . The floss 124 is stretched and held taut between the arms 120 in this manner, and the tautness thereof is determined by how tightly the user winds the ends of the floss 124 around the binding posts 126 and the grooves 122 . The orthodontia flosser 100 is now ready for use in a manner similar to the orthodontia flosser 10 described above.
[0028] As shown in FIGS. 5 and 7 , the recesses 128 each provide space for the user's fingers to ease securing of each end of the floss 124 . In addition, each binding post 126 includes an enlarged head or cap 127 at the distal end to prevent the floss end from sliding out of secure engagement with the binding post 126 .
[0029] It is to be understood that the orthodontia flossers 10 , 100 encompass a variety of alternatives. For example, the orthodontia flossers 10 , 100 are preferably made from lightweight plastic. However, other materials such as lightweight, nonporous, food grade composites, steel, wood, or a combination thereof may also be used. Moreover, the orthodontia flosser 10 , 100 may include a variety of colors and indicia.
[0030] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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The orthodontia flosser includes a floss head integrally attached to an elongate handle. The handle includes a finger depression at the attachment juncture to facilitate ergonomic gripping of the orthodontia flosser for use thereof. The floss head includes a pair of arms extending perpendicular to the handle. A recess in each arm supports floss therebetween and maintains the floss in a taut condition. The arms may be dimensioned to reach under the wires of bracers.
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Be it known that we, Christoph Menzenbach, a citizen of Germany, residing in Neustadt/Wied, Germany; Heiko Böhme, a citizen of Germany, residing in Vettelschoss, Germany; Cyrus Barimani, a citizen of Germany, residing in Königswinter, Germany; and Güer Hähn, a citizen of Germany, Residing in Königswinter, Germany have invented a new and useful “Stabilizer Or Recycle”.
This application claims benefit of German Patent Application DE 10 2009 008 884.9, filed Feb. 14, 2009.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a stabilizer or recycler which has a rotor housing, in which a milling/mixing rotor is arranged, and a unit for discharging binder for soil or base material stabilization.
2. Description of the Prior Art
To improve or consolidate soils or base materials, it is known for a binder in powder form, such as lime or cement for example, to be introduced into the soil or base material to increase the ability to be laid or load-bearing capacity thereof. Typical applications for soil or base material stabilization are the building of roads or railways or surfaces for industrial use.
There are known stabilizers or recyclers by which the binder can both be discharged onto the soil or base material and introduced into the soil or base material directly after being discharged. The introduction of the binder immediately after being discharged has the advantage that the binder cannot be blown away. It is therefore possible for the civil engineering machine to operate with little dust.
Basically, the known stabilizers or recyclers which do not have binder spreaders can be operated in the forward and backward directions. However, stabilizers or recyclers which do have a binder spreader have only one direction of working because the binder is always intended to be discharged ahead of the milling/mixing rotor. Therefore, what will be referred to in what follows is the direction of working of the type of stabilizer or recycler which is fitted with a binder spreader.
The known stabilizers or recyclers have running gear which supports a chassis. The running gear has wheels which are at the front and rear in the direction of working, and the rotor housing which holds the mill/mixing rotor is arranged between these. As well as this, the known stabilizers or recyclers also have a drive unit which comprises not only the driving engine but also other sub-units which are required for driving the civil engineering machine itself and for driving the milling/mixing rotor. These include for example hydraulic pumps to operate hydraulic motors by which the wheels of the self-propelled civil engineering machine are driven.
The unit for discharging the binder of known stabilizers or recyclers has a supply container for the binder and a metering arrangement for metering the binder. There are known stabilizers or binders in which the metering arrangement has one or more rotary feeders of the compartmented rotor type.
A characteristic feature of the known stabilizers or recyclers is that the rotor housing containing the milling/mixing rotor is arranged on the chassis of the machine between the front or rear wheels, the binder being discharged ahead of the milling/mixing rotor in the direction of working. As well as this, another characteristic feature of the known stabilizers or recyclers is that the supply container for the binder is arranged mainly ahead of the milling/mixing rotor in the direction of working.
EP 1 012 396 B1 describes a stabilizer or recycler which has a unit for discharging binders. The funnel-shaped supply container for the binder has a lower sub-section which is arranged between the front wheels and the milling and mixing rotor, and an upper sub-section which is arranged above the milling and mixing rotor. The rotary feeder of the compartmented rotor type for metering the binder is arranged at the outlet of the lower sub-section of the supply container.
SUMMARY OF THE INVENTION
In designing stabilizers or recyclers having a unit for discharging binder, the problem arises of accommodating on the one hand the drive unit for the civil engineering machine and on the other hand the supply container for the binder in or on the chassis of the machine. Factors which play a part in this case are not only the limited physical dimensions of the civil engineering machine but also the weight of the drive unit. Because the supply container is relatively high in weight when filled with binder, the weight distribution of the civil engineering machine is determined mainly by where the supply container is arranged on the chassis of the machine.
When the binder is being discharged, the problem of exact metering arises, because the desired amount spread is intended to be maintained regardless of the speed of travel of the civil engineering machine. In known rotary feeders of the compartmented rotor type which are generally used in stabilizers or recyclers, the compartmented rotor, as it rotates, transports the binder to a drop-through opening from which the binder drops downwards under the prompting of gravity. The rate of flow of the binder depends on the volume of the compartments and how densely filled they are and on the speed of revolution of the compartmented rotor of the rotary feeder which is doing the metering. Metering of high volumetric accuracy presupposes that the density of the bulk material is constant at all times, so that the compartmented rotor is always equally densely filled.
However, with a stabilizer or recycler whose rotary feeder of the compartmented rotor type is arranged below a funnel-shaped supply container, it is not possible to ensure that the compartmented rotor is always equally densely filled as the container empties. For example, when the container is still full, a considerably larger mass of binder rests on the compartmented rotor than when the container is already almost empty, which means that it has to be assumed that the binder is of different densities when the container is still full and when it is almost empty. This can cause inaccuracies in the metering.
The object underlying the invention is to provide a stabilizer or recycler which is of simplified structural design and whose weight distribution is improved.
In a civil engineering machine according to the invention at least part, and in particular the larger part, of the supply container for the binder, i.e. the part of the container of larger volume for receiving the binder, is arranged to the rear of the milling/mixing rotor in the direction of working.
It is not absolutely necessary for the entire supply container to be situated to the rear of the milling/mixing rotor in the direction of working. However, at least that part of the supply container which is of the larger volume should be arranged to the rear of the milling/mixing rotor. A part of the milling/mixing rotor may also be arranged above the milling/mixing rotor in this case. Preferably, the center of gravity of the supply container is arranged to the rear of the axis of rotation of the milling/mixing rotor in the direction of working.
The special way in which the supply container is arranged gives an optimum weight distribution. Whereas the supply container, which is relatively heavy when filled with binder, is situated mainly to the rear of the milling/mixing rotor, the drive unit of the civil engineering machine can be arranged ahead of the milling/mixing rotor. The drive unit may in this case be arranged to the rear of a driver's position arranged at the front end of the civil engineering machine or it may be arranged ahead of a driver's position arranged in the center of the machine. There is enough space available to accommodate all the sub-units of the drive unit in this region of the chassis of the machine ahead of the milling/mixing rotor. The region of the chassis of the machine to the rear of the milling/mixing rotor, which is generally shorter than the region ahead of the milling/mixing rotor, still provides enough space for the supply container to be arranged in this case. Because the weight of the supply container, when filled with binder, is greater than that of the drive unit, the proportions which the parts of the machine ahead of and to the rear of the milling/mixing rotor represent of the length of the machine result in an optimum weight distribution. With the supply container and drive unit arranged in this way between the front and rear wheels, the center of gravity is situated in the region of the milling/mixing rotor, which is something that is aimed for in practice.
Even though the supply container is situated to the rear of the milling/mixing rotor in the civil engineering machine according to the invention, the binder is still discharged ahead of the milling/mixing rotor. The arrangement for the emergence of the binder is therefore arranged ahead of the milling/mixing rotor in the direction of working. The binder may also be discharged into the rotor housing in this case. The arrangement concerned may be an arrangement which is used in general in the known stabilizers or recyclers. The binder may for example emerge from a funnel-shaped enclosure which is fitted with an anti-dust arrangement.
A preferred embodiment of the invention makes provision for the supply container to have an outlet which is provided on a sub-section of the supply container which is at the front in the direction of working. When the supply container is of a funnel-shaped form, the outlet should be situated on an upper sub-section of the supply container. The metering arrangement for metering the binder may be arranged directly below the outlet of the supply container. Because, when the supply container is filled with binder, the column of binder which is situated above an outlet on the upper sub-section of the supply container is, overall, smaller than the column which would be situated above an outlet on the lower sub-section of the supply container, there are smaller variations in the density of the binder which is fed to the metering arrangement. Any variations in the density of the binder which would lead to inaccuracies in metering can therefore be largely ruled out.
To feed the binder to the metering arrangement, the unit for discharging binder preferably has a feeding means by which the binder can be fed even from the bottom sub-section of a funnel-shaped supply container to the upper sub-section thereof.
The feeding means for feeding binder may take different forms. In a preferred embodiment, the feeding means has at least one scraper-flight conveyor which has flights driven by chains or belts to feed the binder. The scraper-flight conveyor has the advantage that the binder can be fed over the entire working width of the civil engineering machine. An alternative embodiment provides one or more feed screws as the feeding means. However, what may be provided in place of scraper-flight conveyors or feed screws is also a pneumatic feeding means or some other feeding means familiar to the person skilled in the art. Such scraper-flight conveyors, feed screws, pneumatic feeding means, and the like, may all be generally referred to as conveyors.
In a further preferred embodiment, the feeding means, such for example as the scraper belt or feed screw, is arranged at least partly inside the supply container so that the feeding means and container form a common sub-assembly.
The supply container preferably takes the form of a funnel-shaped container, thus enabling the binder to collect and be received on the floor of the container. The supply container may for example have a floor which is formed by parts of the body of the container which taper obliquely towards one another and which extend across part of the working width of the machine or the entire working width thereof. However, parts of the side-walls too may taper obliquely towards one another. Basically however, it is also possible for the supply container to have a flat floor.
An embodiment which is a particular preference makes provision for the supply container to have a sub-section at the front in the direction of working which is arranged above the milling/mixing rotor and to have a sub-section at the rear in the direction of working which is arranged above the rear wheels or running-gear units, while a central sub-section extends between the milling/mixing rotor and the rear wheels or running-gear units. The rear section of the supply container may end before the axis of the rear wheels or may also extend to a point beyond the axis of the rear wheels.
The central sub-section of the supply container preferably comprises a lower sub-section which is situated at a relatively low level and in which the binder can collect. Consequently, the container is of a maximum depth in the region between the milling/mixing rotor and the rear wheels or running-gear units and the center of gravity of the supply container is thus situated approximately in this region.
In the embodiment in which the metering arrangement on the supply container is arranged in particular below the outlet of the supply container, the unit for discharging binder has a transporting means to feed the binder leaving the metering arrangement to the arrangement from which the metered binder emerges ahead of the milling/mixing rotor. The binder is preferably fed by gravity. The transporting means may for example be a gravity chute.
An alternative embodiment makes provision for the metering arrangement to be arranged not directly below the outlet of the supply container but at the arrangement for the emergence of the binder. This embodiment has the advantage that the distance which the binder has to cover after being metered out is relatively short, thus enabling a particularly high accuracy of metering to be achieved.
The metering arrangement for metering the binder preferably has at least one rotary feeder of the compartmented rotor type. It is also possible for a plurality of rotary feeders of the compartmented rotor type to be provided which are arranged one behind the other, in the longitudinal direction of the rotary feeders of the compartmented rotor type, across the entire working width of the civil engineering machine. Individual rotary feeders of the compartmented rotor type may also be arranged to be staggered relative to one another in the longitudinal direction of the civil engineering machine in this case. All the rotary feeders of the compartmented rotor type should be capable of being switched on individually. Basically, it is however also possible for the metering of the binder to be performed with means other than one or more rotary feeders of the compartmented rotor type, which other means are known from the prior art.
For the metering arrangement to be fed as evenly as possible, it is of advantage for a means to be provided of distributing the binder in a direction extending transversely to the longitudinal direction of the chassis of the machine. The means of distributing the binder is preferably a distributing screw arranged transversely to the chassis of the machine. It is however also possible for a plurality of distributing screws to be arranged one behind the other in the longitudinal direction of the distributing screws. Individual distributing screws may also be arranged to be staggered relative to one another in the longitudinal direction of the stabilizer or recycler in this case.
Because the supply container for binder is relatively large in volume, which means that its heightwise and/or widthwise dimensions are relatively large, special consent may be needed if the civil engineering machine is to be driven or transported on public roads. An effort is therefore made for the overall height and/or width of the supply container to be as small as possible, though this does limit the use of the civil engineering machine.
Regardless of where the supply container is arranged, this problem is solved by designing the supply container to be a container whose volume is variable. When the supply container is not full of binder, the said container can be reduced to a size at which there is not then any need for consent for transportation. The height and/or width of the machine for transport purposes can be reduced in this way.
In a preferred embodiment of the variable volume supply container, the body of the container comprises a top and a bottom part which can be displaced relative to one another. The connection between the top and bottom body parts may for example be designed after the fashion of a telescope. However, to increase its volume, additional rigid body parts may also be fitted into the supply container, e.g. between the top and bottom body parts.
In an embodiment which is a particular preference, the top and bottom body parts are connected together by a bellows which is compressed together and spread apart like a concertina to respectively reduce and enlarge the volume. Suitable drives may be provided for this purpose such for example as hydraulic or pneumatic drives or electric adjusting motors.
When the stabilizer or recycler is being manufactured, the problem also arises that stabilizers or recyclers are used which do or do not have a binder spreader which has a supply container for the binder. There is however a desire for a retrofittable binder container which can be fitted to an existing platform.
A preferred embodiment of the invention therefore makes provision for the supply container to take the form of a binder tank which can be inserted in the chassis of the machine. The civil engineering machine can thus be supplied with or without a binder tank. The supply container may thus form either an integral part of the chassis of the machine or an exchangeable unit.
An alternative embodiment makes provision for at least part of the walls of the supply container to be formed by parts of the chassis of the machine, and in particular at least parts of the side-walls of the supply container may be formed by parts of the chassis of the machine. At least parts of the front and rear walls of the supply container may also be parts of the chassis of the machine. In this embodiment the top part and/or bottom part of the body of the supply container may take the form of parts which can be fitted to the chassis of the machine, thus enabling the supply container to be produced retrospectively simply by the fitting of the top or bottom parts of the body of the supply container to the existing chassis of the machine. Because parts of the supply container are already parts of the chassis of the machine, relatively few parts are needed for the supply container to be installed.
A number of embodiments of the invention will be described in detail below by reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a highly simplified schematic view of a first embodiment of self-propelled civil engineering machine according to the invention,
FIG. 2 shows the stabilizer or recycler shown in FIG. 1 , with the supply container for the binder extended to increase its volume,
FIG. 3 shows a further embodiment of stabilizer or recycler according to the invention,
FIG. 4 shows a further embodiment of stabilizer or recycler according to the invention,
FIG. 5 shows a further embodiment of stabilizer or recycler,
FIG. 6 shows a further embodiment of stabilizer or recycler.
DETAILED DESCRIPTION
FIG. 1 is a highly simplified schematic view showing the main components of a self-propelled stabilizer or recycler. This civil engineering machine has a chassis 1 which is supported by running gear 2 . The running gear 2 has two wheels 3 which are at the front in the direction of working and two wheels 4 which are at the rear in the direction of working, which wheels are fastened to front and rear lifting pillars 5 , 6 . The front and rear lifting pillars 5 , 6 , which can be operated independently of one another, are in turn fastened to the chassis 1 of the machine, thus enabling the height of the chassis of the machine relative to the ground to be adjusted. It is also possible for running-gear units, such for example as running-gear units having rubber tracks, to be provided in place of the wheels 3 , 4 . Either the wheels or the tracks may be generally referred to as running gear units.
In the present embodiment, the driver's position 7 of the stabilizer or recycler is arranged, on the chassis of the machine, ahead of the front wheels 3 in the direction of working (direction of travel). Between the front and rear wheels 3 , 4 is a rotor housing 8 in which is arranged a milling/mixing rotor 9 (not shown in detail) which rotates on an axis extending transversely to the longitudinal direction of the chassis 1 of the machine. The milling/mixing rotor may for example be driven mechanically or hydraulically. The milling/mixing rotor is provided with tools (not shown) to enable work to be done on the ground. The rotor housing 8 for the milling/mixing rotor 9 , which takes the form of a hood, has adjustable flaps 8 A and 8 B at the front and rear in the direction of working. To allow the depth of milling to be set, the milling/mixing rotor 9 can be adjusted in the heightwise direction on pivoting arms 11 which are hinged to the chassis 1 of the machine between the front wheels 3 and the milling/mixing rotor 9 .
Arranged on the chassis 1 of the machine, to the rear of the driver's position 7 and between the front wheels 3 and the milling/mixing rotor 9 is the drive unit 12 of the stabilizer or recycler, which comprises an internal combustion engine (not shown in detail) and other sub-units, such for example as clutches, hydraulic pumps, etc., which are used to drive the hydraulic motors (not shown) for the front and rear wheels 3 , 4 and to drive the milling/mixing rotor 9 . All these components are combined into a unit which is situated between the front wheels 3 and the milling/mixing rotor 9 . In the event of the driver's position being arranged in the center of the machine, the drive unit is situated ahead of the driver's position in the direction of working.
The stabilizer or recycler according to the invention has a unit 13 for discharging binder in powder form, such as lime or cement for example, which is to be introduced into the soil or base material which is milled up immediately after the milling up.
The unit 13 for discharging binder comprises a supply container 14 to receive the binder, a metering arrangement 15 for metering the binder and an arrangement 20 from which the metered binder emerges above the ground at a point ahead of the milling/mixing rotor 9 in the direction of working. The individual components of the unit 13 for discharging binder will be explained in detail below.
In the present embodiment, the supply container 14 for the binder takes the form of a binder tank which can be inserted in the chassis 1 of the machine. The binder tank thus forms an exchangeable unit.
Whereas the drive unit 12 is arranged on the chassis 1 of the machine ahead of the milling/mixing rotor 9 in the direction of working, the supply container 14 is arranged on the chassis of the machine to the rear of the drive unit in the direction of working. Consequently, the drive unit 12 and supply container 14 are separated from one another in space, thus enabling the individual components of the two units to form respective units in space, which simplifies the structural design.
With regard to its arrangement on the chassis 1 of the machine, the supply container 14 is divided into the following sub-sections. The supply container 14 has a sub-section 14 A which is at the front in the direction of working and which is arranged above the milling/mixing rotor 9 , and it has a sub-section 14 B which is at the rear in the direction of working and which is arranged above the rear wheels 4 . The central sub-section 14 C of the supply container 14 extends between the milling/mixing rotor 9 and the rear wheels 4 . The center of gravity A of the supply container 14 is situated between the milling/mixing rotor 9 and the rear wheels 4 of the stabilizer or recycler, and in particular to the rear of the axis of rotation 10 of the milling/mixing rotor 9 .
In the present embodiment, the supply container 14 is a metal container in the form of a funnel which has a lower sub-section 14 D in which the walls of the supply container taper towards one another obliquely, and an upper sub-section 14 E. At that end of the upper sub-section 14 E which is at the front in the direction of working, the supply container 14 has an outlet 14 F for the binder.
In the present embodiment, the metering arrangement 15 for metering the binder, which has an inlet 15 A and an outlet 15 B, is situated directly below the outlet 14 F of the supply container 14 . The metering arrangement 15 may form a separate sub-assembly, or it may be part of the supply container so that the metering arrangement can be exchanged together with the supply container. The metering arrangement 15 may also be referred to as a metering feeder.
To feed the binder from the floor of the supply container 14 in its lower sub-section 14 D to the outlet 14 F of the container 14 in its upper sub-section 14 E, use is made of a feeding means 16 which is arranged inside the container. In the present embodiment the feeding means 16 is a scraper-flight conveyor which extends across the entire working width of the stabilizer or recycler and by which the binder is fed along the floor part 14 G of the supply container 14 , which floor part 14 G extends obliquely to the direction of working, to the outlet 14 F. Scraper-flight conveyors of this kind are part of the prior art.
The scraper-flight conveyor 16 feeds binder continuously to the outlet 14 F of the supply container 14 , which is situated at a higher level, and the binder then drops into the inlet 15 A of the metering arrangement 15 . The binder which emerges from the outlet of the metering arrangement 15 is fed by a transporting means 17 to the arrangement 20 from which the metered binder is then sprinkled out onto the ground. The transporting means 17 is a chute which extends downwards obliquely in the direction of working and which connects the outlet of the metering arrangement 15 to the arrangement 20 from which the binder emerges. Instead of one chute, it is also possible for a plurality of chutes to be arranged, distributed transversely to the longitudinal direction of the civil engineering machine. The individual chutes may for example each be formed by a tube or a hose. The arrangement 20 for the emergence of the binder is an enclosure extending across the working width of the machine which is open at the bottom. There may be provided on the enclosure an anti-dust arrangement in the form of hanging flaps, though these are merely indicated. The arrangement 20 for the emergence of binder may also be referred to as a discharge enclosure.
In the present embodiment, the metering arrangement 15 comprises a rotary metering feeder which extends across the working width of the machine and which has a rotating compartmented rotor 15 C to meter the binder. Rotary feeders of the compartmented rotor type of this kind are part of the prior art. What may however also be provided rather than one rotary feeder of the compartmented rotor type are a plurality of rotary feeders of the compartmented rotor type which are arranged one behind the other transversely to the direction of working. What may be provided are for example three rotary feeders of the compartmented rotor type which can be operated separately from one another and which each cover a third of the overall width. Rather than three rotary feeders of the compartmented rotor type, one rotary feeder of the compartmented rotor type may also be provided which is fed with binder over only a predetermined part of the working width. The working width may be varied with for example adjustable flaps or metal plates which are able to confine the binder.
Because the present arrangement allows the metering arrangement 15 to be supplied continuously with material to fill it of constant density, a particularly high volumetric accuracy of metering is obtained for the binder.
In the present embodiment, the body of the supply container 14 for the binder comprises a bottom part 14 H and a top part 14 I which are connected together with a seal by a bellows 14 J, thus making the volume of the body of the container variable. FIG. 1 shows the position in which the bellows is compressed together after the fashion of a concertina. When this is the case, the stabilizer or recycler is of only a small overall height.
FIG. 2 shows the case where the bellows 14 J is extended, thus making available a substantially larger volume of space for the binder. Special consent might have to be obtained for the transport of the civil engineering machine solely because of its height when transported and this may not be necessary when the bellows is collapsed. A volume of space of for example 10 m 3 is available for the operation of the machine when the supply container 14 is in the extended position.
FIG. 3 shows an alternative embodiment of stabilizer or recycler according to the invention which differs from the embodiment which has been described by reference to FIGS. 1 and 2 in the arrangement of the metering arrangement 15 . Whereas in the embodiment shown in FIGS. 1 and 2 the metering arrangement 15 is situated directly underneath the outlet 14 F of the supply container 14 , in the embodiment shown in FIG. 3 the metering arrangement 15 is arranged directly above the arrangement 20 from which the binder emerges. Hence the metering arrangement 15 is situated at the bottom end of the gravity chute 17 . Otherwise the two embodiments do not differ from one another. Those parts which correspond to one another are therefore also identified by the same reference numerals.
FIG. 4 shows a further alternative embodiment of the stabilizer or recycler, which differs from the embodiment which was described by reference to FIGS. 1 and 2 in that a feed screw 16 is provided in place of a scraper-flight conveyor to feed the binder to the outlet 14 F of the supply container 14 . Feed screws of this kind are familiar to the person skilled in the art. Instead of only one feed screw, it is also possible for a plurality of feed screws to be provided which are arranged to be distributed across the working width of the machine. Because, in contrast to a conveyor belt, binder can be fed over only a limited part of the working width with a feed screw, the alternative embodiment has a means 18 by which the binder dropping from the feed screw 16 can be distributed over the whole of the working width of the civil engineering machine, or over a part of its working width, before it drops into the metering arrangement 15 . The arrangement for distributing the binder is preferably a distributing screw 18 which is arranged above the inlet 15 A of the metering arrangement 15 and whose longitudinal axis extends transversely to the longitudinal direction of the chassis 1 of the machine. Those parts which correspond to one another are once again identified by the same reference numerals. A means of this kind for distributing the binder in the transverse direction may however also be of advantage in the embodiments which have a scraper-flight conveyor ( FIGS. 1 to 3 ), to obtain a supply to the metering arrangement which is as even as possible across the whole of the working width.
FIG. 5 is a view from the side showing a further embodiment of stabilizer or recycler which differs from the embodiments described above in that the supply container 14 for the binder does not form an exchangeable unit but is an integral part of the chassis 1 of the machine. In this present embodiment, at least part of the bottom part 14 H of the body of the supply container 14 is part of the chassis 1 of the machine, the chassis 1 of the machine forming the two side-walls 15 K of the bottom part of the body. The front and rear walls of the supply container 14 , which cannot be seen in FIG. 5 , may also be part of a transverse reinforcing structure of the chassis 1 of the machine.
In the rear part of the stabilizer or recycler, its chassis 1 is so designed that the top part 14 I of the body of the container can be placed down on the chassis 1 by the bellows 14 J. The top part 14 I of the body of the supply container thus forms the lid thereof. At the underside, the chassis of the stabilizer or recycler is so formed in the rear part of the latter that a part 14 L of the body of the supply container 14 which forms the floor thereof can be fitted to the side-walls 15 K of the chassis. It is possible in this way for civil engineering machines of the kind mentioned to be delivered with or without a supply container.
In the view from the side, FIG. 5 also shows components of the civil engineering machine which cannot be seen in FIGS. 1 to 4 , such for example as the hydraulic cylinder arrangements 19 , although these are of no significance for the purposes of the present invention.
FIG. 6 shows an embodiment of stabilizer or recycler which differs from the embodiments described above in that what the supply container 14 has is not a floor part which extends obliquely in the direction of working but a floor part 14 G which is horizontal in the direction of working when the civil engineering machine is standing on horizontal ground. Consequently, in this embodiment the outlet 14 F of the supply container 14 is not situated at a higher level than the floor part thereof when the civil engineering machine is standing on horizontal ground. Hence the scraper-flight conveyor 16 too extends in the horizontal direction. The scraper-flight conveyor 16 , which extends across the entire working width of the civil engineering machine, feeds the binder continuously to the outlet 14 F of the supply container 14 , from which the binder drops via the gravity chute 17 into the outlet 15 A of the metering arrangement 15 , the outlet 15 B of which latter is arranged above the arrangement 20 from which the binder finally emerges ahead of the milling/mixing rotor 9 . In this respect the embodiment shown in FIG. 6 corresponds to the embodiment shown in FIG. 3 . In other respects too the two embodiments do not differ from one another. Those parts which correspond to one another are therefore once again identified by the same reference numerals.
In the embodiment shown in FIG. 6 there may be provided, instead of a supply container 14 having a floor to its body which extends across the entire working width of the civil engineering machine, a supply container the floor of whose body has a flat portion which continues into portions extending obliquely upwards in a direction transverse to the longitudinal direction of the civil engineering machine. In an embodiment of this kind, what suggests itself for use as a feeding means 16 rather than a scraper-flight conveyor is a feed screw which extends in the longitudinal direction of the machine above the flat portion of the floor.
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The invention relates to a stabilizer or recycler which has a rotor housing 8 , in which a milling/mixing rotor 9 is arranged, and a unit 13 for discharging binder for soil or base material stabilization. In the civil engineering machine according to the invention, at least part of the supply container 14 for the binder, and in particular the part thereof which is of larger volume, is arranged to the rear of the milling/mixing rotor 9 in the direction of working. The center of gravity A of the supply container 14 is preferably arranged to the rear of the axis of rotation 10 of the milling/mixing rotor 9 in the direction of working. This special way in which the supply container is arranged gives an optimum weight distribution. Whereas the supply container 14 , which is relatively heavy when filled with binder, is situated mainly to the rear of the milling/mixing rotor 9 , the drive unit 12 of the civil engineering machine can be arranged ahead of the milling/mixing rotor. With the supply container and drive unit arranged in this way between the front and rear wheels 3, 4 , the center of gravity of the civil engineering machine is situated in the region of the milling/mixing rotor 9 , which is something that is aimed for in practice.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a virtual LAN system and, particularly, to a virtual LAN system in which a virtual LAN is constructed every protocol.
2. Description of Related Art
In order to construct a plurality of virtual LAN's every protocol indicative of communication procedures in a virtual LAN system of this kind, it has been usual, as disclosed in Japanese Patent Application Laid-open No. Sho 64-54954, to determine a protocol higher in level than a network layer of OSI reference model used in a communication every LAN (referred to as "upper protocol", hereinafter) such that a communication is possible in a LAN according to only the determined protocol.
The term "virtual LAN" in this description means a LAN which services a host terminal by connecting the host terminal to the LAN through not a physical port of the host terminal but a logical connection.
Further, in order to enable the host terminal to belong to a plurality of virtual LAN's, virtual LAN's to which the host terminal can belong are preliminarily registered in a virtual server for controlling the construction of the virtual LAN's and a connection is made to the virtual LAN server by assigning the virtual LAN to be used in a communication when the host terminal starts the communication.
Since such conventional virtual LAN system determines the upper protocol to be used in a communication every LAN in order to construct a plurality of virtual LAN's every protocol indicative of the communication procedures, a communication within the LAN must be performed by using only this protocol. Therefore, there is a problem that the host terminal can not perform communication by using a plurality of upper protocols within the connected LAN. Further, since, in order to enable the host terminal to belong to a plurality of virtual LAN's, virtual LAN's to which the host terminal can belong are preliminarily registered in a virtual server for controlling the construction of the virtual LAN's and a connection is made to the virtual LAN server by assigning the virtual LAN to be used in a communication when the host terminal starts the communication, there is another problem that can not use other virtual LAN's than the virtual LAN to which the connection is made.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a virtual LAN system in which a host terminal can perform communication by using a plurality of upper protocols within a LAN to which the host terminal is connected and can use other virtual LAN's than a virtual LAN to which a connection is made.
In the virtual LAN system according to the present invention, a plurality of virtual LAN's are provided in each of which a communication is performed between ports in a port group including a plurality of ports which communicate with each other by using the same protocol.
Further, the virtual LAN system according to the present invention which uses an intelligent switching hub device including a plurality of ports and a frame switch for outputting a frame to one of the ports according to a destination MAC (Media Access Control) address indicative of the one port as a destination and contained in the frame received by one of the ports, is featured by that the frame switch comprises a port table having pointers A indicative of next tables corresponding to the respective ports, a plurality of protocol ID tables produced correspondingly to the pointers A of the respective port tables and having pointers B indicative of respective next tables corresponding in number to protocols which can be communicated with the ports corresponding to the respective pointers A, a plurality of virtual LAN data tables produced for respective virtual LAN's preliminarily determined in the frame switch and having pointers C indicative of respective next tables appointed by the pointers B in the protocol ID tables and a port information indicative of the ports belonging to the respective virtual LAN's and a plurality of MAC forwarding tables produced correspondingly to the respective pointers C in the virtual LAN data tables and having port numbers of the ports corresponding to the respective pointers A and produced correspondingly to transmitting MAC addresses contained in the frame received by the ports corresponding to the pointers A in the port tables and indicative of transmitters and a count value of a counter for continuously counting from a time at which the port numbers are registered.
Further, the virtual LAN system according to the present invention which uses an intelligent switching hub device including a plurality of ports and a frame switch for outputting a frame to one of the ports according to a destination MAC address indicative of the one port as a destination and contained in the frame received by one of the ports, is featured by that the frame switch receives the frame at one of the ports, searches the pointer A from the port table according to the number of the port which received the frame, searches the pointer B from the protocol ID table indicated by the pointer A according to a protocol ID indicative of the kind of protocol contained in the received frame and used in the frame communication, extracts the pointer C from the virtual LAN data table indicated by the pointer B, searches the MAC forwarding table indicated by the pointer C according to the transmitting MAC address contained in the received frame and, when there is a constructive component of the MAC forwarding table corresponding to the transmitting MAC address, sets the port number of the received frame to the port number of the constructive component and resets the count value of the timer of the constructive component, newly registers the port number in the MAC forwarding table correspondingly to the transmitting MAC address when there is no constructive component, searches the MAC forwarding table indicated by the pointer C using the destination MAC address contained in the frame and, when there is a constructive component of the MAC forwarding table corresponding to the destination MAC address, sends the received frame to the port indicated by the port number of the searched constructive component, and sends the received frame to all of the ports indicated by the port numbers which can communicate by the virtual LAN indicated by the port information in the virtual LAN table having the pointers C indicated by the MAC forwarding table when there is no constructive component.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment of a virtual LAN system according to the present invention;
FIG. 2 shows a construction of a frame switch;
FIG. 3 shows a port information indicative of a port belonging to a virtual LAN; and
FIG. 4 shows a construction of a frame.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Now, preferred embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a block diagram showing an embodiment of a virtual LAN system according to the present invention. In this embodiment, the virtual LAN system, which uses an intelligent switching hub device 1 comprising a plurality of ports 3 which include physical ports which can be physically connected or logical ports which can be logically connected and a frame switch 2 for outputting a frame 9 to one of the ports 3 according to a destination MAC (Media Access Control) address indicative of the one port as a destination and contained in the frame 9 received by one of the ports 3, is featured by that the frame switch 2 comprises a port table 4 having pointers A indicative of next tables corresponding to the respective ports 3, a plurality of protocol ID tables 5 produced correspondingly to the respective pointers A and having pointers B indicative of respective next tables, a plurality of virtual LAN data tables 6 produced for respective virtual LAN's preliminarily determined in the frame switch 2 and having pointers C indicative of respective next tables and a port information 8 indicative of the ports 3 belonging to the respective virtual LAN's and a plurality of forwarding tables 7 produced correspondingly to the respective pointers C in the virtual LAN data tables 6 and having port numbers of the ports 3 corresponding to the respective pointers A and a count value of a counter for continuously counting from a time at which the port numbers are registered. Incidentally, the MAC is a control using a MAC sub-layer among data link layers of a hierarchical model of LAN.
An operation of the virtual LAN system according to this embodiment will be described in detail with reference to FIGS. 2, 3 and 4.
FIG. 2 shows a construction of the frame switch. The frame switch 2 comprises the port table 4 having pointers A indicative of next tables corresponding to the respective ports 3, the plurality of the protocol ID tables 5 produced correspondingly to the respective pointers A and having pointers B indicative of respective next tables the number of which corresponds to the number of the protocols according to which the ports 3 corresponding to the pointers A can communicate, the plurality of the virtual LAN data tables 6 produced for respective virtual LAN's preliminarily determined in the frame switch 2 and having the pointers C indicative of respective next tables and the port information 8 indicative of the ports 3 belonging to the respective virtual LAN's and the plurality of the forwarding tables 7 produced correspondingly to the respective pointers C in the virtual LAN data tables 6 and having the port numbers of the ports 3 corresponding to the respective pointers A and the count value of the timer for continuously counting from the time at which the port numbers are registered.
FIG. 3 shows an example of the port information indicating a port belonging to the virtual LAN. The shown port information indicates that the ports P2, P3, P5 and Pn of the n ports 3 belong to the virtual LAN.
FIG. 4 shows an example of a construction of the frame 9 which is composed of the destination MAC address indicative of a destination of the frame 9, the transmitting MAC address indicative of a transmitter of the frame 9, the protocol ID indicative of a protocol which defines the communication procedures used in the communication of this frame 9, a packet indicative of a content of the communication using the frame 9 and FCS indicating a code for checking the frame 9.
In FIG. 1, the frame switch 2 of the intelligent switching hub device 1 receives the frame 9 at one of its ports 3 and searches the pointer A from the port table 4 according to the number of the port which received the frame 9 as shown in FIG. 2. According to the protocol ID indicative of the kind of the protocol contained in the received frame 9, used in the communication of the frame 9 and shown in FIG. 4, the pointer B is searched from the protocol ID table 5 indicated by the pointer A, as shown in FIG. 2. Then, as shown in FIG. 2, the pointer C is extracted from the virtual LAN data table 6 indicated by the pointer B and the MAC forwarding table 7 indicated by the pointer C with using the transmitting MAC address contained in the received frame 9 and shown in FIG. 4. When there is the constructive component of the MAC forwarding table 7 corresponding to the transmitting MAC address, the number of the port which received the frame 9 is set to the port number of the searched constructive component and the count value of the timer of this constructive component is reset. When there is no constructive component, the number of the port 3 is newly registered in the MAC forwarding table 7 correspondingly to the transmitting MAC address as the port number. In this case, the port number and the count value of the timer corresponding to this port number and continuing the counting from the time at which the port number is registered become the constructive components of the MAC forwarding table 7. Then, the MAC forwarding table 7 indicated by the pointer C is searched by using the destination MAC address contained in the frame 9 and shown in FIG. 4 and, when there are constructive components of the MAC forwarding table 7 corresponding to the destination MAC address, the frame 9 received at the port 3 having the port number of the searched constructive components is sent. When there is no constructive component, the received frame 9 is sent to all of the ports 3 which are indicated in the port information 8 shown in FIG. 3 and contained in the virtual LAN data table 6 having the pointer C indicating the MAC forwarding table 7 and are enabled to communicate by the virtual LAN. When the count value of the timer among other constructive components produced in the MAC forwarding table 7 correspondingly to the transmitting MAC address contained in the frame 9 received by the port 3 and indicative of the transmitter exceeds a predetermined value, the constructive component corresponding to the transmitting MAC address is deleted from the MAC forwarding table 7.
As described hereinbefore, according to the virtual LAN system of the present invention, a protocol ID table is provided every part for defining a protocol according to which the port can communicate. Therefore, a communication is possible according to a plurality of upper protocols by using a port.
Further, since a virtual LAN data table is provided which makes a virtual LAN to which the frame belongs passible to define by a protocol ID contained in a received frame, it is possible to join other virtual LAN's than a connection is provided.
Further, since, in a case where a destination MAC address in the received frame is not learnt (indicating that there is no constructive component corresponding to this MAC address registered in the MAC forwarding table), the frame is transmitted to only ports which can communicate through a virtual LAN corresponding to a protocol ID which is indicated in the port information of the virtual LAN data table and corresponds to the protocol ID in this frame. Therefore, there are only frames in the virtual LAN, which are to be communicated with according to a protocol corresponding to the virtual LAN, so that an intra-LAN communication can be performed with high transmission efficiency without unnecessary load on the virtual LAN.
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By providing a plurality of virtual LAN's such that ports communicating according to one protocol are grouped and communication is performed between the ports in the group, a communication is possible according to a plurality of protocols and it is possible to enter into other virtual LAN's than a virtual LAN to which a connection is made.
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FIELD
[0001] The present invention relates generally to fenestration assemblies. More particularly, the present invention relates to fenestration assemblies that effectively secure substrates, such as energy-efficient window films.
BACKGROUND
[0002] Fenestration means products that fill openings in a building envelope, such as windows, doors, skylights, curtain walls, etc., that are designed to permit the passage of air, light, vehicles, or people. A building envelope, in turn, generally refers to the separation between the interior and the exterior environments of a building. It serves as the outer shell to protect the indoor environment as well as to facilitate its climate control.
[0003] In order to increase a building's energy efficiency, and to decrease the loads on a building's air conditioning and heating systems, fenestration assemblies are used to cover the interior of a building's window frame cavity with transparent window film. By way of example, using such a window/film combination in the winter season causes interior light to reflect back inside, trapping a relatively greater amount of heat inside the building envelope. Conversely, in the summer season, a relatively large amount of exterior light is reflected back to the exterior of the building, allowing cooler temperatures to prevail inside the building envelope.
[0004] What is therefore needed are energy-efficient systems and methods that reduce the load on air conditioning units regulating the temperature inside the building envelope in an economical, time-efficient, and effective.
SUMMARY
[0005] In one aspect, the present teachings provide a fenestration assembly. The fenestration assembly includes: (1) a base frame capable of having secured thereon a substrate; (2) a tensioner capable of engaging with the base frame such that when the base frame has secured thereon the substrate, the tensioner places the substrate under tension relative to the base frame. Preferably, the substrate is window film, and is more preferably a transparent window film.
[0006] In preferred embodiments of the present teachings, the tensioner includes a male member and the base frame includes a female region, and when the tensioner engages with the base frame, the male member occupies and contacts at least a portion of the female region. The male member may include a protruding region having one or more crimps thereon, the female region surrounds and has defined therein a cavity region, which has serrations thereon, and in an engaged position of the tensioner with the base frame, the crimps on the protruding region are disposed adjacent to the serrations of the cavity region. Further, the tensioner may comprise a substrate grip that is capable of gripping the substrate when the base frame engages with the tensioner. The base frame may comprise a substrate tape bed and the substrate grip grips the substrate when the base frame engages with the tensioner.
[0007] In certain embodiments of the present arrangements, the tensioner comprises one or more nipples capable of applying tension to the substrate when the base frame engages with the tensioner. In some of these embodiments, the base frame comprises a sloped region, and the one or more nipples is disposed proximate to the slope region when the base frame engages with the tensioner. In this configuration, the sloped region forces the substrate, which is disposed between the base frame and the tensioner, toward the tensioner. This facilitates disposing a stable and/or requisitely tense substrate between the tensioner and the base frame. In certain aspects of the present arrangements, the base frame includes a tension enhancer that enhances the tension when the substrate is disposed between the base frame and the tensioner.
[0008] Preferably, the base frame also includes a compressible material track capable of receiving compressible material, which compresses and expands when the fenestration assembly is being installed inside a window frame cavity. In alternate embodiments of the present arrangements, however, the tensioner includes a compressible material track capable of receiving compressible material, which compresses and expands when the fenestration assembly is being installed inside a window frame cavity. Thus, the compressible material track may be part of the base frame or part of the tensioner.
[0009] In another aspect, the present teachings disclose a process for building a fenestration assembly. The process includes: (1) placing a substrate on a base frame, and (2) engaging and/or mating a tensioner with the base frame such that the tensioner places the secured substrate in tension relative to the base frame. Preferably, the placing is carried out by taping the substrate to the base frame. More preferably, taping includes adhering the substrate to a tape bed area on the base frame.
[0010] In preferred embodiments of the present arrangements, the above-described process includes applying an additional force to the tensioner and/or the base frame to facilitate the engaging and/or mating of the base frame and the tensioner. Applying, as mentioned above, may be carried out using at least one device chosen from a group comprising hammer, roller, and presser.
[0011] In another aspect, the present teachings provide a process of building a fenestration assembly. The process includes: (1) building a base frame having a cambered profile; (2) placing a substrate on the base frame; (3) transforming the cambered profile of the base frame to a non-cambered profile; and (4) engaging and/or mating a tensioner with the base frame having a non-cambered profile. Preferably, transforming includes applying an external force to transform from the cambered profile to the non-cambered profile, and further includes ceasing to apply the external force after engaging and/or mating the tensioner with the base frame.
[0012] The construction and method of operation, however, together with additional objects and advantages thereof will be best understood from the following descriptions of specific embodiments when read in connection with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows a side-sectional view of a tensioner, according to one preferred embodiment of the present arrangements, used to grip and apply tension to a substrate when the present fenestration assembly is in an assembled state.
[0014] FIG. 2 shows a side-sectional view of a base frame, according to one preferred embodiment of the present arrangements, used to secure a substrate when the present fenestration assembly is in an assembled state.
[0015] FIG. 3 shows a side-sectional view of a fenestration assembly in an assembled state, according to one preferred embodiment of the present arrangements, having secured thereon a substrate.
[0016] FIG. 4 shows a side-sectional view of a tensioner, according to an alternate embodiment of the present arrangements, capable of holding a compressible material, and used to grip and apply tension to a substrate when the fenestration assemblies of the present teachings are in an assembled state.
[0017] FIG. 5 shows a side-sectional view of a base frame, according to an alternate embodiment of the present arrangements, that the tensioner of FIG. 4 engages with in an assembled state of the two components.
[0018] FIG. 6 shows a side-sectional view of a base frame, according to another alternate embodiment of the present arrangements, that includes a tension enhancer.
[0019] FIG. 7 shows a top view of a base frame, according to one preferred embodiment of the present arrangements, which transforms from a cambered profile to a non-cambered profile.
[0020] FIG. 8 shows a front view of an assembled window frame according to one preferred embodiment of the present arrangements.
[0021] FIG. 9 shows a flowchart showing a process, according to one embodiment of the present teachings, for assembling fenestration assemblies of the present arrangements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] In the following description numerous specific details are set forth in order to provide a thorough understanding of the present teachings. It will be apparent, however, to one skilled in the art that the present teachings may be practiced without limitation to some or all of these specific details. In other instances, well known process steps have not been described in detail in order to not unnecessarily obscure the present teachings.
[0023] The present teachings provide a fenestration assembly that is used for securing substrates, such as transparent window film, for energy efficiency applications. The present teachings also offer a process for assembling such fenestration assemblies. In preferred embodiments, the present fenestration assemblies include a tensioner and a base frame, both of which engage and/or mate with each other, to secure firmly a substrate therebetween.
[0024] FIG. 1 shows a side-sectional view of a tensioner 100 , according to one preferred embodiment of the present arrangements, for gripping and applying tension to a substrate. Tensioner 100 is one component of a fenestration assembly, which in an assembled state (shown below with reference to FIG. 3 ), is used to increase energy efficiency when installed over an opening or a window frame cavity of a building. Preferably, the substrate is window film, and is more preferably a transparent window film. When installed, the present fenestration assembly provides significant reduction in transmission of heat through an opening or a window frame cavity, resulting in increased energy efficiency and decreased loads on a building's heating and air conditioning systems.
[0025] Tensioner 100 includes an endcap 102 disposed at a first end and an endcap 110 disposed at a second end. A protruding nipple 104 a and protruding nipple 104 b are each disposed adjacent to endcap 102 , preferably proximate to a middle of a length of tensioner 100 . A protruding male member 108 is disposed adjacent to endcap 110 . A film grip region 106 is disposed between nipple 104 b and male member 108 .
[0026] Endcap 102 and endcap 110 are designed to cap tensioner 100 at each end. The function of endcap 102 and endcap 110 , in certain embodiments of the present arrangements, is largely aesthetic, providing smooth edges that are more pleasing to the viewer when the present fenestration assembly is installed over an opening or a window frame cavity.
[0027] Though the embodiment of FIG. 1 shows endcap 102 and endcap 110 each with an L-shaped configuration, the present teachings recognize that alternate shapes may be employed for each or either of endcap 102 and endcap 110 . By way of example, endcap 102 or endcap 110 may each or both be fabricated as a straight edge. In the L-shaped configuration shown in the embodiment of FIG. 1 , a portion of endcap 102 relatively perpendicular to the tensioner preferably extends outwardly between about 0.04 inches and about 0.06 inches from the base of the tensioner, though certain other embodiments of the present arrangements have a variance of up to about 75% of these values. Preferably, endcap 102 does not directly contact a substrate when the fenestration assemblies of the present teachings are in an assembled state. A portion of endcap 110 relatively perpendicular to tensioner 100 outwardly extends between about 0.05 inches and about 0.07 inches from the base of tensioner 100 , though certain other embodiments of the present arrangements have a variance of about 75% of these values. Alternate embodiments of the present arrangements use different lengths and different sizes for each of endcaps 102 and 110 , and some embodiments do not require use of an endcap.
[0028] Nipple 104 a and nipple 104 b are each a protruding portion of tensioner 100 designed to increase tension of a substrate, according to preferred embodiments of the present arrangements, when the fenestration assemblies are in an assembled state. As will be explained in more detail below, in an assembled state of the fenestration assemblies, protruding nipples 104 a and 104 b each push a portion of a secured substrate, creating additional tension in the substrate. The additional tension in the substrate offers a tighter fit, which provides a relatively transparent, glare-free, and more aesthetically pleasing window film when the present fenestration assemblies are installed. Though FIG. 1 shows a tensioner that includes two nipples, the present teachings contemplate use of any number of nipples to increase or decrease window film tension to desired levels. In alternate embodiments of the present teachings, however, a nipple is not used. Though the embodiment of FIG. 1 shows nipples 104 a and 104 b each extending at an approximately 90° angle from the length of tensioner 100 , the present teachings recognize that nipples 104 a and 104 b may extend from the length of tensioner 100 at any angle, so long as each of nipples 104 a and 104 b is capable of applying tension to a substrate when the present fenestration assemblies are in an assembled state.
[0029] According to preferred embodiments of the present arrangements, nipples 104 a and 104 b protrude between about 0.015 inches and about 0.215 inches from the base of tensioner 100 , though certain other embodiments of the present arrangements have a variance of about 75% of these values. In alternate embodiments of the present arrangements, nipple 104 a and nipple 104 b may be of varying lengths, so long as each provides sufficient clearance between tensioner 100 and a corresponding base frame (described below with reference to FIG. 2 ) to secure a substrate when the present fenestration assemblies are in an assembled state.
[0030] Male member 108 , according to preferred embodiments of the present arrangements, is another protruding portion of tensioner 100 . As shown below with reference to the embodiment of FIG. 3 , when the present fenestration assemblies are in an engaged state, at least a portion of protruding male member 108 pushes a substrate into a corresponding female part (described below with reference to FIG. 2 ) that receives protruding male member 108 and secures the substrate in the fenestration assemblies of the present teachings. To this end, male member 108 may include crimps on at least one end that engage with a serrated surface of the female cavity region, thus securing the substrate therein. According to the embodiment of FIG. 1 , the crimps of male member 108 form an indentation in male member 108 of approximately 90°, though alternate embodiments may employ crimps of varying angles, so long as they are capable of engaging with the serrations of the female region (described below with reference to FIGS. 2 and 3 ). In other embodiments of the present arrangements, male member 108 is fabricated without crimps, so long as male member 108 is capable of securing a substrate when engaged with the female region of the base frame.
[0031] The present teachings thus provide the advantage of additional stability of the substrate over other methods of stabilizing a substrate, such as tape, glue, rubber mounting, screws, nails, or the like. Thus, the present teachings also provide an advantage of assembled fenestration assemblies that require relatively few materials and supplies, thus reducing the expense and time necessary to create and assemble fenestration assemblies. Finally, the present teachings provide for fenestration assemblies that last longer and require replacement or replacement of parts less often, because, for example, tape will lose its ability to affix a substrate over time; or nails or screws will often tear a substrate, particularly when the tension of the substrate is relatively high. Thus, the present teachings provide a more cost-effective and efficient means of securing a substrate over a window frame cavity.
[0032] While the embodiment of FIG. 1 shows male member 108 extending perpendicularly away from the length of tensioner 100 at an approximately 90° angle, the present teachings recognize that male member 108 may extend from tensioner 100 at any angle, so long as some portion of male member 108 is capable of being received by the female region of a corresponding base frame (described below with reference to FIGS. 2 and 3 ) in a manner that will secure a substrate in the present fenestration assemblies. In preferred embodiments of the present arrangements, male member 108 protrudes between about 0.282 inches and about 0.482 inches from the length of tensioner 100 , though certain other embodiments of the present arrangements have a variance of about 75% of these values. In alternate embodiments of the present arrangements, male member 108 may be of varying lengths, so long as some portion of male member 108 is capable of being received by, and securing a substrate in, a corresponding female region.
[0033] Film grip region 106 is disposed between nipple 104 b and male member 108 . In preferred embodiments of the present arrangements, film grip region 106 comprises a serrated edge of tensioner 100 , capable of gripping a substrate. A substrate is gripped by the serrations of film grip region 106 when region 106 engages with the corresponding serrated tape bed area of the base frame (explained below with reference to FIG. 3 ). The length of film grip region 106 preferably is between about 0.27 inches and about 0.47 inches from the base of tensioner 100 , though certain other embodiments of the present arrangements have a variance of about 75% of these values. In certain embodiments, the length of film grip region 106 is any value, so long as it grips a substrate that is used in the present fenestration assemblies.
[0034] The serrations of film grip region 106 have a pitch value that is preferably between about 0.04 inches and about 0.06 inches, though certain other embodiments of the present arrangements have a variance of about 75% of these values. In alternate embodiments of the present arrangements, film grip region 106 is not serrated and forms a relatively flat surface.
[0035] FIG. 2 shows a side-sectional view of a base frame 200 , according to one preferred embodiment of the present arrangements, that engages with a corresponding tensioner (e.g., tensioner 100 of FIG. 1 ). Base frame 200 includes an endcap 202 disposed at a first end and a compressible material track 212 disposed at a second end. On a first side of base frame 200 , a viewing area 206 is disposed between endcap 202 and compressible material track 212 . On a second side of base frame 200 , across from viewing area 206 , a female region 210 is disposed adjacent to compressible material track 212 . A tape bed area 208 is disposed adjacent to female region 210 . A slope region 204 is disposed adjacent to tape bed area 208 .
[0036] Compressible material track 212 , according to preferred embodiments of the present arrangements, receives a compressible material capable of tightly securing the present fenestration assemblies in a window envelope and preventing air infiltration through the assembly when installed. Accordingly, when assembled, compressible material is disposed in compressible material track 212 on an outer edge of an assembled fenestration assembly. The height and width of the inner cavity of compressible material track 212 may be any width capable of receiving a compressible material. The width of the inner cavity of compressible material track 212 is preferably a value that is between about 0.025 inches and about 0.225 inches in width, though certain other embodiments of the present arrangements have a variance of about 75% of these values. The height of compressible material track 212 is a value that is preferably between about 0.04 inches and about 0.06 inches, though certain other embodiments of the present arrangements have a variance of about 75% of these values.
[0037] The opening to the inner cavity of compressible material track 212 is preferably some width less than the inner cavity region, which is capable of securing a compressible material inside compressible material track 212 . In preferred embodiments of the present arrangements, the compressible material is foam, though the present teachings recognize that any material known to those in the prior art, capable of compressing due to the application of pressure, may be used. By way of example, in certain embodiments of the present arrangements, a spring is used. In alternate embodiments of the present arrangements, a compressible material track is not used. In such embodiments, compressible material is affixed to an outer edge of an assembled fenestration assembly. In certain other embodiments, however, compressible material is not used.
[0038] Though not shown in FIG. 2 , in an operative state, the compressible material housed inside compressible material track 212 will extend beyond the outer edge of base frame 200 . In this manner, the compressible material forms a portion of the present fenestration assembly that abuts the window frame cavity when the present fenestration assembly is installed. When installed, the compressible material compresses against the edge of the window frame cavity, tightly securing the present fenestration assembly inside the window frame cavity.
[0039] After installation of the assembly, e.g., inside a window frame cavity, the compressible material is compressed between the assembly and the window frame, creating a relatively secure and air-tight fit. In this compressed state, the present teachings provide the further advantage of insulation by significantly reducing, and preferably eliminating, air passage through the present fenestration assembly. Thus, the present teachings recognize that air infiltration through a fenestration assembly will reduce the energy efficiency gained by use of a substrate. Accordingly, the present arrangements provide the ability to greatly reduce or prevent such air infiltration.
[0040] In alternate embodiments of the present arrangements, the present fenestration assembly may be installed over a window frame cavity by use of magnetic strips secured on the assembly. In such embodiments, the present teachings contemplate component parts of a fenestration assembly (e.g., a base frame or a tensioner) that are not fabricated with a compressible material track.
[0041] Female region 210 , according to preferred embodiments of the present arrangements, is disposed adjacent to compressible material track 212 . Female region 210 comprises a cavity capable of receiving at least a portion of a corresponding male member of a tensioner (e.g., male member 108 of tensioner 100 of FIG. 1 ) when the present fenestration assembly is in an assembled state. Female region 210 includes serrations on at least one end of the inner surface of the cavity disposed therein. In preferred embodiments of the present arrangements, the cavity of female region 210 is capable of receiving a substantial portion of a male member, though the present teachings recognize that the cavity of female region 210 may be any size, so long as it is capable of receiving a portion of a male member. Preferably, the height of female region 210 is a value that is between about 0.015 inches and about 0.025 inches, though certain other embodiments of the present arrangements have a variance of about 75% of these values. Preferably, the length of female region 210 is a value that is between about 0.25 inches and about 0.45 inches, though certain other embodiments of the present arrangements have a variance of about 75% of these values.
[0042] As shown below with reference to FIG. 3 , in an assembled state, at least a portion of a male member of a tensioner 302 pushes a substrate into the female region of a base frame 304 . In this manner, the substrate is secured between one or more corresponding crimps on the male member of tensioner 302 and at least a portion of one serrated edge of the female region's cavity. This mating configuration realizes the advantage of increased stability and tension.
[0043] Tape bed area 208 is capable of securing a substrate on the present base frame prior to and during engagement of a tensioner (e.g., tensioner 100 of FIG. 1 ) with base frame 200 . As explained below with reference to step 901 of FIG. 9 , when the component parts of the present fenestration assembly, i.e., the tensioner, the base frame, and the substrate, are being assembled, two-sided tape is preferably applied to the tape bed area such that the tape receives and stabilizes the substrate prior to engagement of a tensioner to a base frame (described further below with reference to FIG. 3 ). The length of tape bed area may be a value that is between about 0.2 inches and about 0.4 inches, though certain other embodiments of the present arrangements have a variance of about 75% of these values. Preferably, the pitch value for the serrations of tape bed area is a value that is between about 0.02 inches and about 0.08 inches, though certain other embodiments of the present arrangements have a variance of about 75% of these values. In alternate embodiments of the present arrangements, the pitch value of the serrations of the tape bed area may be any value so long as the serrations are capable of securing a substrate. In certain alternate embodiments of the present arrangements, however, a tape bed area is used to secure a substrate using alternate means that are not tape, e.g., nails. In certain other embodiments, however, a tape bed area is not used.
[0044] The tape bed area preferably comprises a serrated edge that, when the present fenestration assembly is in an assembled state, engages with a corresponding serrated edge of a tensioner's film grip area (e.g., film grip area 106 of FIG. 1 ). In this manner, the engaged film grip and tape bed regions provide additional stability and the required tension to the substrate when the present fenestration assemblies are installed.
[0045] A slope region 204 provides a distance, or a gap, between a tape bed area disposed on a first end of the slope region, and an opposite end of the slope region. When the present fenestration assemblies are in an assembled state, the nipples of a tensioner may be received by any point after slope region 204 . The gap created by the two ends of slope region 204 and the tensioner accommodate one or more nipples of tensioner 100 of FIG. 1 . According to preferred embodiments of the present arrangements, the substrate is secured by an engaged and/or mating configuration of the tensioner's male member and the base portion's female region, the interface between the film grip region and the tape bed region, and nipples pushing into a portion of the substrate, which is adjacent to locations on the base frame after the slope region. Accordingly, the present teachings realize the advantage of increased stability and/or tension applied to the substrate when fenestration assembly 300 is in an assembled state.
[0046] Though FIG. 2 shows the slope of slope region 204 at an approximately 45° angle relative to adjacent tape bed area 208 , the present teachings contemplate the use of any angle, so long as the slope creates a region proximate to slope region 204 that is sufficient to receive a corresponding nipple of a tensioner. Preferably, the angle of slope region 204 is a value that is between about 30° and about 60° relative to adjacent tape bed area 208 .
[0047] As shown in FIG. 2 , viewing area 206 spans the length of one side of base frame 200 . Viewing area 206 may be a region of base frame 200 that, when the fenestration assembly is assembled and installed, is an outer surface of the fenestration assembly. In other words, this may be the portion of the assembly that is visible to an observer inside a building envelope. In alternate embodiments of the present arrangements, however, a backside of the tensioner is the portion of the assembly that is visible to an observer inside a building envelope. In other words, in such embodiments, a back side of a tensioner represents a viewing area.
[0048] Endcap 202 is designed to cap base frame 200 at a first end. Though the embodiment of FIG. 2 shows endcap 202 with an L-shaped configuration, alternate embodiments of the present arrangements use varying shapes for endcap 202 . By way of example, in certain embodiments, endcap 202 is configured as a straight edge.
[0049] FIG. 3 shows a side-sectional view of an assembled fenestration assembly 300 , according to one preferred embodiment of the present arrangements. Assembled fenestration assembly 300 includes a tensioner 302 engaged with a base frame 304 and a substrate 306 therebetween. As shown in the embodiment of FIG. 3 , substrate 306 is secured between the corresponding crimps of a male member (e.g., male member 108 of FIG. 1 ) and the serrated edge of the inner surface of the cavity of a female region (e.g., female region 210 of FIG. 2 ). Likewise, substrate 306 is further secured by gripping between the corresponding serrated edges of tensioner 306 's film grip region (e.g., film grip region 106 of FIG. 1 ) and the base frame's tape bed region (e.g., similar to tape bed region 208 of FIG. 2 ). Further, the tape bed region provides stability to a substrate disposed on a base prior to engagement between the tensioner and the base frame. The tape bed area, preferably using two-sided tape, secures the substrate to the base frame.
[0050] Further, as shown in the embodiment of FIG. 3 , the protruding nipple of tensioner 302 pushes substrate 306 against the gap created proximate to the slope region of base frame 304 . A gap refers to a space created between a base frame and a tensioner when they are in a mating and/or engaged configuration. In this manner, the nipple produces additional tension in substrate 306 . Thus, the present teachings realize the advantage of a substrate installed not only with stability, but also with additional tension. This arrangement provides a relatively transparent and glare-free means of using energy-efficient window film over a window frame cavity.
[0051] Tensioner 302 and base frame 304 are composed of any rigid material capable of stabilizing substrate 306 and being installed in a window frame cavity as part of the present fenestration assembly. Representative materials to make tensioner 302 and base frame 304 include at least one member chosen from a group comprising aluminum, steel, graphite, plastic, glass, wood, and composites.
[0052] According to preferred embodiments of the present arrangements, tensioner 302 and base frame 304 are each fabricated as contiguous structures. Alternate embodiments of the present arrangements, however, contemplate fabrication of one or more parts of tensioner 302 or base frame 304 separately. By way of example, male member 108 may be fabricated separately from the other component parts of tensioner 302 , and is then connected to tensioner 302 by any method known to those skilled in the art. In such embodiments, separate parts may be fabricated using different materials.
[0053] Preferably, substrate 306 used by fenestration assembly 300 is any window film, and more preferably, transparent window film, that increases a window's energy-efficient and is capable of being secured by the present fenestration assembly. By way of example, Silver 35, which is commercially available from 3M Corporation of Minneapolis, Minn., may be used. Preferably, however, V-kool 70, which is commercially available from Southwall Technologies Inc. of Palo Alto, Calif., is used.
[0054] In one embodiment of the present arrangements, the window film can be any thickness so long as it can be secured in the frame and is not too flimsy. In certain embodiments of the present arrangements, the thickness of the window film depends on the dimensions of the window, which is ultimately covered by the fenestration assembly of the present teachings. Preferably, however, window film is between about 1 mm and about 30 mm in thickness. In a more preferred embodiment of the present arrangements, window film is between about 6 mm and about 12 mm in thickness, and in even more preferred embodiments of the present arrangements, window film is between about 8 mm and about 10 mm in thickness.
[0055] FIG. 4 shows a side-sectional view of a tensioner 400 , according to an alternate embodiment of the present arrangements. Tensioner 400 includes an endcap 402 , nipples 404 a and 404 b , a film-grip region 406 , and a male member 408 , which are substantially similar to their counterparts in FIG. 1 . Unlike the embodiment of FIG. 1 , however, the embodiment of FIG. 4 replaces endcap 102 of FIG. 1 with a compressible material track 412 , which is substantially similar to compressible material track 212 of FIG. 2 .
[0056] FIG. 5 shows a side-sectional view of a base frame 500 , according to an alternate embodiment of the present arrangements. Base frame 500 includes an endcap 502 , a slope region 504 , a viewing area region 506 , a tape bed area 508 , and a female region 510 , which are substantially similar to their counterparts in FIG. 3 . Unlike base frame 300 of FIG. 3 , however, base frame 500 of FIG. 5 does not include a compressible material track disposed adjacent to female region 510 .
[0057] Tensioner 400 of FIG. 4 is designed to engage with base frame 500 of FIG. 5 such that a substrate is secured therebetween. The resulting fenestration assembly operates in a substantially similar manner to the assembled fenestration assembly 300 shown in FIG. 3 . In other words, though certain parts of tensioner 400 and base frame 500 have essentially been moved from one component to another (relative to FIGS. 1 and 2 , respectively), these components still engage and/or mate as shown in FIG. 3 .
[0058] FIG. 6 shows a base frame 600 , according to one alternate embodiment of the present arrangements. Base frame 600 includes an endcap 602 , a slope region 604 , a viewing area 606 , a tape bed area 608 , a female region 610 , and a compressible material track 612 , which are substantially similar to their counterparts in FIG. 2 . The embodiment of FIG. 6 , however, also includes a protruding tension enhancer 614 disposed adjacent to slope region 604 . When base frame 600 engages with a tensioner (e.g., tensioner 100 of FIG. 1 ), tension enhancer 614 adds additional tension to the substrate by pushing against a substrate. In an assembled state of the tensioner and the base frame, the substrate is disposed along a “serpentine” pathway, where a first portion of the substrate is pushed by the nipple of the tensioner toward the base frame, and a second, adjacent portion of the substrate is pushed in direction of the tensioner by the tension enhancer of the base frame. As a result, the one or more nipples of the tensioner work in conjunction with the tension enhancer of the base frame to provide a high level of tension on the substrate.
[0059] Though the embodiment of FIG. 6 shows base frame 600 with one tension enhancer 614 , alternate embodiments of the present arrangements utilize a plurality of tension enhancers fabricated on or attached to base frame 600 . Likewise, according to other embodiments of the present arrangements, one or more tension enhancers 614 may be fabricated on or connected to tensioner 600 . In such embodiments, each additional tension enhancer 614 produces additional tension on a substrate.
[0060] FIG. 7 shows a top view of a base frame used in a fenestration assembly, according to one preferred embodiment of the arrangements, which transforms from a cambered profile to a non-cambered profile during assembly of the present fenestration assemblies. In preferred embodiments of the present arrangements, a base frame (e.g., base frame 200 of FIG. 2 ) and/or a tensioner (e.g., tensioner 100 of FIG. 1 ) are fabricated with a cambered profile. However, the present teachings propose that this cambered profile should be transformed to a non-cambered profile after a substrate is secured between the tensioner and the base frame. Such a transformation puts the substrate in a requisite tension that also makes it stable. A cambered base frame and/or tensioner may be straightened on each edge by engaging with clamps configured to stabilize a base frame in a non-cambered profile.
[0061] FIG. 8 shows a front view of a fenestration assembly 800 , according to one preferred embodiment of the present arrangements. Assembly 800 includes a substrate 802 , a viewing area 804 , a compressible material 806 , and a sealed portion 808 . Substrate 802 is substantially similar to substrate 306 of FIG. 3 . Viewing area 804 is substantially similar to viewing area 206 of FIG. 2 . Compressible material is installed in a compressible material track (e.g., compressible material track 212 of FIG. 2 ), as discussed above.
[0062] With reference to fenestration assembly 800 of FIG. 8 , four straight base frame and tensioner components are arranged at approximately right angles relative to each other to form a base frame and a tensioner. The base frame and the tensioner mate and/or engage to form fenestration assembly 800 of FIG. 8 . In order to facilitate connection between the discrete fenestration assembly segments, the ends of each base frame and/or tensioner components are sealed at sealed portion 808 . The present teachings recognize that sealed portion 808 may be sealed in any manner well known to those skilled in the art, but that sealing by welding represents the preferred embodiment of the present invention. In one embodiment of fenestration assembly 800 , abutting base frame and/or tensioner components have complementary profiles to minimize gaps that are to be sealed.
[0063] FIG. 9 shows a flowchart 900 for a method for assembling a fenestration assembly (e.g., fenestration assembly 300 of FIG. 3 ), according to preferred embodiments of the present arrangements. Process 900 begins with a step 902 , which includes placing a film or a substrate on a base frame (e.g., base frame 100 of FIG. 1 ). In this step, the film or substrate is preferably substantially immobile relative to the base frame. The substrate may be secured on the base frame by any method known to those skilled in the art. By way of example (described above with reference to FIG. 2 ), adhering two-sided tape on the tape bed area of the base frame allows the substrate to be secured when attached to that tape. This is particularly useful when the substrate being used is relatively large. Furthermore, when a relatively larger substrate is placed on a base frame, a residual portion of the substrate that extends beyond the boundary of the base frame is cut off. This allows the dimensions of the base frame and the substrate to be coextensive with respect to each other. At the conclusion of step 902 , a substrate/base frame sub-assembly is formed.
[0064] Next, a step 804 includes applying a tensioner to the substrate/base frame subassembly. Such an assembled configuration is shown in FIG. 3 , for example. The tensioner may be applied to the substrate/base frame sub-assembly by any method known to those skilled in the art. By way of example, sufficient force to insert at least a portion of the male member of a tensioner (e.g., tensioner 100 of FIG. 1 ) into the female region of a base frame (e.g., base frame 200 of FIG. 2 ) may be applied. To this end, a hammer or a roller may be used.
[0065] Although illustrative embodiments of these arrangements have been shown and described, other modifications, changes, and substitutions are intended. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure, as set forth in the following claims.
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Energy-efficient fenestration assemblies that effectively secure substrates, such as window films, are described. The fenestration assembly includes: (1) a base frame capable of having secured thereon a substrate; and (2) a tensioner capable of engaging with the base frame such that when the base frame has secured thereon the substrate, the tensioner places the substrate under tension relative to the base frame.
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TECHNICAL FIELD
The present invention relates to a wind turbine generator.
BACKGROUND ART
As conventional means for converting wind power energy into thermal energy, wind power energy is converted into electric energy, the converted electric energy is converted into thermal energy through a heat pump (see PTL 1 and 2 for example).
For example, “a cooling system using a wind turbine and a heat pump” announced in 1987 is known as an apparatus for driving a heat pump. This system converts wind power energy into electric energy by means of a wind turbine, the electric energy is charged into a secondary battery, and a refrigeration cycle (the heat pump) is operated by a DC generator.
As an example of the combination of a wind turbine and a heat pump, there is known a system in which a heat pump (a refrigeration cycle) is disposed outside the wind turbine, mechanical energy obtained by the wind turbine is transmitted through a rotation shaft passing through a tower, a compressor of the heat pump is driven to convert the mechanical energy into thermal energy, as described in PTL 2.
CITATION LIST
Patent Literature
{PTL 1}
Specification of U.S. Patent Application No. 2007/0024132
{PTL 2}
The Publication of Japanese Patent No. 3949946
SUMMARY OF INVENTION
Technical Problem
However, a large wind turbine having several MW output is used as recent commercial wind turbine generators. In a case where such a large wind turbine and a heat pump are combined with each other, the following problems are caused.
Specifically, when the wind turbine is increased in size, the tower is increased in height (e.g., 50 m to 70 m). Therefore, there is a problem that a rotation shaft passing through the tower for transmitting power becomes long and heavy, and loss of mechanical energy converted from wind power energy is largely increased.
Further, a radiation amount of heat radiated from a machine disposed in a nacelle, e.g., a gear box, a main bearing, a transformer and a generator is several % of output of the wind turbine generator (e.g., 100 kW to 300 kW), but there is a problem that in Patent Citations referred to above, a cooling system for dealing with the heat is unclear.
Generally, the outside air is introduced into a nacelle through an air intake such as a louver provided in the nacelle, and devices in the nacelle are cooled by the introduced outside air. That is, using the cooling system, heat is dissipated to the outside air introduced from a cooler of the cooling system, and the outside air of which heat is absorbed is discharged outside of the nacelle.
When the wind turbine is disposed at sea or at seaside, however, since outside air containing salt is introduced into the nacelle, there is a problem that lifetime of a device in the nacelle is shortened by salt.
When the wind turbine generator is disposed near a house, there is caused a problem of noise from the cooling system, e.g., noise caused by rotation of a cooler fan. In addition, an application range of a large wind turbine generator is expanded to a cold region, but since there is no cooling system (heat pump) in the nacelle, there is a problem that the wind turbine generator cannot be applied to the cold region.
The present invention has been accomplished to solve the above problems, and it is an object of the present invention to provide a wind turbine generator capable of preventing salt damage, capable of reducing noise, and capable of easily starting in the cold region.
Solution to Problem
To achieve the above object, the present invention provides the following solutions.
According to an aspect of the present invention, a wind turbine generator includes: a nacelle for accommodating a generator set; an internal heat exchanging unit accommodated in the nacelle to exchange heat between the generator set and refrigerant; an external heat exchanging unit disposed outside the nacelle to exchange heat between outside air and the refrigerant; a compressor disposed in the nacelle to compress the refrigerant and circulate the refrigerant between the internal heat exchanging unit and the external heat exchanging unit; and an expansion unit to expand a pressure of the refrigerant compressed by the compressor.
According to this aspect, for example, a refrigerant is circulated from a compressor through an external heat exchanging unit, an expansion unit, an internal heat exchanging unit, and the compressor in this order so as to constitute a refrigeration cycle. With this, heat generated in a device disposed in the nacelle, e.g., generated in a generator set can be radiated outside of the nacelle via the refrigerant. That is, heat of a device in the nacelle can sufficiently be radiated outside the nacelle even if the nacelle is not provided with an opening through which the outside air is introduced into the nacelle. Thus, it is possible to prevent the outside air including salt from flowing into the nacelle. Further, noise generated from the device in the nacelle does not leak outside of the nacelle.
If a refrigerant is circulated in a direction opposite from that described above, i.e., from the compressor through the internal heat exchanging unit, the expansion unit, the external heat exchanging unit and the compressor in this order so as to constitute a heat pump cycle, the device in the nacelle can be heated. When a wind turbine generator is started when the outside air is cold, even if it is necessary to heat a lubricant such as oil used for the device in the nacelle to lower its viscosity, it is possible to easily heat the lubricant such as oil.
In the above aspect, preferably, there is further included a wind turbine to supply a rotation driving force to the generator set using wind power, wherein the compressor is driven by the rotation driving force supplied by the wind turbine.
According to this structure, the compressor is driven using a rotation driving force supplied by branching the wind turbine energy. Therefore, a heat exchanging ability in the internal heat exchanging unit, i.e., a cooling ability of the generator set is changed in accordance with the number of revolutions of the wind turbine or the rotation torque. In other words, the cooling ability of the generator set is automatically controlled by the rotation driving force supplied from the wind turbine.
For example, if the rotation driving force supplied to the compressor is increased, a mass flow rate of a refrigerant discharged in the compressor is increased. Thus, the heat exchanging ability in the internal heat exchanging unit is enhanced, and the cooling ability of the generator set is automatically controlled such that the ability is enhanced.
In the above aspect, preferably, there is further included a motor to rotate and drive the compressor.
According to this structure, for example, by driving the compressor using electricity generated by the generator set, the heat exchanging ability in the internal heat exchanging unit, i.e., the cooling ability of the generator set is changed in accordance with the output of the wind, turbine generator. In other words, the cooling ability of the generator set is automatically controlled by the electricity supplied by the generator set.
For example, if the electricity supplied to the compressor is increased, a mass flow rate of a refrigerant discharged in the compressor is increased. Thus, the heat exchanging ability in the internal heat exchanging unit is enhanced, and the cooling ability of the generator set is automatically controlled such that the ability is enhanced.
In the above aspect, preferably, the external heat exchanging unit is provided with a heater to supply heat to the refrigerant.
According to this structure, when refrigerant is evaporated using the external heat exchanging unit as an evaporator, even when the outside air temperature outside the nacelle is low, the refrigerant can easily be evaporated by heating the refrigerant using a heater. Further, heat can be supplied to the main body of the external heat exchanging unit and a piping system to the external heat exchanger. When it is necessary to heat lubricant such as oil used for the generator set to lower its viscosity, it is possible to easily heat the lubricant such as oil.
Advantageous Effects of Invention
According to the wind turbine generator of the present invention, by circulating a refrigerant from the compressor through the external heat exchanging unit, the expansion unit, the internal heat exchanging unit and the compressor in this order so as to constitute a refrigeration cycle, without an opening in the nacelle, heat of a device in the nacelle can sufficiently be radiated outside of the nacelle. Therefore, there is an effect that salt damage and noise can be reduced. Further, by circulating a refrigerant from the compressor through the internal heat exchanging unit, the expansion unit, the external heat exchanging unit and the compressor in this order so as to constitute a heat pump cycle, a device in the nacelle can be heated. Therefore, there is an effect that a wind turbine generator can easily be started in a cold region.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a general view for explaining a structure of a wind turbine generator according to a first embodiment of the present invention.
FIG. 2 is a schematic diagram for explaining a structure of an interior of a nacelle shown in FIG. 1 .
FIG. 3 is a schematic diagram for explaining a flow of a refrigerant when the wind turbine generator shown in FIG. 2 is started from a cold state.
FIG. 4 is a schematic diagram for explaining a structure of a wind turbine generator according to a second embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
First Embodiment
A wind turbine generator according to a first embodiment of the present invention will be explained with reference to FIGS. 1 to 3 .
FIG. 1 is a general view for explaining a structure of the wind turbine generator according to the present embodiment.
A wind turbine generator 1 produces electricity using wind power.
As shown in FIG. 1 , the wind turbine generator 1 includes a column (a tower) 2 standing on a base B, a nacelle 3 provided on an upper end of the column 2 , a rotor head (wind turbine) 4 provided on the nacelle 3 such that the rotor head 4 can rotate around a substantially horizontal axis, a head capsule 5 covering the rotor head 4 , a plurality of wind turbine rotor blades (the wind turbine) 6 radially mounted around a rotation axis of the rotor head 4 , and a device in the nacelle (a generator set) 7 which generates electricity by rotating the rotor head 4 .
Although three wind turbine rotor blades 6 are provided in the present embodiment of the invention, the number of the wind turbine rotor blades 6 is not limited to three, but the number may be two, four or more with no particular limitation.
As shown in FIG. 1 , the column 2 extends upward from the base B (upward in FIG. 1 ), and a plurality of units is connected in the vertical direction or the like. The uppermost portion of the column 2 is provided with the nacelle 3 . When the column 2 includes the plurality of units, the nacelle 3 is disposed on the uppermost unit.
As shown in FIG. 1 , the nacelle 3 rotatably supports the rotor head 4 , and the device 7 in the nacelle for generating electricity by rotating the rotor head 4 is accommodated in the nacelle 3 .
The nacelle 3 is not provided with a venting opening (a louver) through which the outside air is introduced into the nacelle 3 from outside the nacelle 3 , and the nacelle 3 is only provided with an opening for allowing a main shaft (not shown) for transmitting a rotation driving force of the rotor head 4 to pass through, and a doorway for maintenance.
As shown in FIG. 1 , the plurality of wind turbine rotor blades 6 , which radially extends, is mounted on the rotor head 4 around the rotation axis thereof, and the periphery, of the rotor head 4 is covered with the head capsule 5 .
The rotor head 4 is provided with a pitch control unit (not shown) which rotates the wind turbine rotor blade 6 around an axis of the wind turbine rotor blade 6 to change a pitch angle of the wind turbine rotor blade 6 .
In this structure, when a wind hits the wind turbine rotor blades 6 from a direction of the rotation axis of the rotor head 4 , a force for rotating the rotor head 4 around its rotation axis is generated in the wind turbine rotor blades 6 , and the rotor head 4 is rotated and driven.
FIG. 2 is a schematic diagram for explaining a structure of an interior of the nacelle shown in FIG. 1 .
As shown in FIG. 2 , a device 7 in the nacelle accommodated in the nacelle 3 is provided with a main bearing 11 which rotatably supports a main shaft (not shown). The main shaft transmits a mechanical rotation driving force of the rotor head 4 to a generator 14 . The device 7 in the nacelle is also provided with a gear box (generator set) 12 which accelerates rotation of the rotor head 4 and transmits the rotation to the generator 14 , an oil heat exchanging unit (internal heat exchanging unit) 13 which cools or heats oil used for lubricating the main bearing 11 and the gear box 12 , the generator (generator set) 14 which generates electricity using the transmitted mechanical rotation driving force, a generator heat exchanging unit (internal heat exchanging unit) 15 which cools or heats the generator 14 , and an inverter heat exchanging unit (internal heat exchanging unit) 16 which cools or heats an inverter. The inverter controls voltage and frequency of generated electricity. The device 7 in the nacelle is also provided with an external heat exchanging unit 17 which exchanges heat between a refrigerant and the outside air outside the nacelle 3 , a compressor 18 which circulates a refrigerant between the oil heat exchanging unit 13 , the generator heat exchanging unit 15 , the inverter heat exchanging unit 16 and the external heat exchanging unit 17 . The device 7 in the nacelle is also provided with an expansion valve (expansion unit) 19 which expands a pressure of a compressed refrigerant.
The main bearing 11 includes a bearing tank 22 and a bearing pump 21 which pumps lubricant oil (lubricant) for lubricating inside the main bearing 11 . The bearing pump 21 and the bearing tank 22 constitute a circulation path for lubricant oil together with the main bearing 11 and the oil heat exchanging unit 13 .
The main bearing tank 22 includes a main bearing heater (heater) 23 for heating lubricant oil stored therein.
The gear box 12 transmits a mechanical rotation driving force transmitted from the rotor head 4 to the generator 14 and to the compressor 18 . The number of revolutions, i.e., the rotation speed of the rotation driving force transmitted to the generator 14 and the compressor 18 is increased.
The gear box 12 includes a gear box tank 32 and a gear box pump 31 which pumps lubricant oil for lubricating inside the gear box 12 . The gear box pump 31 and the gear box tank 32 constitute a circulation path for lubricant oil together with the gear box 12 and the oil heat exchanging unit 13 .
The gear box tank 32 is provided with a gear box heater (heater) 33 which heats lubricant oil stored therein.
The oil heat exchanging unit 13 is a heat exchanger into which lubricant oil that lubricated the main bearing 11 and the gear box 12 flows. The oil heat exchanging unit 13 exchanges heat between a refrigerant circulated by the compressor 18 and a lubricant oil.
In a state where a viscosity of the lubricant oil is sufficiently low and the wind turbine generator 1 is operated, the oil heat exchanging unit 13 is used as an evaporator and the lubricant oil radiates heat to the refrigerant.
On the other hand, when the wind turbine generator 1 is started when the outside air is cold and a viscosity of lubricant oil is high, the oil heat exchanging unit 13 is used as a condenser, and a refrigerant radiates heat to lubricant oil.
The oil heat exchanging unit 13 is connected such that a refrigerant which flowed out from the oil heat exchanging unit 13 flows into the compressor 18 , the external heat exchanging unit 17 , and the expansion valve 19 in this order in a state where a viscosity of lubricant oil is sufficiently low and the wind turbine generator 1 is operated, and a refrigerant passing through the expansion valve 19 again flows into the oil heat exchanging unit 13 . By circulating the refrigerant in this manner, a refrigeration cycle is constituted.
The generator heat exchanging unit 15 is a heat exchanger disposed in adjacent to the generator 14 , and radiates heat generated by the generator 14 to a refrigerant.
The generator heat exchanging unit 15 is connected such that a refrigerant which flowed out from the generator heat exchanging unit 15 flows into the compressor 18 , the external heat exchanging unit 17 , and the expansion valve 19 in this order in a state where the wind turbine generator 1 is operated, and a refrigerant passing through the expansion valve 19 again flows into the generator heat exchanging unit 15 . By circulating a refrigerant in this manner, a refrigeration cycle is constituted.
The inverter heat exchanging unit 16 is a heat exchanger disposed behind the nacelle 3 , and radiates heat generated by an inverter (not shown) to a refrigerant.
The inverter heat exchanging unit 16 is connected such that a refrigerant which flowed out from the inverter heat exchanging unit 16 flows into the compressor 18 and the external heat exchanging unit 17 in this order in a state where the wind turbine generator 1 is operated, and a refrigerant passing through the expansion valve 19 again flows into the inverter heat exchanging unit 16 . By circulating a refrigerant in this manner, a refrigeration cycle is constituted.
The external heat exchanging unit 17 exchanges heat between a refrigerant and the outside air, and is disposed on a lower surface behind the nacelle 3 .
The external heat exchanging unit 17 is connected such that a refrigerant which flowed out from the external heat exchanging unit 17 flows into the expansion valve 19 , any of the oil heat exchanging unit 13 , the generator heat exchanging unit 15 , and the inverter heat exchanging unit 16 , and the compressor 18 in this order in a state where the wind turbine generator 1 is operated, and a refrigerant which is discharged from the compressor 18 again flows into the external heat exchanging unit 17 . By circulating a refrigerant in this manner, a refrigeration cycle is constituted.
The external heat exchanging unit 17 is provided with an external heat exchanging heater (heater) 41 which heats lubricant oil stored in a main body of the external heat exchanging unit 17 or in a piping system connected to the external heat exchanging unit 17 . It is preferable to provide a shower (not shown) for washing off salt adhered to the external heat exchanging unit 17 to prevent the external heat exchanging unit 17 from being corroded by salt of the external heat exchanging unit 17 .
In the case of a refrigeration cycle which absorbs heat of a refrigerant in the oil heat exchanging unit 13 , the compressor 18 compresses a refrigerant and discharges the refrigerant into the external heat exchanging unit 17 . In the case of a heat pump cycle which supplies heat to a refrigerant in the oil heat exchanging unit 13 , the compressor 18 , compresses a refrigerant and discharges the refrigerant toward the oil heat exchanging unit 13 , the generator heat exchanging unit 15 , and the inverter heat exchanging unit 16 .
A mechanical rotation driving force is transmitted to the compressor 18 from the rotor head 4 through the gear box 12 , and the compressor 18 compresses a refrigerant by the transmitted mechanical rotation driving force. In the present embodiment, the compressor 18 switches a discharging direction of a refrigerant. That is, the compressor 18 discharges a refrigerant to the external heat exchanging unit 17 in the case of a refrigeration cycle, and the compressor 18 discharges a refrigerant to the oil heat exchanging unit 13 , the generator heat exchanging unit 15 , and the inverter heat exchanging unit 16 in the case of a heat pump cycle.
A compressor capable of switching a discharging direction of a refrigerant may be used as described above, or a compressor which discharges a refrigerant only in one direction, and a three-way valve or a four-way valve which controls a flowing direction of a refrigerant may be used, and this is not especially limited.
An outline of an electricity generating method in the wind turbine generator 1 having the above-described structure will be explained.
In the wind turbine generator 1 , wind power energy which hits the wind turbine rotor blade 6 from a rotation axial direction of the rotor head 4 is converted into mechanical energy which rotates the rotor head 4 around the rotation axis.
Rotation of the rotor head 4 is transmitted to the device 7 in the nacelle. In the device 7 in the nacelle, electricity, e.g., AC electricity having frequency of 50 Hz or 60 Hz suitable for a subject to which electricity is supplied is generated.
At least while electricity is generated, in order to effectively apply wind power energy to the wind turbine rotor blade, the nacelle 3 is appropriately rotated on a horizontal plane, thereby controlling the rotor head 4 such that it is oriented to an upstream direction of wind.
Next, as the feature of the present embodiment, the heat exchanging operation in the oil heat exchanging unit 13 , the generator heat exchanging unit 15 , the inverter heat exchanging unit 16 and the external heat exchanging unit 17 will be explained.
When electricity is generated in the wind turbine generator 1 , to constitute a refrigeration cycle as shown in FIG. 2 , the oil heat exchanging unit 13 , the generator heat exchanging unit 15 and the inverter heat exchanging unit 16 act as a cooler (evaporator). That is, a refrigerant absorbs heat in the oil heat exchanging unit 13 and the like and evaporates the refrigerant. The external heat exchanging unit 17 acts as a condenser, and a refrigerant radiates heat to the outside air and is condensed.
More specifically, a refrigerant is compressed to have a high temperature and high pressure by the compressor 18 to which a mechanical rotation driving force of the rotor head 4 is transmitted through the gear box 12 , and the refrigerant is discharged toward the external heat exchanging unit 17 . The refrigerant which flowed into the external heat exchanging unit 17 radiates heat to the outside air in the external heat exchanging unit 17 and is condensed. The condensed and liquefied refrigerant flows into the expansion valve 19 and is expanded when the refrigerant passes through the expansion valve 19 . The expanded refrigerant flows into the oil heat exchanging unit 13 , the generator heat exchanging unit 15 , and the inverter heat exchanging unit 16 .
The refrigerant which flowed into the oil heat exchanging unit 13 lubricates the main bearing 11 and the gear box 12 in the oil heat exchanging unit 13 , the refrigerant absorbs heat from the high temperature lubricant oil and is evaporated. The evaporated refrigerant flows out from the oil heat exchanging unit 13 , flows into the compressor 18 , and is compressed again.
Lubricant oil for main bearing of which heat is removed and which is cooled is circulated through the bearing tank 22 , the bearing pump 21 , and the main bearing 11 in this order and again flows into the oil heat exchanging unit 13 . Lubricant oil for the gear box is circulated through the gear box 12 , the gear box tank 32 , and the gear box pump 31 in this order and again flows into the oil heat exchanging unit 13 .
The refrigerant which flows into the generator heat exchanging unit 15 absorbs heat generated from the generator 14 in the generator heat exchanging unit 15 and is evaporated. The evaporated refrigerant flows out from the generator heat exchanging unit 15 , flows into the compressor 18 , and is again compressed.
The refrigerant which flows into the inverter heat exchanging unit 16 absorbs heat generated from the inverter 14 in the inverter heat exchanging unit 16 and is evaporated. The evaporated refrigerant flows out from the inverter heat exchanging unit 16 , flows into the compressor 18 and is again compressed.
FIG. 3 is a schematic diagram for explaining a refrigerant flow when the wind turbine generator shown in FIG. 2 is started from its cold state.
When the wind turbine generator 1 is started under such an environment in which the outside air temperature is, for example, −30° to −40°, i.e., when the wind turbine generator 1 is started in a state where a viscosity coefficient of lubricant oil which lubricates the main bearing 11 and the gear box 12 is as high as a few ten thousand cSt and lubrication ability cannot be expected, a circulation direction of a refrigerant is set to a direction opposite from that shown in FIG. 2 , i.e., a refrigerant is allowed to flow so as to constitute a heat pump cycle instead of a refrigeration cycle, and lubricant oil is heated.
More specifically, a refrigerant compressed by the compressor 18 to have a high temperature and high pressure is discharged toward the oil heat exchanging unit 13 , the generator heat exchanging unit 15 , and the inverter heat exchanging unit 16 .
The high temperature and high pressure refrigerant which flowed into the oil heat exchanging unit 13 discharges heat to lubricant oil which lubricates the main bearing 11 and the gear box 12 and is condensed. The condensed refrigerant flows out from the oil heat exchanging unit 13 and flows into the expansion valve 19 .
Lubricant oil which absorbs heat discharged from the refrigerant and which is heated is lowered in viscosity to such a level that lubricating ability can be expected. The lubricant oil flows out from the oil heat exchanging unit 13 and then, the lubricant oil is supplied to the main bearing 11 and the gear box 12 and used for lubrication.
As described above, only heat of a refrigerant may be used and the lubricant oil may be heated, or the bearing heater 23 may further be used to heat the lubricant oil, or the gear box heater 33 may further be used to heat the lubricant oil. The heating method of lubricant oil is not especially limited to heating from a refrigerant.
A refrigerant flows into the expansion valve 19 from the oil heat exchanging unit 13 , the generator heat exchanging unit 15 , and the inverter heat exchanging unit 16 , and when the refrigerant passes through the expansion valve 19 , the refrigerant is expanded. The expanded refrigerant flows into the external heat exchanging unit 17 .
An external heat exchanging heater 41 is disposed in a main body of the external heat exchanging unit 17 or in a piping system connected to the external heat exchanging unit 17 . A refrigerant heated by the external heat exchanging heater 41 is evaporated, and the evaporated refrigerant flows into the compressor 18 and is again compressed.
As described above, a refrigerant may be evaporated by the main body of the external heat exchanging unit 17 or the external heat exchanging heater 41 disposed on the piping system connected to the external heat exchanging unit 17 , or a refrigerant may be evaporated by an other heating device (not shown). The evaporating device of a refrigerant is not especially limited.
According to the above structure, for example, in a generator system of the wind turbine generator 1 disposed on the ocean, if a refrigerant is circulated from the compressor 18 through the external heat exchanging unit 17 , the expansion valve 19 , the generator heat exchanging unit 15 and the like and again the compressor 18 in this order, heat generated in the generator 14 can be radiated outside the nacelle 3 through the refrigerant. That is, it is possible to sufficiently radiate heat of the generator set outside the nacelle 3 without directly introducing the outside air including salt into the nacelle 3 from outside the nacelle 3 , and it is possible to prevent lifetime of the wind turbine generator 1 from being shortened. As well as the generator 14 , this effect can be expected also in the device 7 in the nacelle such as the main bearing 11 , the gear box 12 and the inverter.
Further, since noise generated from the generator 14 and a cooler fan of the gear box 12 is enclosed in the nacelle 3 , it is possible to prevent noise from leaking outside of the wind turbine generator 1 .
If a refrigerant is circulated from the compressor 18 through the oil heat exchanging unit 13 , the expansion valve 19 , and the external heat exchanging unit 17 , and again the compressor 18 this order to constitute a heat pump cycle, oil in the gear box 12 and the main bearing 11 can be heated. For example, when the wind turbine generator 1 is started in a state where the outside air temperature is as cold as −30° to −40°, even if it is necessary to heat lubricant oil used for the gear box 12 and the main bearing 11 and to lower the viscosity of the lubricant oil to such a level that lubricating ability can be expected, it is possible to easily heat the lubricant oil and easily start the wind turbine generator 1 .
If a refrigerant is heated using the main body of the external heat exchanging unit 17 or the external heat exchanging heater 41 disposed on the piping system connected to the external heat exchanging unit 17 , it is possible to easily evaporate the refrigerant. Therefore, even when it is necessary to increase the temperature of lubricant oil used for the gear box 12 or the main bearing 11 and to lower the viscosity of the lubricant oil to such a level that lubricating ability can be expected, it is possible to make it easier to start the wind turbine generator 1 .
Since the compressor 18 is driven using a mechanical rotation driving force supplied by the rotor head 4 , the heat exchanging ability in the oil heat exchanging unit 13 , i.e., cooling ability of lubricant oil in the generator 14 or the gear box 12 is changed in accordance with the number of revolutions and the rotation torque of the rotor head 4 . In other words, the cooling ability of the generator 14 or the gear box 12 is automatically controlled by the mechanical rotation driving force supplied by the wind turbine generator 1 .
For example, when the rotation driving force supplied to the compressor 18 is increased, a mass flow rate of a refrigerant discharged in the compressor 18 is increased. Therefore, control is performed such that the heat exchanging ability in the oil heat exchanging unit 13 is enhanced and the cooling ability in the cooler of the generator 14 or the gear box 12 is enhanced.
Second Embodiment
Next, a second embodiment of the present invention will be explained with reference to FIG. 4 .
The basic structure of the wind turbine generator of the present embodiment is the same as that of the first embodiment, but the driving method of the compressor is different from that of the first embodiment. Therefore, in the present embodiment, only the structure of the periphery of the compressor will be explained with reference to FIG. 4 , and explanation of other structures will not be repeated.
FIG. 4 is a schematic diagram for explaining the structure of the wind turbine generator according to the present embodiment.
The same constituent elements as those of the first embodiment are designated with the same symbols, and explanation thereof will not be repeated.
As shown in FIG. 4 , a generator set 107 accommodated in a nacelle 3 in a wind turbine generator 101 includes a main bearing 11 , a gear box 12 , an oil heat exchanging unit 13 , a generator 14 , a generator heat exchanging unit 15 , an inverter heat exchanging unit 16 , an external heat exchanging unit 17 , a compressor 18 , an expansion valve 19 , and an electric motor (a motor) 118 which rotates and drives the compressor 18 .
Electricity generated by the generator 14 is supplied to the electric motor 118 , and the motor 118 rotates and drives the compressor 18 using the supplied electricity.
When electricity is generated in the wind turbine generator 101 , the compressor 18 rotated and driven by the electric motor 118 discharges a refrigerant compressed to have a high temperature and high pressure toward the external heat exchanging unit 17 . Since the operation thereafter is the same as that of the first embodiment, explanation thereof will not be repeated.
According to the above structure, since the compressor 18 is driven using electricity generated by the generator 14 , the heat exchanging ability in the oil heat exchanging unit 13 , i.e., cooling ability in a cooler of the generator 14 or the gear box 12 , is changed in accordance with output of the wind turbine generator 101 . In other words, the cooling ability of the cooler of the generator 14 or the gear box 12 can be automatically controlled by the electricity supplied from the generator 14 .
For example, when supplied electricity is increased, a mass flow rate of a refrigerant discharged in the compressor 18 is increased. Therefore, control is performed such that the heat exchanging ability in the oil heat exchanging unit 13 is enhanced and the cooling ability in the cooler of the generator 14 or the gear box 12 is enhanced.
REFERENCE SIGNS LIST
1 , 101 : Wind turbine generator
3 : Nacelle
4 : Rotor head (Wind turbine)
6 : Wind turbine rotor blade (Wind turbine)
7 : Device in nacelle (Generator set)
12 : Gear box (Generator set)
13 : Oil heat exchanging unit (Internal heat exchanging unit)
14 : Generator (Generator set)
15 : Generator heat exchanging unit (Internal heat exchanging unit)
16 : Inverter heat exchanging unit (Internal heat exchanging unit)
17 : External heat exchanging unit
18 : Compressor
19 : Expansion valve (Decompression unit)
23 : Bearing heater (Heater)
33 : Gear box heater (Heater)
41 : External heat exchanging heater (Heater)
118 : Motor
|
A wind turbine generator capable of preventing a salt damage and reducing noise as well as easily starting in a cold region is provided. The wind turbine generator includes a nacelle ( 3 ) for accommodating a generator set, an internal heat exchanging unit ( 13, 15, 16 ) accommodated in the nacelle ( 3 ) to exchange heat between the generator set and a refrigerant, an external heat exchanging unit ( 17 ) disposed outside the nacelle ( 3 ) to exchange heat between an outside air and the refrigerant, a compressor ( 18 ) disposed in the nacelle ( 3 ) to compress the refrigerant and circulate the refrigerant between the internal heat exchanging unit ( 13, 15, 16 ) and the external heat exchanging unit ( 17 ), and an expansion unit ( 19 ) to expand the refrigerant compressed by the compressor ( 18 ).
| 5
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/682,281 filed on Aug. 12, 2012, which is incorporated by reference herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with government support under DE-FC02-07ER64494 awarded by the US Department of Energy and 2011-67009-30043 awarded by the USDA/NIFA. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] This disclosure relates generally to a synthetic Lactobacillus casei bacterium engineered to produce increased amounts of ethanol, as compared to wild type Lactobacillus casei , as well as to methods of making and using such a bacterium.
BACKGROUND OF THE INVENTION
[0004] Microbial production of biofuels from lignocellulosic substrates is a component of the United States plan to reduce its dependency on fossil fuels. The microorganisms typically considered for the production of biofuels include Saccharomyces cerevisiae, Zymomonas mobilis, Escherichia coli , and Clostridium sp. However, all of these microorganisms suffer from one or more of the following deficiencies: relatively low tolerance to the environmental stresses likely to be encountered in fermentation (e.g., high levels of alcohols, acids, and/or osmolarity), complex physiology, poor availability of genetic tools, and limited ability to secrete enzymes. Accordingly, there is a need in the art for improved microorganisms for the production of biofuels such as ethanol from lignocellulosic substrates.
BRIEF SUMMARY OF THE INVENTION
[0005] In a first aspect, this disclosure encompasses an engineered bacterium for producing ethanol from one or more carbohydrates. The engineered bacterium is made by (a) inactivating within a Lactobacillus casei bacterium one or more endogenous genes encoding a lactate dehydrogenase; or (b) introducing into a Lactobacillus casei bacterium one or more exogenous genes encoding a pyruvate decarboxylase and one or more exogenous genes encoding an alcohol dehydrogenase II. The engineered bacterium can also be made using a combination of both approaches. The resulting engineered bacterium produces significantly more ethanol than the wild type Lactobacillus casei bacterium.
[0006] In certain embodiments, the Lactobacillus casei bacterium is made from L. casei strain 12A.
[0007] In certain embodiments, the step of inactivating within a Lactobacillus casei bacterium one or more endogenous genes encoding a lactate dehydrogenase also includes inactivating within the Lactobacillus casei bacterium an endogenous gene encoding D-hydroxyisocaproate dehydrogenase. In certain embodiments, the engineered bacterium includes the gene deletion mutation Δ L-lactate dehydrogenase 1 (ΔL-ldh1), the gene deletion mutation Δ L-lactate dehydrogenase 2 (ΔL-ldh2), or both. In some such embodiments, the engineered bacterium further includes the gene deletion mutation Δ D-lactate dehydrogenase (ΔD-ldh) or Δ D-hydroxyisocaproate dehydrogenase (ΔD-hic).
[0008] In certain embodiments, the exogenous gene encoding a pyruvate decarboxylase includes the gene of Zymomonas mobilis that encodes for pyruvate decarboxylase (Pdc), and the exogenous gene encoding an alcohol dehydrogenase II includes the gene of Zymomonas mobilis that encodes for dehydrogenase II (AdhII). Preferably, the exogenous genes are modified to utilize L. casei codon usage for highly expressed genes.
[0009] In certain embodiments, the exogenous genes are introduced into the L. casei bacterium using an expression vector. A non-limiting example of an expression vector that could be used is pP pgm -PET.
[0010] In certain embodiments, the exogenous genes are operably linked to a promoter. Preferably, the promoter is an L. casei promoter. An non-limiting example of a preferred L. casei promoter is the phosphoglycerate mutase (pgm) promoter (P pgm ). The L. casei promoter may also be a promoter that is highly expressed in the stationary phase. Non-limiting examples of such promoters include the L. casei GroEL promoter and the L. casei DnaK promoter.
[0011] In a second aspect, the disclosure encompasses an engineered bacterium for producing ethanol from one or more carbohydrates. The engineered bacterium is a derivative of L. casei 12A containing the deletion mutation ΔL-ldh1, an exogenous gene encoding a pyruvate decarboxylase, and an exogenous gene encoding an alcohol dehydrogenase II. The exogenous genes are operably linked to a native L. casei promoter, and the engineered bacterium produces significantly more ethanol than the wild-type L. casei bacterium.
[0012] In certain embodiments, the engineered bacterium further includes the deletion mutation ΔL-ldh2.
[0013] Non-limiting examples of native L. casei promoters that could be operably linked to the exogenous genes include the phosphoglycerate mutase promoter, the GroEL promoter, and the DnaK promoter.
[0014] In certain embodiments, the exogenous genes are from Zymomonas mobilis.
[0015] In certain embodiments, the exogenous genes are included in a pP pgm -PET expression vector. In some such embodiments, the pgm promoter (P pgm ) in the pP pgm -PET expression vector may be substituted with a promoter that is highly expressed in the stationary phase. Non-limiting examples of such a promoter include a GroEL promoter or a DnaK promoter.
[0016] In a third aspect, this disclosure encompasses a method of making ethanol. The method includes the step of culturing the engineered bacterium of any of the embodiments described above on a substrate comprising a carbohydrate, and collecting the ethanol produced by the bacterium.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 . Growth (▪,) and glucose utilization (□,∘) by Lactobacillus casei 12AΔ-ldh(pP PGM -PET) (squares) and 12AΔL-Idh1ΔL-Idh2ΔD-hic(pP PGM -PET) (circles) at 37° C. in modified chemical defined media (mCDM; Díaz-Muñiz and Steele, 2006) containing 10% glucose (w/v) with pH maintained at 6.0. See Díaz-Muñiz, I. and J. L. Steele, Antonie van Leeuwenhoek 90 (2006): 233-243.
[0018] FIG. 2 . Growth, glucose consumption, and ethanol production by Lactobacillus casei 12AΔLldh1(pP PGM -PET) (2A) and 12AΔL-ldh1ΔL-ldh2ΔD-hic (pP PGM -PET) ( 2 B) at 37° C. in a chemically defined media containing 10% glucose with pH maintained at 6.0.
[0019] FIG. 3 . Metabolism of pyruvate (PYR) in Lactobacillus casei 12A and derivatives. The pyruvate related enzymes and pathways present in L. casei 12A: L-lactate dehydrogenases (L-Ldh); D-lactate dehydrogenase (D-Ldh); D-Hydroxyisocaproate dehydrogenase (D-Hic); acetolactate synthase (Als); oxaloacetate decarboxylase (Oad); pyruvate kinase (Pyk); phophoenolpyruvate carboxikinase (Pck); pyruvate-formate lyase (Pfl); alcohol dehydrogenase (Adh). The enzymes and pathway from Zymomonas mobilis are shown as thick arrows: pyruvate decarboxylase (Pdc); alcohol dehydrogenase (Adh). Abbreviations: EMP, Embden-Meyerof-Parnas pathway; Glu, glucose; PEP, phosphoenolpyruvate.
[0020] FIG. 4 . Schematic illustrating the gene replacement procedure developed for gene replacement in L. casei 12A. Presence of the pheS* loci results in sensitivity to p-Cl-Phe. This phenotype (derivatives with pheS* form smaller colonies) allows for selection derivatives that have undergone recombination resulting in loss of the pheS* loci (derivatives without phe* form bigger colonies).
[0021] FIG. 5 . “Production of ethanol” or PET cassette in pTRKH2 designed for L casei 12A, called pP pgm -PET. Panel A, Construction of PET cassette in pTRKH2. PET cassette sequence was obtained from Zymomonas mobilis . Codon usage of pdc and adhII were optimized specifically for L. casei 12A using Java Codon Adaptation Tool (Jcat). Codon optimized cassette was synthesized then cloned into pTRKH2 for expression in L casei 12A. Panel B, detail of gene organization in the PET cassette: Ppgm, native promoter from L. casei 12A phosphoglycerate mutase; ribosomal binding site (RBS); pdc, pyruvate decarboxylase; adhII, alcohol dehydrogenase; Pin structure, native L. casei 12A transcriptional terminator of kdgR transcriptional regulator protein. The cassette was flanked by PstI and BamHI restriction sites for cloning into pTRKH2.
[0022] FIG. 6 . Growth curves of L. casei 12A and 12A Δldh1 transformed with empty pTRKH2 (control) or pPgm-PET growth in chemically defined medium (CDM) for 48 hrs. Working cultures were prepared from frozen stocks by two sequential transfers in MRS broth (see J. C. de Man, M. Rogosa and M. Elisabeth Sharpe, Appl. Bact. 23. 130-135 (1960)) with incubations conducted statically at 37° C. for 24 hrs and 18 hrs, respectively. These cultures were then transferred to mCDM overnight and monitored every 6 hrs for OD600 (optical density at 600 nm).
DETAILED DESCRIPTION OF THE INVENTION
I. In General
[0023] Before the present materials and methods are described, it is understood that this invention is not limited to the particular methodology, protocols, materials, and reagents described, as these may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention which will be limited only by any later-filed nonprovisional applications.
[0024] As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise. As well, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. The terms “comprising”, “including”, and “having” can be used interchangeably.
[0025] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications and patents specifically mentioned herein are incorporated by reference for all purposes including describing and disclosing the chemicals, instruments, statistical analysis and methodologies which are reported in the publications which might be used in connection with the invention. All references cited in this specification are to be taken as indicative of the level of skill in the art. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention.
II. The Invention
[0026] We have developed a bioengineered biofuel-producing strain of Lactobacillus casei . The following characteristics make L. casei an ideal biofuels fermentation organism: ability to use lignocellulosic-derived mono- and di-saccharides; resistance to environmental stresses likely to be encountered in industrial biofuels fermentations, including high levels of biofuels, acids, and/or osmolarity; relatively simple fermentative metabolism with almost complete separation of cellular processes for biosynthesis and energy metabolism; possibility to direct metabolic flux of both pentoses and hexoses to pyruvate (allowing for construction of derivatives producing second generation biofuels (i.e. isobutanol)); the availability of established platforms for introducing and expressing foreign DNA; availability of a deep portfolio of molecular-genetic data related to L. casei ecological adaptation, genomics, transcriptomics, lipidomics, and metabolomics; the ability to secrete and display proteins, hence potential for use in consolidated bioprocessing; and designation as a GRAS (Generally Regarded As Safe) species.
[0027] L. casei 12A, a strain isolated from corn silage on the University of Wisconsin-Madison campus, was selected as the biofuels-producing parental strain, due to its alcohol resistance, carbohydrate utilization profile, and amenability to genetic manipulation.
[0028] A two pronged approach has been employed to redirect metabolic flux in L. casei 12A to ethanol. The first approach was to inactivate genes that encode enzymes which compete with the 12A pathway to ethanol. The second approach utilized the introduction of the genes from Zymomonas mobilis that encode pyruvate decarboxylase (Pdc) and alcohol dehydrogenase II (Adh2) activities (PET cassette). These genes were designed utilizing the L. casei codon usage for highly expressed genes with a constitutive L. casei promoter (phosphoglycerate mutase), synthesized, ligated with digested pTRKH2 to form pP PGM -PET), and introduced into 12A derivatives by electroporation. This two pronged approach has resulted in an L. casei 12A derivative that produces ethanol as more than 80% of its metabolic end products.
[0029] The constructed derivative of L. casei 12A produces ethanol as more than 80% of its final metabolic end products from glucose, and the path to greater than 90% conversion is clear. This is by far the greatest conversion that has been reported with a lactobacilli, and will allow us to exploit the advantages of the use of lactobacilli as biocatalysts for the production of biofuels. These advantages are further delineated below.
[0030] The specific features and advantages of the present invention will become apparent after a review of the following experimental examples. However, the invention is not limited to the specific embodiments disclosed herein.
III. Examples
Example A
[0031] This example addresses (1) what level of carbohydrate Lactobacillus casei 12A derivatives are capable of using; and (2) what level of ethanol production takes place at elevated glucose concentrations.
[0032] In the first experiment, 48 small volume (2 ml) fermentations were conducted in GC vials containing our L. casei chemically defined media to examine glucose utilization and end product formation. In parallel, these fermentations were conducted in a 96 well plate reader to monitor growth. The experimental matrix was: 3 levels of glucose (2.5, 5.0, and 10% w/v), with and without the osmoprotectants present in ACSH (0.7 mM betaine, 0.7 mM choline chloride, and 0.2 mMDL-carnitine), with and without 2.5 μg/ml erythromycin (Ery) to select for the plasmid encoded PET cassette, and four different strains. The strains utilized were: (1) an L. casei 12A derivative (12AΔL-ldh1) lacking L-lactate dehydrogenase 1 (L-ldh1), the primary fermentative lactate dehydrogenase, with pTRKH2 (empty vector control); (2) 12AΔL-ldh1 containing pPPGMPET, pTRKH2 with an insert containing the L. casei codon optimized Zymomonas mobilis genes encoding pyruvate decarboxylase (Pdc) and alcohol dehydrogenase II (Adh2) activities under the control of the L. casei phosphoglycerate mutase (pgm) promoter; (3) an L. casei 12 A derivative (12AΔL-ldh1ΔL-ldh2ΔD-hic) lacking L-ldh1, L-ldh2, and D-hydroxyisocaproate dehydrogenase (D-Hic) containing pTRKH2; and (4) 12AΔL-ldh1ΔL-ldh2ΔD-hic containing pPPGM-PET. These fermentations were conducted at 37° C. for 96 h and the media had an initial pH of 6.0.
[0033] Three of the strains (12AΔL-ldh1(pTRKH2), 12AΔL-ldh(pP PGM -PET) and 12AΔL-ldh1ΔLldh2ΔD-hic (pP PGM -PET) reached an OD600 of greater than 1.0 within 24 h and grew at indistinguishable rates regardless of the glucose concentration, the presence or absence of either osmoprotectants, or Ery. The other strain, 12AΔL-ldh1ΔL-Idh2ΔD-hic (pTRKH2) grew poorly, never reaching an OD600 of greater than 0.05, even after 96 h, regardless of media composition; this corresponds with previous experiments and was expected, as this strain lacks an efficient mechanism to regenerate NAD+ from pyruvate.
[0034] The addition of osmoprotectants did not have a significant effect on growth of any of the strains under the conditions examined; however, the presence of the osmoprotectants did result in a reduction in lysis of strains producing ethanol in the presence of 2.5% glucose. No lysis was observed by the ethanol producing strains at the higher glucose concentrations, suggesting that the higher osmolarities induced genes that provide enhanced ethanol tolerance. The most significant finding from the growth experiments is that growth of L. casei 12A derivatives is not affected by the glucose (osmolarity) concentrations up to 10%, rather these conditions seem to enhance cell viability in stationary phase of 12A derivatives producing ethanol.
[0035] Metabolic end product accumulation in the small volume fermentations were determined by GLBRC Enabling Technologies (HPLC-RID), and the results for L. casei 12AΔL-ldh(pP PGM PET) and 12AΔL-ldh1ΔL-ldh2ΔD-hic(pP PGM -PET) are presented in Table 1. All of the glucose was consumed in fermentations containing 2.5% (139 mM) and 5.0% (278 mM) glucose. In fermentations containing 10% (566 mM) glucose, glucose utilization ranged from 8.1 to 9.5% (459.1 to 536.4 mM). The ethanol formed in the 2.5% (139 mM) glucose fermentations ranged from 1.3 to 1.4% (219.6 to 247.6 mM), with % theoretical yields ranging from 79 to 89%. The ethanol formed in the 5.0% (278 mM) glucose fermentations ranged from 2.6 to 2.7% (438.0 to 466.0 mM), with % theoretical yields ranging from 79 to 84%. The ethanol formed in the 10% (566 mM) glucose fermentations ranged from 3.3 to 3.8% (563 to 651.5 mM), with % theoretical yields ranging from 50 to 58%. In fermentations containing 10% (556 mM) glucose, significant accumulation of pyruvate (73.2 to 92.4 mM) was observed, suggesting that pyruvate decarboxylase activity has become limiting. Under all the conditions examined, L. casei 12AΔLldh1ΔL-ldh2ΔD-hic (pP PGM -PET) produced slightly more ethanol and slightly less lactate than L. casei 12AΔl-ldh (pP PGM -PET). Possible reasons for incomplete glucose utilization in fermentations containing 10% glucose include changes in the pH of the media and increases in pressure due to conducting the fermentations in closed vials. To overcome these issues, fermentations that allow for pH control and CO 2 release have been conducted.
[0036] Fermentations with 10% glucose with osmoprotectants and Ery have been conducted in our larger scale (500 ml) fermentation equipment that allows for pH control and CO 2 release with L. casei 12AΔL-ldh (pP PGM -PET) and 12AΔL-ldh1ΔL-ldh2ΔD-hic (pP PGM -PET) at 37° C., with pH maintained at 6.0. The growth and glucose utilization (enzymatic determination) results are presented in FIG. 1 . Growth of the two strains are indistinguishable under these conditions; however, greater glucose utilization was observed by 12AΔL-ldh(pP PGM -PET). Metabolic end product accumulation in these fermentations was determined by GLBRC Enabling Technologies (HPLC-RID), and the results are presented in Example B.
[0037] The 19 12A derivatives that were constructed via our two-step gene replacement method are presented in Table 2, clearly demonstrating the successful construction of a variety of 12A mutants.
[0000]
TABLE 1
Metabolic end products accumulated by L. casei 12A ethanologens during growth
in a chemically defined medium (initial pH 6.0) containing a different levels
of glucose, with and without osmoprotectants at 37° C. for 96 hrs.
%
Osmo-
Glucose (mM)
Products (mM)
Final
Ethanol
Strain
protectant
Int
Con
Rem
EtOH
Pyr
Lac
Ace
pH
(v/v)*
12A ΔL-Ldh1
−
142.0
142.0
BQL
227.9
BQL
12.3
6.6
5.4
1.3
(pP PGM -PET)
12A ΔL-Ldh1
−
277.0
277.0
BQL
438.0
14.1
26.6
4.9
4.7
2.6
(pP PGM -PET)
12A ΔL-Ldh1
−
499.7
393.7
106.0
600.0
73.2
31.8
5.3
4.5
3.5
(pP PGM -PET)
12A ΔL-Ldh1
+
137.3
137.3
BQL
219.6
BQL
11.8
6.6
6.2
1.3
(pP PGM -PET)
12A ΔL-Ldh1
+
278.1
278.1
BQL
445.4
3.3
39.1
3.2
4.7
2.6
(pP PGM -PET)
12A ΔL-Ldh1
+
499.3
469.6
29.6
563.0
86.1
40.5
5.3
4.4
3.3
(pP PGM -PET)
12A ΔL-Ldh1/
−
142.3
142.3
BQL
247.6
BQL
7.7
8.7
7.4
1.4
ΔL-Ldh2/ΔD-Hic
(pP PGM -PET)
12A ΔL-Ldh1/
−
282.6
282.6
BQL
443.5
18.3
17.9
9.1
7.2
2.6
ΔL-Ldh2/ΔD-Hic
(pP PGM -PET)
12A ΔL-Ldh1/
−
508.0
401.1
106.9
625.0
91.6
22.3
11.7
6.6
3.6
ΔL-Ldh2/ΔD-Hic
(pP PGM -PET)
12A ΔL-Ldh1/
+
139.5
139.5
BQL
233.2
BQL
7.6
8.0
6.1
1.4
ΔL-Ldh2/ΔD-Hic
(pP PGM -PET)
12A ΔL-Ldh1/
+
280.9
280.9
BQL
466.0
18.1
15.2
8.3
6.7
2.7
ΔL-Ldh2/ΔD-Hic
(pP PGM -PET)
12A ΔL-Ldh1/
+
507.9
408.9
99.0
651.5
92.4
26.0
12.4
6.8
3.8
ΔL-Ldh2/ΔD-Hic
(pP PGM -PET)
Abbreviations: BQL = Below Quantitative Level. Abbr: Int—initial, Con—consumed, Rem—remaining, EtOH—ethanol, Pyr—pyruvate, Lac—Lactate, Ace—acetate.
[0000]
TABLE 2
Lactobacillus casei 12A derivatives constructed in the past 10 months in the Steele
laboratory via gene replacement.
Single knockouts
Double knockouts
Triple knockouts
Quadruple knockouts
ΔL-ldh1*
ΔL-ldh1/ΔL-ldh2*
ΔL-ldh1/ΔL-ldh2/ΔL-ldh3
ΔoadA/Δpck/Δpyc/Δfum
ΔL-ldh2*
ΔL-ldh1/ΔL-ldh3
ΔL-ldh1/ΔL-ldh2/ΔL-ldh4
ΔoadA/Δpck/Δpyc/Δaspal
ΔL-ldh3
ΔL-ldh1/ΔL-ldh4
ΔL-ldh1/ΔLldh2/ΔD-ldh
ΔL-ldh4
ΔL-ldh1/ΔD-ldh
ΔL-ldh1/ΔL-ldh2/ΔD-hic*
ΔD-ldh
ΔL-ldh1/ΔD-hic
ΔoadA/Δpck/Δpyc
ΔD-hic
ΔL-ldh1/Δpck
Δals
ΔoadA/Δpck
Δald
ΔoadA/Δpyc
Δaldrc
Δpyc/Δpck
ΔoadA
Δpyc
Δpck
Δaspal
Abbreviations:
L-ldh—L-lactate dehydrogenase,
D-ldh—D-lactate dehydrogenase,
D-hic—D-hydroxyisocaproate dehydrogenase,
als—acetolactate synthase,
ald—alpha acetolactate decarboxylase,
a/drc—acetoin/diacetyl reductase,
oad—oxaloacetate decarboxylase,
pyc—pyruvate carboxylase,
pck—phosphoenolpyruvate carboxikinase.
aspal—aspartate-ammonia lyase,
fum—fumarase.
Asterisk - derivatives transformed with pP PGM -PET are available.
Example B
[0038] This example shows the analysis of the data we obtained from the fermentations with 10% glucose with osmoprotectants and Ery that were conducted in our larger scale (500 ml) fermentation equipment with Lactobacillus casei 12AΔL-ldh (pP PGM -PET) and 12AΔL-ldh1ΔLldh2ΔD-hic (pP PGM -PET) at 37° C., with pH maintained at 6.0. We could only accommodate three fermentation vessels at a time. Therefore, only the 12AΔL-ldh (pP PGM -PET) fermentation was conducted in duplicate.
[0039] The growth, glucose utilization, and ethanol production shown by these strains are presented in FIGS. 2A ( L. casei 12AΔL-ldh (pP PGM -PET)) and 2 B ( L. casei 12AΔL-ldh1ΔLldh2ΔD-hic (pP PGM -PET)). The growth of the two strains under these conditions was indistinguishable. However 12AΔL-ldh (pP PGM -PET) utilized a greater quantity of glucose and produced more ethanol than 12AΔL-ldh1ΔL-ldh2ΔD-hic (pP PGM -PET). The glucose utilization and ethanol formation obtained with 12AΔL-ldh (pP PGM -PET) in the larger fermentation vessels was significantly greater than that obtained in the small volume fermentations described in Example A. The mostly likely reason for this difference is that the larger vessels allow for pH control.
[0040] The metabolic end products formed and glucose utilized as a function of time for these fermentations is presented in Tables 3 and 4. 12AΔL-ldh1 (pP PGM -PET) will be the focus of this discussion, due to its higher productivity. This 12A derivative utilized 504.5 mM glucose (9.1%) glucose in 96 h and produced 934.7 mM of “pyruvate-derived” metabolic end products, which is 87.4% of the theoretical yield from glucose. Ethanol was produced at a level of 771.3 mM (4.5%), which was 82.5% of the metabolic end-products.
[0041] The second most abundant metabolic end product was pyruvate, which was present at 110.1 mM after 96 h. Pyruvate accumulation began at approximately 21 h, at the same time, ethanol as a percentage of the total metabolic end products began to decrease (% ethanol in total), suggesting that pyruvate decarboxylase activity becomes limiting at that time. This corresponds to the entry of this organism into stationary phase, suggesting that the L. casei phosphoglycerate mutase (pgm) promoter used to drive expression of the PET cassette is poorly expressed in stationary phase. It is highly likely that pyruvate accumulation can be overcome by utilizing a L. casei promoter highly expressed in stationary phase. If the pyruvate, which had accumulated after 96 h in the 12AΔL-ldh1(pPPGM-PET) fermentation, had been converted to ethanol, a total of 881.4 mM (5.14%) ethanol would have been produced. Additionally, the rate of glucose utilization would have been even higher, as pyruvate accumulation is known to inhibit glycolysis.
[0042] It is difficult to directly compare our results to what is known concerning other biocatalysts, due to differences in media and fermentation equipment utilized. However, the results obtained in these L. casei 12AΔL-ldh1 (pP PGM -PET) fermentations are most similar to the Escherichia coli GLBRCE1 synthetic hydrolysate fermentations reported by Schwalbach et al. (2012, AEM 78:3442) in E. coli . GLBRCE1 converted 338 mM glucose into 477 mM ethanol, an ethanol yield of 70.5% of the theoretical maximum. L. casei 12AΔL-ldh1 (pP PGM -PET) converted 504.5 mM glucose into 771.3 mM ethanol, an ethanol yield of 76.4% of the theoretical maximum.
[0000]
TABLE 3
Metabolic end products formed and glucose consumption by Lactobacillus casei
12A ΔL-Ldh1 (pP PGM -PET) at 37° C. in a chemically defined
media containing 10% glucose with pH maintained at 6.0.
%
%
Time
Glucose (mM)
Products (mM)
%
Ethanol
Ethanol
Ethanol:Lactate
(hr)
Rem
Con
Total
EtOH
Pyr
Lac
Ace
yield
in total
(v/v)
ratio (mM:mM)
0
534.9
BQL
12.5
11.1
0.0
0.1
1.2
1.2
89.2
0.1
85
1
540.6
BQL
22.7
12.0
0.0
5.4
5.3
2.1
52.7
0.1
2
2
545.2
BQL
24.0
12.8
0.0
5.5
5.7
2.2
53.4
0.1
2
3
544.8
BQL
19.2
12.8
0.0
2.5
3.8
1.8
67.0
0.1
5
4
536.5
BQL
21.5
15.0
0.0
2.3
4.2
2.0
70.0
0.1
7
5
531.4
BQL
33.5
27.1
0.0
1.3
5.0
3.1
81.0
0.2
20
6
544.4
BQL
28.2
21.7
0.0
0.9
5.6
2.6
77.0
0.1
25
7
542.2
BQL
36.8
29.4
0.0
1.8
5.7
3.4
79.8
0.2
17
8
551.2
BQL
42.3
34.4
0.0
2.1
5.8
4.0
81.3
0.2
16
9
539.9
BQL
51.2
42.8
0.0
2.7
5.8
4.8
83.5
0.2
16
10
535.1
BQL
67.0
58.1
0.0
3.3
5.6
6.3
86.7
0.3
18
11
513.9
21.0
74.9
66.1
0.0
3.6
5.2
7.0
88.2
0.4
18
12
521.1
13.8
90.6
82.5
0.0
2.9
5.2
8.5
91.0
0.5
28
13
512.8
22.1
105.1
96.8
0.0
3.4
4.9
9.8
92.1
0.6
29
14
506.3
28.7
124.5
116.1
0.0
3.9
4.4
11.6
93.3
0.7
29
15
490.8
44.1
140.0
131.7
0.0
4.4
4.0
13.1
94.0
0.8
30
16
481.5
53.5
158.7
150.1
0.0
4.9
3.7
14.8
94.6
0.9
31
17
463.4
71.5
175.4
166.6
0.0
5.4
3.4
16.4
95.0
1.0
31
18
439.5
95.4
196.7
187.6
0.0
5.9
3.2
18.4
95.4
1.1
32
19
442.9
92.0
223.0
213.2
0.0
6.7
3.1
20.8
95.6
1.2
32
20
419.4
115.5
235.4
225.5
0.0
7.0
2.8
22.0
95.8
1.3
32
21
414.8
120.1
258.5
247.6
0.4
7.8
2.7
24.2
95.8
1.4
32
22
402.2
132.7
275.1
263.0
1.1
8.4
2.7
25.7
95.6
1.5
31
23
389.1
145.8
292.6
278.7
2.1
9.2
2.5
27.3
95.3
1.6
30
24
412.0
122.9
297.6
281.5
3.4
9.8
2.8
27.8
94.6
1.6
29
25
375.9
159.0
336.1
318.4
4.4
10.8
2.5
31.4
94.7
1.9
29
26
357.3
177.6
353.2
332.4
5.7
11.8
3.3
33.0
94.1
1.9
28
27
343.8
191.1
363.0
339.7
7.8
12.4
3.1
33.9
93.6
2.0
27
28
339.7
195.2
387.7
362.0
9.4
13.3
2.9
36.2
93.4
2.1
27
29
336.6
198.3
411.0
382.9
10.5
14.3
3.2
38.4
93.2
2.2
27
30
318.4
216.5
411.7
383.1
11.1
14.7
2.9
38.5
93.0
2.2
26
32
292.4
242.5
451.8
421.5
12.9
15.1
2.3
42.2
93.3
2.5
28
34
289.7
245.2
481.8
445.1
16.3
17.4
2.9
45.0
92.4
2.6
26
44
221.6
313.3
588.7
533.1
29.3
22.8
3.4
55.0
90.6
3.1
23
50
187.2
347.7
656.5
584.7
41.6
25.7
4.4
61.4
89.1
3.4
23
58
151.4
383.5
714.0
623.4
56.3
28.5
5.8
66.7
87.3
3.6
22
66
118.6
416.3
768.6
664.1
65.3
31.5
7.7
71.8
86.4
3.9
21
70
99.9
435.0
813.2
691.8
78.8
33.4
9.2
76.0
85.1
4.0
21
74
92.2
442.7
827.3
702.8
81.3
33.8
9.4
77.3
85.0
4.1
21
82
62.4
472.5
873.8
744.0
81.1
36.8
11.9
81.7
85.1
4.3
20
90
44.1
490.8
913.8
764.4
97.8
38.3
13.2
85.4
83.7
4.5
20
96
30.4
504.5
934.7
771.3
110.1
39.2
14.1
87.4
82.5
4.5
20
[0000]
TABLE 4
Metabolic end products formed and glucose consumption by Lactobacillus casei
12A ΔL-Ldh1/ΔL-Ldh2/ΔD-Hic (pP PGM -PET) at 37° C. in a
chemically defined media containing 10% glucose with pH maintained at 6.0.
%
Ethanol
%
Time
Glucose (mM)
Products (mM)
%
in total
Ethanol
Ethanol:Lactate
(hr)
Rem
Con
Total
EtOH
Pyr
Lac
Ace
yield
product
(v/v)
ratio (mM:mM)
0
575.3
BQL
13.3
13.3
0.0
0.0
0.0
1.2
100.0
0.1
—
1
557.1
18.3
12.9
12.9
0.0
0.0
0.0
1.1
100.0
0.1
—
2
553.1
22.3
12.7
12.5
0.0
0.0
0.2
1.1
98.1
0.1
—
3
566.0
9.3
15.2
14.5
0.0
0.0
0.6
1.3
96.0
0.1
—
4
541.8
33.6
16.7
15.2
0.0
0.0
1.5
1.5
90.9
0.1
—
5
548.8
26.5
21.7
18.7
0.0
0.0
3.0
1.9
86.2
0.1
—
6
543.2
32.1
25.8
21.0
0.0
0.0
4.9
2.2
81.2
0.1
—
7
551.2
24.1
31.6
25.5
0.0
0.0
6.1
2.7
80.6
0.1
—
8
554.9
20.4
36.8
30.6
0.0
0.0
6.2
3.2
83.1
0.2
—
9
551.3
24.0
45.6
38.5
0.0
1.1
6.0
4.0
84.4
0.2
36
10
532.7
42.6
55.5
48.7
0.0
0.9
5.9
4.8
87.6
0.3
53
11
532.3
43.0
64.5
57.7
0.0
1.1
5.8
5.6
89.4
0.3
54
12
544.0
31.3
76.6
70.6
0.0
0.0
6.1
6.7
92.1
0.4
—
13
536.6
38.7
87.7
82.1
0.0
0.0
5.6
7.6
93.6
0.5
—
14
519.6
55.8
101.5
93.7
0.0
2.6
5.2
8.8
92.3
0.5
36
15
510.2
65.1
111.9
107.0
0.0
0.0
4.9
9.7
95.7
0.6
—
16
513.9
61.4
134.2
125.5
0.0
3.8
4.8
11.7
93.6
0.7
33
17
474.2
101.1
134.7
130.7
0.0
0.0
3.9
11.7
97.1
0.8
—
18
485.3
90.0
167.7
158.3
0.0
5.5
3.9
14.6
94.4
0.9
29
19
463.7
111.6
179.9
170.4
0.0
5.9
3.5
15.6
94.8
1.0
29
20
462.1
113.2
199.4
189.4
0.0
6.8
3.2
17.3
95.0
1.1
28
21
459.0
116.3
218.4
207.8
0.0
7.6
3.0
19.0
95.1
1.2
27
22
451.9
123.5
236.9
224.9
0.7
8.6
2.8
20.6
94.9
1.3
26
23
426.3
149.0
238.0
235.8
0.0
0.0
2.3
20.7
99.0
1.4
—
24
380.6
194.7
314.8
299.9
3.5
9.4
1.9
27.4
95.3
1.8
32
25
426.0
149.3
295.3
279.1
3.6
10.4
2.2
25.7
94.5
1.6
27
26
384.5
190.8
297.1
283.3
2.5
9.6
1.7
25.8
95.3
1.7
29
27
365.0
210.3
301.5
289.6
0.5
9.6
1.8
26.2
96.1
1.7
30
28
371.3
204.1
331.6
317.2
1.7
11.0
1.6
28.8
95.7
1.9
29
29
360.5
214.8
339.2
320.3
5.6
10.9
2.3
29.5
94.4
1.9
29
30
332.9
242.4
341.2
326.4
2.9
10.9
1.0
29.7
95.7
1.9
30
32
333.5
241.8
395.1
375.6
5.8
12.5
1.2
34.3
95.1
2.2
30
34
296.7
278.6
381.7
363.9
5.3
12.1
0.4
33.2
95.3
2.1
30
44
272.5
302.8
520.6
480.5
22.4
14.4
3.2
45.2
92.3
2.8
33
50
245.1
330.2
578.6
527.3
30.5
16.6
4.2
50.3
91.1
3.1
32
58
216.0
359.4
627.0
564.1
39.4
17.6
5.8
54.5
90.0
3.3
32
66
194.1
381.3
681.0
606.2
49.2
18.3
7.2
59.2
89.0
3.5
33
70
175.2
400.1
700.5
618.2
54.8
19.5
8.0
60.9
88.3
3.6
32
74
169.5
405.8
706.8
622.6
56.7
19.2
8.3
61.4
88.1
3.6
32
82
149.8
425.5
712.2
639.6
63.1
0.0
9.5
61.9
89.8
3.7
—
90
141.0
434.3
752.9
672.0
70.1
0.0
10.8
65.4
89.3
3.9
—
96
126.6
448.7
774.2
663.3
79.0
21.1
10.7
67.3
85.7
3.9
31
Abbreviations in Tables: Rem, Remaining; Con, consumed; EtOH, ethanol; Pyr, pyruvate; Lac, lactate; Ace, acetate.
% yield = (mM Total product/(2 × mM initial Glucose)) × 100
% Ethanol = (mmol/L ethanol × 46.068 g/mol)/(1000 mg/g) × (1000 ml/L/100 ml) × (0.789 g/ml).
Example C
Screening Strains of L. casei for Biofuels Relevant Phenotypes and Genes
[0043] Our laboratory has a culture collection contains approximately 60 strains of L. casei isolated from green plant material (i.e. corn silage), cheese, wine, and humans. The eleven strains with genome sequences were screened for the ability to utilize 60 different carbohydrates, including numerous carbohydrates present in lignocellulosic feed stocks. Individual strains were able to grow on between 17 and 26 different substrates. The strains isolated from corn silage (12A and 32G) grew on the greatest number of substrates. Nine gene clusters potentially involved in cellobiose utilization and one gene cluster involved in xylose utilization were identified.
[0044] The eleven strains with genomic information were also screened for alcohol tolerance (ethanol, 1-propanol, 1-butanol, and 2-methyl-1-butanol), growth in AFEX-pretreated corn stover hydrolysate (ACSH), and transformation (electroporation) efficiency. L. casei 12A exhibited the greatest tolerance to the biofuels examined. For example, when grown in the presence of 10% ethanol, it reached a final cell density 40% of that it attained in the absence of ethanol. Of the 11 strains examined for growth in corn stover hydrolysate, 3 of these strains (ATCC 334, 21-1, and 12A) grew significantly better, reaching a final optical density at 600 nm of approximately 2.0 within 28 h. Five L. casei strains were examined for transformation efficiency with pTRKH2 (O'Sullivan and Klaenhammer 1993). L. casei 12A exhibited a frequency (approximately 5×10 5 transformants per ug of pTRKH2) at least 50-fold higher than that observed with any of the other strains examined. Based upon the results from these analyses, L. casei 12A was selected as the biofuel producing parental strain.
[0045] Completing the L. casei 12A genome. For further information regarding the L. casei 12A genome, see Broadbent, et al., BMC Genomics 2012, 13:533, which is incorporated by reference herein. To enhance the depth of genomic sequence coverage of 12A, genomic DNA was prepared and submitted to the Joint Genome Institute (JGI) for genome sequencing. A draft genome of L. casei 12A with approximately 500× coverage assembled into 397 scaffolds was received from JGI. This genome assembly was subsequently merged with the previous 23×454-generated paired end genome assembly in collaboration with personnel from DuPont Inc. (Madison, Wis.), yielding a genome assembly with 19 ordered contigs. We have generated PCR amplicons across all 19 gaps, and have sequenced 10 of these amplicons.
[0046] L. casei Metabolic Models.
[0047] We have developed a genome-scale metabolic model for L. casei ATCC334 (the neotype strain) and 12A using the ModelSEED database and the genome annotation from RAST. We have modified the draft L. casei 12A model from ModelSEED using the following processes: 1) thermodynamically infeasible cycles were removed, 2) elementally imbalanced metabolic reactions were corrected; and 3) model predictions for amino acid requirements were compared against experimental growth phenotypes determined in a lactobacilli chemically defined medium (CDM) described by Christensen and Steele (J. Bacteriol. 185 (2003): 3297-3306). Inconsistencies were corrected by the addition or deletion of some reactions.
[0048] Redirecting Metabolic Flux in L. casei 12A to Ethanol.
[0049] The development of a method to inactivate genes in L. casei was a requirement for the construction of a L. casei strain capable of converting lignocellulosic biomass to ethanol. An efficient gene replacement method based on the introduction of pCJK47-based constructs (Kristich et al. 2007) via a 12A optimized electroporation protocol was developed.
[0050] A two pronged approach was employed to redirect metabolic flux in L. casei 12A to ethanol. The first approach is to inactivate genes that encode enzymes which compete with the 12A pathway to ethanol, which has acetyl-CoA as an intermediate. There are a large number of genes that encode enzymes potentially involved in anaerobic pyruvate metabolism in L. casei . We have inactivated 9 of these genes: pyruvate-formate lyase (Pfl), the four L-lactate dehydrogenases (L-ldh1, Lldh2, L-ldh3, and L-ldh4), D-lactate dehydrogenase (D-ldh), D-hydroxyisocaproate dehydrogenase (DHic), acetolactate synthase (Als), and oxaloacetate decarboxylase (OadA). Additionally, 5 derivatives lacking two or three of the dehydrogenases have been constructed. Characterization of the end product distribution these mutants is presented in Table 5. The highest level of metabolic redirection to ethanol achieved to date using this approach, is 21%, achieved with the 12A ΔL-ldh1ΔL-ldh2ΔD-hic derivative. It is interesting to note that this derivative also accumulates pyruvate.
[0051] The second approach utilized to direct metabolic flux in 12A towards ethanol was the introduction of the genes from Zymomonas mobilis that encode pyruvate decarboxylase (Pdc) and alcohol dehydrogenase II (Adh2) activities (PET cassette). These genes were designed utilizing the L. casei codon usage for highly expressed genes with a constitutive L. casei promoter (phosphoglycerate mutase), synthesized by GeneArt, ligated with digested pTRKH2 (pPGM-PET), and introduced into 12A derivatives by electroporation. Characterization of the end product distribution of two of these derivatives has been completed and is presented in Table 5. The highest level of metabolic redirection to ethanol achieved to date using this approach is 85.3%, achieved with the 12A ΔL-ldh1ΔL-ldh2 (pP pgm -PET) derivative. It is interesting to note that 12A derivatives with pP pgm -PET grow more rapidly than their corresponding strains, suggesting that ethanol is less inhibitory to 12A derivatives than lactate.
[0052] These results suggest that the two pronged approach is effective for redirecting 12A metabolic flux to ethanol.
[0000]
TABLE 5
Growth, substrate consumption, and metabolic end products formed by Lactobacillus casei
12A and derivatives during growth in a chemically defined media at 37° C. for 48 hrs.
Concentration (mM)
Growth
Substrate
Metabolic End Products
EtOH/
Max
T
Utilization a
(% of total) b
Yield
Lac
Derivative
OD
(h)
Glc
Cit
Total
L-lac
D-lac
EtOH
Ace
Pyr
(%) c
ratio d
12A
1.05
8.1
51.5
0.6
112.2
105.4,
3.3
1.4,
2.1,
BQL
108
0.0
(94)
(3)
(1)
(2)
12A ΔL-ldh1
1.28
7.0
52.6
11.5
87.0
42.3,
28.2,
16.5,
BQL
BQL
68
0.2
(49)
(32)
(19)
12A ΔL-ldh2
1.01
8.3
53.1
5.8
111.8
105.0,
3.2,
1.6,
2.0,
BQL
95
0.0
(94)
(3)
(1)
(2)
12A ΔL-ldh3
1.02
8.0
52.7
9.0
110.2
103.0,
3.2,
2.1,
1.9,
BQL
90
0.0
(94)
(3)
(2)
(2)
12A ΔD-ldh
1.02
7.7
51.9
BQL
112.4
103.5,
5.4,
1.1,
2.4,
BQL
108
0.0
(92)
(5)
(1)
(2)
12A ΔD-hic
1.26
7.9
51.5
BQL
112.0
109.7,
BQL
0.5,
1.8,
BQL
109
0.0
(98)
(1)
(2)
12A ΔL-ldh1/
1.26
7.1
52.8
15.0
86.7
32.1,
42.6,
12.0,
BQL
BQL
64
0.2
ΔD-ldh
(37)
(49)
(14)
12A ΔL-ldh1/
1.11
9.7
51.2
13.9
79.8
64.9,
BQL
14.9,
BQL
BQL
61
0.2
ΔD-hic
(81)
(19)
12A ΔL-ldh1/ΔL-
0.93
9.4
52.5
10.3
71.4
BQL
51.5,
18.6,
BQL
1.3,
57
0.4
ldh2/ΔD-ldh
(72)
(26)
(2)
12A ΔL-ldh1/ΔL-
0.52
31.3
21.7
12.8
36.1
0.6,
0.4
7.6,
7.2,
20.3,
52
7.6
ldh2/ΔD-hic
(2)
(1)
(21)
(20)
(56)
12A (pTRKH2)
1.01
13.2
52.5
BQL
108.9
100.4,
7.6,
BQL
0.9,
BQL
104
0.0
(92)
(7)
(1)
12A (pPGM-PET)
0.95
6.79
51.3
8.2
95.1
14.8,
13.2,
58.1,
9.0,
BQL
80
2.1
(16)
(14)
(61)
(10)
12A ΔL-ldh1
1.11
11.3
52.3
2.7
87.7
41.6,
34.0,
12.1,
BQL
BQL
80
0.2
(pTRKH2)
(47)
(39)
(14)
12A ΔL-ldh1
1.03
6.8
51.0
16.3
102.1
2.7,
5.0,
84.5,
9.8
BQL
76
10.9
(pPGM-PET)
(3)
(5)
(83)
(10)
12A ΔL-ldh1/ΔL-
1.01
7.9
50.9
16.0
100.2
0.7,
5.1,
85.3,
9.1,
BQL
75
14.7
ldh2 (pPGM-PET)
(1)
(5)
(85)
(9)
a Reported by the initial concentration of glucose or citrate subtracted by the final concentration of the respective compound at 48 hrs.
b In parenthesis, metabolic end product distribution by % of total.
c Calculated by percentage of total metabolic end products produced/2 × (glucose + citrate) in mmoles.
d Expressed as molar ratio, where lactate is the summation of both the L- and D- forms.
Abbreviations: BQL = below quantifiable level; NA = not applicable; Glu = glucose; Cit = citrate; Lac = lactate; ETOH = ethanol; Ace = acetate; Pyr = pyruvuate.
indicates data missing or illegible when filed
Example D
Conversion of a Lactic Acid Bacterium Lactobacillus casei 12A to an Ethanologen
[0053] Lactobacillus casei 12A was selected as the biofuels parental strain based upon its alcohol tolerance (grows in the presence of >10% ethanol), carbohydrate utilization, and relatively high transformation efficiency. This organism metabolizes hexoses through the Embden-Meyerhof-Parnas pathway and converts pyruvate to lactate via a variety of different enzymes; including four L-lactate dehydrogenases (Ldh), one D-Ldh, and one D-hydroxyisocaproate dehydrogenase.
[0054] Essential characteristics of organisms to be utilized for microbial production of ethanol from plant biomass include the ability to secrete enzymes, transport glucose and xylose, metabolize glucose and xylose to ethanol, as well as have sufficient ethanol tolerance to make the fermentation economically viable. It is unlikely an organism capable of meeting all of these criteria will be isolated from nature. Therefore, rational strategies to engineer strains for the industrial production of ethanol from plant biomass are preferred. The following characteristics make L. casei 12A an ideal Gram-positive species for research in this area:
Designation as a GRAS (Generally Regarded As Safe) species. Established platforms for introducing and expressing foreign DNA. Relatively simple fermentative metabolism with almost complete separation of cellular processes for biosynthesis and energy metabolism. Resistance to environmental stress, including high concentrations of acids and biofuels Ability to use lignocellulosic carbohydrates. Ability to secrete and display proteins, hence potential for use in consolidated bioprocessing.
[0061] We pursued two strategies concurrently to redirect L. casei 12A fermentation to ethanol. The first strategy involved inactivation of enzymes that consume pyruvate under anaerobic conditions without producing ethanol, including the D-Ldh; four L-Ldhs; D-(D-Hic); acetolactate synthase (Als); and oxaloacetate decarboxylase (Oad). This approach has been used to inactivate L-ldh1, L-ldh2, and D-hic, as well as to construct the L-ldh1/L-ldh2, double mutant. The highest level of ethanol formation was observed with the ΔL-ldh1/ΔL-ldh2 double mutant, which produces ethanol as 14% of its metabolic end products.
[0062] Our second strategy for increasing flux to ethanol involved expressing ethanol producing enzymes. A codon optimized “PET” cassette comprised of the Zymomonas mobilis genes encoding pyruvate decarboxylase (Pdc) and alcohol dehydrogenase (Adh2) was constructed, and placed under the control of the L. casei 12A pgm promoter, pgm ribosomal binding site and kdgR transcriptional terminator. When this construct was introduced into L. casei 12A, ethanol made up 61% of metabolic end products formed. When introduced into L. casei 12A (ΔL-ldh1), ethanol was the dominant product observed (91% of metabolic end productions). Results from this analysis indicate that the two approaches are complementary and demonstrate that redirecting metabolic flux in L. casei from lactate to an alcohol can be readily achieved.
[0063] The general strategy that was used to redirect metabolic flux in L. casei 12A from lactic acid to ethanol is illustrated in detail in FIG. 3 . Two different methods were used to carry out the strategy. The first method, involving gene deletion, is illustrated in FIG. 4 . The second method, involving the construction and subsequent expression of a synthetic PET expression cassette construct in pTRKH2, is illustrated in FIG. 5 . The growth of the resulting L. casei 12A ethanologens in Chemically Defined Medium (CDM) is illustrated in FIG. 6 . The fermentation by-products of the L. casei mutants grown in CDM were measured, and the results are shown in Table 6.
[0000]
TABLE 6
Fermentation products of L. casei 12A and mutants with and
without pTRKH2 or pPGM-PET growth in CDM for 48 hrs.
Derivative
Ethanol (%)
L-Lactate (%)
D-Lactate (%)
12A
0.0
95.0
5.0
12A ΔL-ldh1
6.0
49.0
45.0
12A ΔL-ldh2
0.0
96.0
4.0
12A ΔD-hic
0.0
71.0
29.0
12A ΔL-ldh1ΔL-ldh2
14.0
34.0
52.0
12A (pTRKH2)
0.0
95.0
5.0
12A (Ppgm-PET)
61.0
34.0
1.0
12A ΔL-ldh1 (pTRKH2)
13.0
47.0
40.0
12A ΔL-ldh1
90.9
1.5
1.5
(Ppgm-PET)
Note:
L. casei 12A mutants were grown in MRS from glycerol stock for 24 hrs at 37° C. then transferred to MRS and incubated for an additional 18 hrs. CDM containing 50 mM glucose was inoculated and incubated in GC vials for 48 hrs at 37° C. At the 48-hr time point, supernanant was drawn off and submitted to GLBRC enabling technologies for fermentation by-product analysis via HPLC-RID.
[0064] Conclusions.
[0065] Inactivation of L-Ldh1 reduced flux towards L-lactate and enhanced flux towards D-lactate and ethanol. Inactivation of L-Ldh2 increased these changes in metabolic flux.
[0066] In L. casei 12A with the PET cassette, ethanol made up 61% of metabolic end products formed, while 91% of metabolic end productions were directed to ethanol when the PET cassette was introduced into L. casei 12A ΔL-ldh1.
[0067] The two pronged strategy, inactivating genes encoding enzymes that produce lactic acid and introducing the PET cassette, effectively converted L. casei 12A from producing lactate as its main metabolic product to producing ethanol as its main metabolic end product.
REFERENCES
[0000]
Cai, H., Thompson, R. L., Broadbent, J. R., and Steele, J. L. (2009). Genome Sequence and Comparative Genome Analysis of Lactobacillus casei : Insights into their Niche-associated Evolution. Genome Biol. and Evol. 1:239-257.
Duong, T., Miller, M. J., Barrangou, R., Azcarate-Peril, M. A., and Klaenhammer, T. R. (2010). Construction of vectors for inducible and constitutive gene expression in Lactobacillus . Microbiol Biotech, 4(3): 357-367.
Kristich, C. J., Chandler, J. R., and Dunny, G. M. (2007). Development of a host-genotype-independent counterselectable marker and a high-frequency conjugative delivery system and their use in genetic analysis of Enterococcus faecalis . Plasmid 57:131-144.
Example E
Use of Alternate Promoter
[0071] In the previous examples, a first generation Lactobacillus casei ethanologen was created by a two pronged approach to redirect metabolic flux in L. casei 12A from lactate to ethanol. The first prong was to inactivate genes encoding lactate dehydrogenases, enzymes which compete with the 12A pathway to ethanol. The second prong was the introduction of the genes from Zymomonas mobilis that encode pyruvate decarboxylase (Pdc) and alcohol dehydrogenase II (Adh2) activities (PET cassette). These genes were designed utilizing the L. casei codon usage for highly expressed genes and placed under the control of L. casei phosphoglycerate mutase promoter, thought to be a constitutively expressed promoter.
[0072] This approach was highly successful, resulting in a strain that utilized 504.5 mM glucose (9.1%) glucose in 96 h and produced 934.7 mM of “pyruvate-derived” metabolic end products, which is 92.6% of the theoretical yield from 504.5 mM glucose in a 500 ml fermentation vessel under anaerobic conditions at 37° C. in a defined media with 540 mM glucose. Ethanol was produced at a level of 771.3 mM (4.5%), which was 82.5% of the metabolic end-products. The second most abundant metabolic end product was pyruvate which was present at 110.1 mM after 96 h.
[0073] Pyruvate accumulation began at approximately 21 h. At the same time, ethanol as a percentage of the total metabolic end products began to decrease (% ethanol in total), suggesting that pyruvate decarboxylase activity becomes limiting at that time. This corresponds to the entry of this organism into stationary phase, suggesting that the L. casei phosphoglycerate mutase (pgm) promoter used to drive expression of the PET cassette is poorly expressed in stationary phase. It is highly likely that pyruvate accumulation can be overcome by utilizing a L. casei promoter highly expressed in stationary phase.
[0074] Accordingly, this prophetic example discloses the next generation L. casei ethanologen, having the PET cassette placed under the control of a promoter that is highly expressed in stationary phase. For example, either the GroEL or DnaK promoters, as they have been demonstrated to be highly expressed in a related organism, L. plantarum , when this organism was exposed to ethanol (Gyu et al. 2012). The anticipated result from such a construct would be that the 110.1 mM pyruvate that was observed to accumulate in the previous fermentation (see above) would be converted to ethanol. This would then yield 881.4 (110.1+771.3) mM of ethanol, or 87.4% of the theoretical yield from 504.5 mM glucose.
REFERENCES
[0000]
Lee, S. G., K. W. Lee, T. H. Park, J. Y. Park, N. S. Han, and J. H. Kim. 2012. Proteomic analysis of proteins increased or reduced by ethanol of Lactobacillus plantarum ST4 isolated from makgeolli , traditional Korean rice wine. J. Microbiol. Biotechnol. 22:516-525.
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An engineered bacterium for producing ethanol from one or more carbohydrates is disclosed. The bacterium can be made by (a) inactivating within a Lactobacillus casei bacterium one or more endogenous genes encoding a lactate dehydrogenase; or (b) introducing into a Lactobacillus casei bacterium one or more exogenous genes encoding a pyruvate decarboxylase and one or more exogenous genes encoding an alcohol dehydrogenase II; or (c) performing both steps (a) and (b). The resulting engineered bacterium produces significantly more ethanol than the wild-type Lactobacillus casei bacterium, and can be used in producing ethanol from a substrate such as biomass that includes carbohydrates.
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BACKGROUND OF THE INVENTION
This invention relates to a continuous high speed process for texturing of thermoplastic synthetic fiber, especially texturing multifilament yarn to exceptionally high crimp levels. A particular feature of this invention is that the yarn is dimensionally stabilized or "set" by heat, in advance of the crimping operation, to low levels of shrinkage. Another feature is that the texturing is fast enough to allow coupling with a high-speed yarn drawing operation in a continuous process.
It is broadly known to couple the drawing and texturing of multifilament thermoplastic synthetic yarns, in particular polyethylene terephthalate ("PET") yarns which have been partially oriented to a birefringent value of about 15-30% of that observed in the drawn yarn, and having appreciable but low crystallinity as indicated by density. See Textile Research Journal, Feb. 1975, pp. 112-117, article by O. L. Shealy and R. E. Kitson.
A particular method of texturing thermoplastic synthetic yarn at high speed is taught in the U.S. patent application of Li, Oswald and Liland, Ser. No. 675,353, filed Apr. 9, 1976, now U.S. Pat. No. 4,074,405, granted 2/21/78 for "Method and Apparatus For Texturing Yarn" and in U.S. Pat. Nos. 4,024,610 and 4,024,611, both of May 24, 1977 to the same Li, Liland and Oswald.
Such method involves advancing and plasticizing a drawn synthetic yarn such as PET yarn drawn over a hot plate between two pairs of heated godets. The yarn is aspirated through a tube, sometimes called an "energy tube" in this art, with hot compressible fluid such as superheated steam; then the yarn strikes with sharp impact, as it issues from the energy tube, at an oblique angle against an unyielding barrier such as a moving perforate (including mesh) surface (especially a wire screen) within a chamber having a stationary cover and an outlet in the cover. A plug of the yarn in the chamber results from allowing a major portion of the fluid to pass out practically immediately, as through the perforate moving surface, and from the relatively slow advancement of the yarn as it is conveyed to the outlet from the chamber on such moving surface, moving at lower linear velocity than that of the yarn issuing from the energy tube. If desired, the yarn can be preheated before entering the energy tube; and/or a further amount of hot fluid can be introduced into the chamber for purposes of setting the crimps.
Another texturing method also involves forwarding incoming yarn by use of hot fluid such as superheated steam, into a chamber with provision for release of steam but without provision for an initial sharp impact of the yarn with an unyielding barrier. Thus, in U.S. Pat. No. 3,438,101 of Apr. 15, 1969 to Le Noir et al. for "Process and Apparatus for Texturizing Yarn," steam forces yarn through a tube onto a revolving wire screen forming the bottom of a peripheral chamber around a revolving drum, which chamber is covered over by an endless belt which drives the drum. The yarn is crimped by impingement against yarn compacted in the revolving chamber. Also, U.S. Pat. No. 4,019,228 of Apr. 26, 1977 to Ozawa et al. teaches use of an ejection nozzle whereby superheated steam forces yarn at high speed into a rotating stuffing chamber, covered with a stationary cover and having a peripheral screen surface. This apparatus is said to allow coupling known drawing processes with the crimping apparatus of the invention (Col. 7, lines 27-43; FIG. 10; FIG. 11; Examples 3, 4 and 6-9). The patent teaches also use of a yarn preheater upstream of the nozzle, operating to enhance the heat setting of the crimps formed by use of the apparatus (Col. 7, lines 16-26, FIG. 9 and Example 2).
Also of interest is U.S. Pat. No. 3,739,056 of June 12, 1973 to E. F. Evans et al. for "Draw/Relax/Anneal Process for Polyesters." This patent teaches processing of undrawn, amorphous polyester (such as PET) fibers including steps of drawing in a spray of heated liquid, relaxing in a steam jet, annealing at constant length by passing over a series of heated rolls, passing through a cooling spray, and passing to a "crimper 58" (Col. 2, lines 8-28 and FIG. 1). An alternative to annealing rolls is a hot plate (Col. 2, lines 38-52 and FIG. 3). The purpose of the relaxing and annealing is to develop both good tenacity and good dyeability (Col. 2, line 53-Col. 3, line 28).
Also to be noted is U.S. Pat. No. 3,665,567 of May 30, 1972 to Clarkson for "Yarn Rebound Texturing Apparatus and Method." Yarn carried by steam through a tube, is crimped by being hurled out of the tube longitudinally against a foraminous surface, from which it rebounds and then drops into a heat-setting chamber. The yarn prior to passage through the tube, is drawn in a conventional manner between two pairs of heated godet rolls.
SUMMARY OF THE INVENTION
In accordance with the present invention, multifilament thermoplastic synthetic yarn such as especially polyethylene terephthalate and nylon of relatively low birefringence and relatively low density (partially oriented or undrawn yarn, as obtained in a melt spinning operation) is drawn to at least the natural draw ratio (at which no undrawn yarn segments remain in the yarn) with provision for advancing the drawn yarn, preferably without intervening windup, through a heat-setting zone, while heating the yarn at constant length, using at least sufficient heat and residence time to increase the yarn density and bring the density, compared to that of undrawn amorphous yarn, up to at least 50%, preferably at least 70% of the normally attainable density increase in such yarn. Then the resulting drawn, dimensionally stabilized ("set") yarn, preferably without any intervening cooling operation, is supplied hot into an energy tube, through which the yarn is carried by a hot compressible fluid stream, as in the above discussed U.S. patent application Ser. No. 675,353 and U.S. Pat. Nos. 4,024,610 and 4,024,611, at linear velocity of the yarn of at least 450 meters per minute (MPM), preferably at least 2500 MPM, to strike first, at an oblique angle, an unyielding barrier within a chamber.
The resulting yarn is conveyed toward the outlet of the chamber by moving surfaces, including a moving perforate surface, traveling at a lower linear velocity than that of the incoming yarn, such moving surfaces and a stationary cover providing the confining surfaces of the chamber.
In the chamber, a part of the compressible hot fluid entering with the yarn through the energy tube escapes immediately through the perforations at the point of impingement of the yarn upon the moving barrier. The remaining fluid blows the yarn away from the barrier, within the confines of the chamber. The yarn then collects in plug form downstream from the point of impingement upon the barrier. The moving surfaces convey the plug of yarn to the outlet from the chamber, where it is removed from the chamber and wound on a bobbin. The residual fluid which did not escape at the point of initial impingement upon the barrier is dissipated through the perforated surface, between the point of impingement and the plug.
It has been found in accordance with the present invention, that the above described step of heat-setting the incoming yarn -- in advance of crimping it by the use of hot compressible fluid in a nozzle, a barrier which the yarn strikes, and a moving perforate surface to convey the yarn as a plug -- favors lower shrinkage and less thickening of the individual filaments, better dyeing uniformity, and a higher texture level (measured by percent crimp or by percent crimp extension) than found, at the same feed velocity of yarn, when such advance heat-setting is less complete or is omitted; and can allow use of lowered temperatures in the crimping operations, if texture level need not be at a maximum.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood when reference is made to the following detailed description and the accompanying drawings in which
FIG. 1 is a diagrammatic plan view illustrating one form of texturing apparatus for carrying out the method of this invention;
FIG. 2 is a partial section along line 2--2 of FIG. 1;
FIG. 3 is a diagrammatic elevation illustrating a steam jet device useful for the hot drawing and plasticization of yarn in accordance with the invention;
FIG. 4 is an enlarged view taken along line 4--4 of FIG. 3;
FIG. 5 is a diagrammatic vertical cross section illustrating an alternative texturing apparatus for carrying out the invention, instead of the apparatus shown in FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, FIG. 1 shows yarn Y passing through ceramic guide 1 and traveling to heated godet 2. After passing in several wraps around the heated godet, so as to acquire the surface temperature of godet 2, the yarn is aspirated by steam directly by nozzle 4 into energy tube 5 of the crimping apparatus, generally designated 3. The crimping apparatus is of the type described in U.S. patent application Ser. No. 675,353 and U.S. Pat. Nos. 4,024,610 and 4,024,611 above cited. The tube 5 terminates in an expansion section 6 which preferably is shaped to discharge the yarn across the full width of screen 7. Screen 7 is in the form of a flat circular band, rotating about vertical axis Z; and forms the bottom of a chamber defined additionally by sidwalls 8, 8 and by cover 9. In the drawing, the cover 9 is shown broken away in the area where tube 5 passes through the cover, so as to show the yarn striking screen 7 and forming a plug spaced from the point of impingement on screen 7, as steam is discharged through the screen, and the yarn fills the chamber and piles up in a plug on the relatively slow-moving screen, as previously explained. (This plug is represented in FIG. 1 by back and forth loops but it is to be understood that these are symbolic only and do not display the actual structure of the yarn plug). Cover 9 includes a stationary circular tongue (not shown) snugly fitting down between the moving walls 8,8.
Cover 9 contains an outlet 10 therein, in the form of an open sector through which the yarn plug is released.
The steam entering the chamber is discharged through screen 7 and withdrawn by means not shown.
The yarn from outlet 10 is passed through a yarn guide 11 and over an assembly of tension bars 12, functioning to reduce tension on the hot, freshly crimped yarn, as would otherwise be imposed by takeup roll 13. The tension bars allow the force applied by the takeup roll to straighten the yarn without applying excessive tension to the crimped yarn upstream from the tension bars. Thereby the yarn is obtained in straightened form for winding, but retains its crimp in latent form which can be developed into a highly crimped form by application of heat and/or hot fluid as in scouring and dyeing operations and the like.
FIG. 2 depicts the angle, θ, between tube 5 and cover 9 of the crimper 3 of FIG. 1.
FIG. 3 illustrates a steam drawing and setting device suitable for use in this invention. The device is designated generally by the numeral 20. Yarn X (not shown) enters inlet 21 of plasticizing channel 22. A steam nozzle 23 meets channel 22 at an oblique angle (α) pointing in the direction of yarn travel through channel 22. At the zone of impingement of the steam near the floor of channel 22, there is inserted in bottom piece 27 a removable ceramic pin 24 which serves to reduce the wear resulting from the sliding of yarn along the floor of channel 22. The yarn exits from the steam drawing-setting zone at exit 26.
FIG. 4 is an enlarged view of a portion of the steam drawing-setting device 20 taken along the line 4--4 and showing in more detail the channel 22 and ceramic pin 24 inserted near the floor of the channel. Also shown is a groove 25 at the top of one side of channel 22, through which groove the yarn X can be inserted into channel 22.
FIG. 5 illustrates in vertical cross-section, an alternative texturing apparatus for performing the invention in which yarn Y is shown entering an insulated box designated generally by the numeral 30. The yarn enters at opening 31 and passes through a steam drawing-setting device 20 such as illustrated in FIGS. 3 and 4. Then the yarn passes around heated godet 2, contained in the same insulated box 30 as the drawing-setting device 20. The resulting heat set yarn leaves the insulated box through an opening 32 and enters a preheater 33, suitably being carried therethrough and heated therein by steam from steam nozzle 34.
From the preheater the yarn is aspirated into energy tube 36 by steam from nozzle 35, and is propelled into a crimping apparatus 41 of a type described in the above-cited U.S. patent application Ser. No. 675,353 and U.S. Pat. Nos. 4,024,610 and 4,024,611. In this crimping apparatus the tube 36 is at an oblique angle, θ, with the tangent to screen 40 at the point where the yarn from tube 36 meets the screen. Screen 40 in this form of apparatus is a cylindrical screen rotating about horizontal axis X. In this form of apparatus the crimping chamber is defined by moving screen 40 and a pair of moving sidewalls or lips 39 and a stationary cover 37. In the drawing of FIG. 5, one sidewall of box 30 and of crimper 41 are omitted and a section is taken through tubes 33 and 36 and through cover 37, to show the yarn passing through the apparatus. Cover 37 includes a tongue (not shown) snugly fitting between the sidewalls 39, 39.
The yarn is crimped and formed into a plug in this form of apparatus as a result of impingement upon the screen 40, escape of the fast flowing fluid through the screen, and relatively slow conveyance of the yarn by the moving screen and sidewalls to the outlet from the chamber, as previously explained. The yarn emerges from the chamber beyond the point 38 where stationary cover 37 terminates; and slides over tension bars 12 whence it is taken up by a takeup roll 13, as for the operations illustrated in FIG. 1.
DETAILED DESCRIPTION
In the tables which follow, the conditions used and the results obtained in specific embodiments of our invention, illustrative of the best mode contemplated by us for carrying out the invention, are shown. Tables 2 and 3 illustrate a preferred form of operation particularly applicable to fine denier yarns, in which the feed yarn is partially oriented yarn obtained in a melt spinning operation, and drawing and heat-setting are effected in contiguous zones under superheated steam.
Certain yarn properties listed in the tables were determined as follows:
(1) Linear % Shrinkage: 100 (Peripheral speed of feed godet -- Peripheral speed of takeup godet)/(Peripheral speed of feed godet).
(2) Boil-off Shrinkage: Cut a 90 cm length of yarn; wrap in a cheese cloth bag; boil in water for 1 hour.
Remove from water bath; rinse; blot dry; hold for 24 hours under 50% relative humidity and 23° C. temperature; measure length L in cm.
% Shrinkage= 100(90-L)/90.
(3) oven Shrinkage: Apply a load of 200 mg/denier* to a yarn; mark off a yarn segment of measured length= L 0 .
Hold the yarn for 10 minutes in air oven at 180° C. under no load.
Remove from oven; hold for 10 minutes under 50% relative humidity and 23° C. temperature.
Apply a load of 200 mg/denier; measure the previously marked yarn segment; new length=L.
% shrinkage=100(L.sub.0 -L)/L.sub.0.
(4) percent crimp: Form a 12-inch long skein of 15 yarn wraps; hold for 5 minutes in air oven at 140° C. under load of 0.15 mg/denier (i.e. 0.15×15×2× denier=load in mg), to develop crimp.
Remove yarn from oven; hold for 5 minutes under 50% relative humidity and 23° C.
Apply load of 1.6 mg/denier; measure new skein length=L.
% crimp=100(12-L)/12.
(5) crimps per inch: Determined by microscopic observation of number of bends per inch, along a stretched out length of yarn.
(6) Dye uniformity: By visual examination of dyed knitted sleeves.
(7) Crimp Extension After Steaming ("CEAS"): Form a 15-inch long skein of two yarn wraps; apply 0.16 mg/denier load; hold for 10 minutes in autoclave in saturated steam at 102° C. (215° F.), to develop crimp.
Remove from autoclave; hold for 2 hours under 50% relative humidity and 23° C.
Apply load of 1.6 mg/denier; measure length=L 0 .
Apply load of 330 mg/denier; measure length=L.
%ceas=100(l-l 0 )/l 0 .
table 1-a______________________________________(figs. 3 and 4)______________________________________Yarn: "POY" (partially oriented) PET (235 den./34 fil.) washot drawn and set in the apparatus of FIGS. 3 and 4 at drawratios of (a) 1.68, (b) 1.90.Drawing Conditions Steam pressure: 150 p.s.i. Drawing speed (exit):1350 MPM (meters per minute) Steam temperatures: selected values from 200° C. to 300°C.Drawing/Heat-Setting Apparatus Characteristics (FIG. 3) Angle (α) of steam nozzle 23 pointing in direction ofyarn travel: 45° Inside diameter of steam nozzle: 0.041 inch Length of channel 22: 6 inchesResults (1-A) Yarn % IncreaseAt draw ratio Boil-Off UTS Density In(a), (b) and Shrinkage.sup.(1) g/den. g/ml Density.sup.(2)steam temps in yarn yarn yarn yarnnozzles 23 (a) (b) (a) (b) (a) (b) (a) (b)______________________________________200° C. 15% 10% 3.9 4.8 1.363 1.368 45 54220° 10 8 4.0 4.6 1.368 1.375 54 66240° 6 7.5 4.1 4.6 1.378 1.379 71 73260° 5 7 4.4 5.1 1.380 1.382 75 79280° 5 -- 4.4 5.2 1.383 1.382 80 79300° 5 -- 4.5 5.3 1.384 -- 82 --______________________________________ Boil-Off UTS YarnComparisons Shrinkage g/d Density______________________________________Partially-Oriented PET.sup.(3) 60% 2.2 1.341Undrawn Amorphous PET.sup.(3) 44 1.2 1.338Drawn PET.sup.(3) 8 4.3 1.380Drawn and textured PET.sup.(4) 1 3.7-4.0 1.393-4______________________________________ Notes: .sup.(1) Se the above description of tests .sup.(2) Percent increase in yarn density is calculated using the above comparisons, i.e. 1.338 for undrawn yarn and 1.394 as the normally attainable density. .sup.(3) Per Text. Res. J., Feb. '75, p. 112; .sup.(4) ibid. p. 116
Table 1-B__________________________________________________________________________(FIG. 1)__________________________________________________________________________Yarn: Partially oriented PET hot drawn at draw ratioof 1.68 and set as per Table 1A at steam pressure of 150 p.s.i.and temperature of 270° C. to 152 den., was wound onto a supplybobbin, then textured in the apparatus of FIG. 1, using selectedlevels of heating of godet 2 and of temperatures of steam, -enteringnozzle 4.(1) Apparatus Characteristics, Heat-Setting (FIG. 1) Diam. of godet 2:6.2 inches Wraps of yarn around godet 2: 11 wrapsHeat-Setting Conditions Rate of travel of yarn from godet 2; 450 MPM - Contact time of yarn withgodet 2: 0.7 sec.Surf. temp. of godet 2: (a) no heat; (b) 125° C.; (c) 145° (d) 165°__________________________________________________________________________Results-Oven Shrinkage:.sup.(1) (a) 10.5% (b) 6.5 (c) 5.5 (d) 4.7 (yarn collected ahead of tube 5, without crimping)Apparatus Characteristics Crimping, (FIG. 1) Steam nozzle 4: 0.034 inch I.D. Tube 5: 0.062 inch I.D. × 1.35 inch long; angle θ (FIG. 2) =60° Tube Outlet 6: Width: 0.180 inch Height: 0.030 inchCircular screen 7 (200 lines per inch, 0.0021 inch diam. stainless steel wire): Diam. at center line: 3.800 inches Width: 0.200 inchCover 9 (a circular tongue fits snugly between walls 8,8): Height of tongue above screen 7: 0.050 inchCrimping conditions Steam pressure entering nozzle 4: 135 p.s.i. Steam temp. (° C.) of steam entering nozzle 4: (a) 240°; (b) 260°; (c) 280°; (d) 300°; (e)320° Linear velocity of entering yarn: 450 MPMResults - Crimping TexturedSurf. Temp. Steam Temp Linear Final Yarn(godet 2) (nozzle 4) Shrinkage.sup.(1) Denier.sup.(2) % Crimp.sup.(3) Density__________________________________________________________________________No heating 240° C. 23% 197 28% -- 280° 27 207 38 -- 300° 35 233 37 --125° C. 240° 13 174 24 -- 280° 22 193 39 1.387g/ml 300° 29 214 40 1.390145° 240° 10 169 14 -- 260° 11.5 172 27 -- 280° 17 184 36 -- 300° 27 207 38 1.391165° 240° 11 171 8 -- 280° 11 171 27 -- 300° 17 184 36 -- 320° 24 200 39 1.391__________________________________________________________________________ Notes .sup.(1), .sup.(2), .sup.(3) See the above description of tests. In general at given crimp level (percent crimp), a relatively low linear percent shrinkage and denier is desirable since the resulting textured yarn retains more of its orientation; whence it shows, in general, better dye characteristics, and usually has better covering power in fabric, per unit weight of yarn.
Table 2__________________________________________________________________________(FIG. 5)__________________________________________________________________________Yarn: POY 235 den./34 fil. PET was hot drawn and set as perTable 1A using a drawing-setting steam zone as in FIG. 3, exceptextended to 12 inches length; and provided with an electricallyheated steam manifold having three steam jets (hereinafterdesignated 23(a), 23(b), 23(c)) each at an angle of 30° pointingin the direction of yarn travel and spaced down channel 22, toaccommodate the comparatively high processing speed employed (3400MPM vs. 1350 MPM in Table 1A); then was further set using a heatedgodet immediately following the drawing-setting step. Then with-out an intervening cooling operation, the yarn was supplied hot,via a preheater, to an energy tube through which steam was flowedto propel the yarn at high speed to the crimping operation - asdiagrammatically illustrated in FIG. 5.Apparatus Characteristics, Drawing/Heat-Setting (FIG. 5) Inside diameter of nozzles of the three steam jets (not shown) in drawing-setting device 20: 23 (a) 0.046 inch; 23 (b) 0.027; 23 (c) 0.027 Diam. of godet 2: 5.8 inches Wraps on godet 2: 11Drawing/Heat-Setting Conditions (FIG. 4) Steam pressure: 100 p.s.i.g. Steam Temp.: 270° C. Yarn travel in drawing-setting device 20: 12 inches Drawing speed (exit): 3400 MPM Contact time of yarn with godet 2: 0.1 sec. Draw ratio: (a) 1.7; (b) 1.9 Temp. setting for godet 2: (a) 115° C.; (b) 155° C.Preheating Conditions (tube 33) Steam pressure entering nozzle 34: 140 p.s.i.g. Steam temp. entering nozzle 34: 250° C.Apparatus Characteristics, Crimper 41 of FIG. 5 Steam nozzle 35: 0.049 inch I.D. Tube 36: 0.095 inch I.D. × 5 inches long, with the outlet ex- tension, into tongued cover 37, being 0.155 inch wide × 0.040 inch high and forming angle (θ) of 55° with the tangent tothe screen, at point of yarn impingement on the screen 40 Cover 37: extends 5 inches along screen 40 Cylindrical screen 40 (200 lines per inch, 0.0021 inch diam. stainless steel wire): Diameter: 9 inches Width: 0.200 inch Height between screen 40 and tongue of cover 37: 0.050 inchCrimping Conditions Steam pressure entering nozzle 35: 130 p.s.i.g. Steam temp. entering nozzle 35: various levels in the range from 232° C. to 315° C. Linear velocity of entering yarn: 3400 MPM Linear velocity of moving screen: 16-18 MPMResults(A) Draw ratio of 1.7; godet 2 set for 115° C..sup.(5) TexturedSteam temp. Wheel Linear % Final Yarn Dye(nozzle 35) RPM Shrink.sup.(1) Denier.sup.(2) % Crimp.sup.(3) Density Unif..sup.(4)__________________________________________________________________________ 232° C. 25.3 15.4% 183 24% -- good249° 24.5 16.5 186 28 -- "265° 24.0 17.5 186 31 -- "280° 23.0 20.0 194 33 1.386g/ml "299° 23.0 21.8 208 38 1.387 dark spots316° 23.2 23.5 204 39 1.388 "__________________________________________________________________________(B) Draw ratio of 1.7; godet 2 set for 155° C..sup.(5) TexturedSteam temp. Wheel Linear % Final Yarn Dye(nozzle 35) RPM Shrink.sup.(1) Denier.sup.(2) % Crimp.sup.(3) Density Unif..sup.(4)__________________________________________________________________________ 260° C. 25.0 15.0% 181 38% -- good263° 24.3 16.0 186 36 1.387g/ml "276° 24.3 18.0 200 38 1.387 dark spots293° 23.6 21.0 197 40 1.389 "302° 23.0 23.2 213 38 1.389 "310° 23.0 24.3 207 41 1.390 "(C) Draw ratio of 1.9; godet 2 set for 115° C..sup.(5) 249° C. 22.2 20.0% 172 30% -- good266° 22.2 22.0 174 34 1.386g/ml "282° 22.2 24.0 180 36 1.385 "299° 22.2 25.8 188 39 1.386 dark spots310° 22.2 27.5 192 38 1.387 "(D) Draw ratio of 1.9; godet 2 set for 155° C..sup.(5) 237° C. 23.0 15.3% 164 32% -- good249° 22.7 17.0 167 36 1.386g/ml "266° 22.4 19.5 176 38 1.387 "274° 23.0 21.3 187 39 1.388 "274° 24.2 20.5 184 39 1.385 dark spots282° 22.4 23.5 181 39 1.388 "291° 22.4 25.8 185 40 1.389 "__________________________________________________________________________ Notes: .sup.(1), .sup.(2), .sup.(3), .sup.(4) See the above description of tests .sup.(5) The actual temperature may be higher because the godet is in insulated box 30.
Table 3______________________________________(FIG. 5)Yarn: POY (PET) den./fil. (a) 115/34; (b) 230/68; (c) 235/34processed generally as per Table 2 (but omitting the preheater).Apparatus, Drawing-Setting: As in Table 2 above.Drawing/Heat-Setting Conditions Steam pressure: 100 p.s.i.g. Steam temperature: 274° C. Yarn travel in drawing-setting device 20: 12 inches Drawing speed (exit): 3130 MPM Draw ratio: 1.7 Surf. temp..sup.(5) of godet 2: yarn (a) 115° to 120° C.,(b) 129° to 132° C., (c) 115° to 120° C.Apparatus, Crimping (FIG. 5) - As for Table 2 except yarn passes immediately from insulated box 30 into energy tube 36. Length of cover 37 to the left of tube 36: 0.75 inch Length of cover 37 to the right of tube 36: 3-11/16 inchesCrimping Conditions Steam entering nozzle 35: Yarn (a) pressure 70 p.s.i.g. temp. 287° C. Yarn (b) pressure 90 p.s.i.g. temp. 283° C. Yarn (c) pressure 130 p.s.i.g. temp. 269° C.Linear velocity of entering yarn (a), (b), (c): 3130 MPMLinear velocity of moving screen:For yarn (a) above: 12.5 MPM; yarn (b): 22.3; yarn (c): 16.2Pressure of steam above point of impingement of yarn on screen:For yarn (a) above: 0.29 to 0.005 p.s.i.g.; yarn (b): 0.06 to0.58; yarn (c): 0.05Wheel RPM of crimper 41For yarn (a) above: 17.3; yarn (b): 31.0; yarn (c): 22.5Results TexturedLinear % Final Crimps YarnYarn Shrink.sup.(1) Denier.sup.(2) % Crimp.sup.(3) per inch.sup.(4) Density______________________________________(a) 19% 83-90 32% 53 1.389g/ml(b) 17 165-175 31 49 --(c) 16 169-180 31 43 -- Notes: (1), (2), (3), (4), (5) - See Notes for Table 2 above.?
From the crimping results set out in Table 1B above, it can be seen that generally lower levels of shrinkage were obtained for a given percent crimp, when higher heat-setting temperatures were employed.
In accordance with the results of Table 2, given steam temperatures in the energy tube 36 produced higher levels of percent crimp at both draw ratios, when the temperature-setting of godet 2 was at 155° C. (especially at the lower energy tube steam temperatures). Moreover, such higher temperatures at godet 2 generally were associated with lower linear shrinkage at any given crimp level.
A combination of conditions is shown at which linear percent shrinkage is about 16%-20% and percent crimp is about 36%-38%, and dye uniformity is good as shown by absence of dark spots in the dyeing uniformity test.
Table 3 shows that a high crimp level, in terms of number of crimps per inch, is obtainable in accordance with this invention.
Particularly preferred conditions for use in texturing operations as above described starting with partially oriented PET yarn, to obtain textured yarn of apparel denier, comprise drawing the yarn at about 1.65 to 2.0 draw ratio in a zone heated by superheated steam, heated to temperature in the range from 235° C. to 300° C.; supplying the drawn feed yarn directly, without winding up, at linear velocity of at least 2500 MPM to a heat-setting operation in a contiguous zone wherein heat-setting is effected by contact between the yarn and superheated steam as above, using at least sufficient residence time to bring the yarn density to at least 1.378 g./ml.; and crimping the resulting heat-set yarn at steam temperature from 250° C. to 300° C.
The following Tables 4 and 5 illustrate use, in accordance with this invention, of nylon yarn.
Partially oriented polycaproamide nylon yarn (80 initial denier, 18 filament) was cold drawn at drawn ratio of 1.2 and heat-set, and was supplied hot to a texturing operation, by passing around a heated feed godet and thence to a crimper as illustrated in the accompanying FIG. 5, reference numeral 41. Steam entering nozzle 35 was at 130 p.s.i.g. and 275° C. Conditions used and results are outlined in Table 4.
Table 4______________________________________(Crimper 41 of FIG. 5)Surf. Temp.of Feed RPM Linear Final %Godet Wheel % Shrink.sup.(1) Denier.sup.(2) Crimp.sup.(3)______________________________________(a) 100° C. 35.5-36.0 14.5 75 32100 34.0-34.2 16.0 72 35100 32.0-32.5 19.5 75 41(b) 112 35.5-36.0 13.0 72 34112 34.0-34.2 14.5 76 35112 32.0-32.5 16.0 73 41(c) 125 35.5-36.0 14.0 71 37125 34.0-34.2 16.5 72 41125 32.0-32.5 19.5 74 42(d) 135 35.5-36.0 13.5 75 38135 34.0-34.2 16.0 72 40135 32.0-32.5 22.0 72 46______________________________________ Notes: (1), (2), (3) - See the above description of tests.
Table 5__________________________________________________________________________(Crimper 41 of FIG. 5) Yarn: Undrawn polycaproamide nylon yarn (3200 ini-tial denier, 70 filament) after cold drawing at draw ratio of 3.0and heat-setting, was supplied hot to a texturing operation bypassing around a heated feed godet and then to a crimper as il-lustrated in the accompanying FIG. 5, reference numeral 41.Apparatus Characteristics, Crimping (Crimper 41 of FIG. 5) Steam nozzle 35: 0.070 inch I.D. Tube 36: 0.150 inch I.D. × 5 inches long, with the outlet extension, into tongue cover 37, being 0.432 inch wide × 0.082 inch high and forming angle (θ) of 60° with the tangentto the screen, at point of yarn impingement on the screen 40 Cover 37: extends 5 inches along screen 40 Cylindrical screen 40 (90 lines per inch, 0.0035 inch diameter stainless steel wire): Diameter: 9 inches Width: 0.500 inchHeat-Setting and Crimping Conditions of cover 37: 0.100 inch l Wraps around heated godet: 8 Surface temp. of heated godet: Tabulated below under "Results" Linear velocity of entering yarn: 3060 MPM Linear velocity of moving screen 40: 46-50 MPM Steam pressure entering nozzle 35: 115 p.s.i.g. Steam temp. entering nozzle 35: Tabulated below under "Results".__________________________________________________________________________ResultsSurf.Steam Yarn Dens.temp. ofTemp. Before PercentHeatedNozzle Wheel Linear % Percent Texturing IncreaseGodet35 RPM Shrink.sup.(1) "CEAS".sup.(2) (g/ml) In Density.sup.(3)__________________________________________________________________________170° C.262° C. 66 14.5 23.6278 66 16.0 24.6289 64 17.5 25.4 ca.1.140 77296 64 18.0 23.9304 64 19.1 28.8316 64 20.0 26.4180° C.264 68 14.0 29.1279 68 15.5 26.8288 70 15.8 29.4 1.141 83299 70 16.5 31.5304 70 17.0 29.3310 70 17.3 29.4316 70 18.3 32.2__________________________________________________________________________ Notes: .sup.(1), .sup.(2) - See the above description of tests. .sup.(3) - Calculated as percent of the difference between highest densit observed in the final yarn (1.144 g/ml) and density of a quenched undrawn filament (1.127g/ml).
The nylon yarn (d) of the above Table 4, which underwent the highest of the four godet temperatures (135° C.), showed the highest crimp level for given Linear Percent shrink. The heavy denier yarn of Table 5 showed higher crimp levels (CEAS) and lower linear Percent Shrink for given tmperature in energy tube 36, when heat-set at the higher of the two temperature (180° C. vs. 170° C.).
It will be recognized that by virtue of the high speed of drawing yarn and of then texturing the yarn without intervening windup, obtainable in accordance with the present invention, it becomes possible using this invention to melt spin, draw, heat-set and texture a thermoplastic synthetic yarn in uninterrupted, continuous sequence at high speeds in all steps, such as at least 2500 MPM feed to the texturing operation, without intervening windup.
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Multifilament thermoplastic synthetic yarn is textured by an improved process involving propelling the yarn through an energy tube by superheated steam to strike, at an oblique angle, an unyielding barrier within a chamber in which the yarn then forms a plug on a moving perforate surface. The improvement comprises heat-setting the yarn, before the texturing operation, at constant length to the point that its density increases to at least 50% of the difference between that of undrawn amorphous yarn and the maximum normally attainable in such yarn; and feeding the resulting yarn hot into the energy tube whereby tendency toward shrinkage of the yarn resulting from undergoing crimping is reduced, and/or a higher texture level is obtainable at given temperature of the crimping operation.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser. No. 293,662, filed Aug. 17, 1981 now U.S. Pat. No. 4,373,535 for a Venting, Self-Stopping, Aspirating Syringe, the disclosure of which is incorporated herein by this reference as though fully set forth.
BACKGROUND OF THE INVENTION
The present invention relates to a vented, aspirating syringe and, more particularly, to a syringe which does not require a timely withdrawal of the syringe from an artery, and which minimizes blood air interface during the obtaining of the blood sample.
DESCRIPTION OF PRIOR ART
Syringe type devices are typically used for obtaining blood samples to perform a blood gas analysis. Many such blood gas analyses require the drawing of arterial blood which has a sufficient pressure whereby it will, in and of itself, under normal circumstances, fill a syringe without the necessity of aspirating. For this purpose, a conventional syringe type device simply consists of a plunger positioned within a main tubular body. The plunger is fully inserted into the main tubular body and the hypodermic needle punctures the artery. As blood flows into the syringe body, the plunger is pushed back thereby.
There are a variety of problems associated with the use of such a conventional syringe. First of all, it is necessary to draw heparin (an anti-coagulant) into the tubular syringe body through the hypodermic needle which exposes the needle to possible contamination. This anti-coagulant is necessary to maintain the integrity of the blood sample. Furthermore, when the plunger is pushed into the syringe body to expel the excess liquid heparin, a small quantity, approximately 1/4 cc, remains in the syringe, in the area between the end of the plunger and the tip of the hypodermic needle. Therefore, when such a syringe is used to obtain a blood sample to perform a blood gas analysis, the 1/4 cc of liquid heparin remains in the syringe. This small amount of heparin represents a diluent which interferes with accurate blood gas analysis values and other chemical evaluations.
As a result of the above problems in the use of conventional syringes for obtaining blood samples to perform a blood gas analysis, several syringe devices have been developed to obtain diluent-free blood samples. An example of such a device is shown in U.S. Pat. No. 4,257,426 to Bailey. In the Bailey patent, a syringe device includes a main tubular body, one end of which slidably receives a combination sealing member and hollow plunger, with the plunger being rotatably connected to the sealing member. The sealing member has several circular lips so that contact, sufficient to create a seal, exists between the lips on the sealing member and the syringe body. The sealing member has a lateral vent between several of the lips. A flexible thread fixed to the plunger selectively crosses the lips and breaches the seal created by the sealing member to establish communication between the interior of the plunger and the interior of the tubular body via the lateral vent in the sealing member. Removal of the thread allows a seal to be restored so that a gas-free blood sample can be isolated in the hollow tubular body. Crystalline heparin is placed in the body, eliminating the need for liquid heparin.
The Bailey syringe has a variety of advantages over a conventional syringe. Initially, through the use of crystalline heparin, the use of liquid heparin can be eliminated, making blood gas analyses more accurate. Secondly, because of the venting action of the plunger, the blood can rush into the syringe body, pushing the air across the lips and around the flexible thread. As soon as the blood passes the first series of lips, the syringe is removed from the patient and the plunger is rotated, removing the thread from the seal lips, restoring the seal so that the blood sample can be isolated in the hollow tubular body.
While the syringe of the Bailey patent solves some problems associated with conventional syringes, it creates a new set of problems. That is, since the flexible thread extends across the seal lips and breaches the seal created by the sealing member, blood, as well as air, can flow past the sealing member. Accordingly, proper operation of the device requires removal of the needle at a precise time from the patient. If the syringe is not removed at the precisely correct time, the blood flows past the sealing member and enters the syringe body, on the backside of the sealing member. Then, when the syringe is removed and inverted, this blood escapes. Furthermore, since the plunger must be preset to the desired volume of blood to be drawn, a blood-air interface is created, resulting in a possible air contamination to the arterial sample which wille affect the blood gas values.
The use of the syringe of the Bailey patent also requires the technician to learn an entirely new procedure, that of rotating the plunger relative to the sealing member to withdraw the thread. In view of the number of technicians which draw blood, this additional training to use the product properly is a significant disadvantage, especially when the operation of the device is not at all apparent from an inspection thereof.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a syringe which solves these problems in a manner unknown heretofore. The present syringe does not require a technician to watch the blood carefully as it moves through the syringe body to prevent spilling into the back of the tubular body, behind the plunger. Still further, the present syringe does not require any additional step, such as the rotation of one member relative to another, as in the syringe of the Bailey patent. Once the flow of blood comes into contact with the filter member, the blood is automatically sealed from air within the hollow tubular body.
The present syringe also permits the use of dry-flake heparin so that the problems associated with liquid heparin are also eliminated. Finally, the present syringe can be used in an aspirating mode in those situations where individuals have insufficient blood pressure to fill the body of the syringe without having to manipulate the plunger.
Briefly, the present syringe comprises a main tubular body being open at one end thereof and being adapted to receive a hypodermic needle at the other end thereof; a plunger, one end of the plunger being extendable into the body, through the open end thereof, the plunger having a longitudinal passageway therein permitting air flow therethrough; means forming a fluid-tight seal between the outside surface of the plunger and the inside surface of the body; an air permeable filter member extending across the first end of the plunger, in the passageway; and a valve extending across the passageway, between the filter member and the open end of the body, the valve being selectively operable to open or closed positions and preventing passage of air through the passageway in either direction when closed. The valve is manually controlled and automatically closes when the syringe handle is pulled, as when used in an aspirating mode.
OBJECTS, FEATURES AND ADVANTAGES
It is, therefore, an object of the present invention to solve the problems encountered heretofore in providing a syringe device for taking blood samples. It is a feature of the present invention to solve these problems by providing a syringe device including a plunger having a passageway therein and an air permeable filter member and a valve extending across the passageway. An advantage to be derived is a syringe in which dry flake heparin can be used. A further advantage is a free venting syringe. Another advantage is a syringe which does not permit blood leakage. Still another advantage is a syringe in which no additional steps are needed to prepare the syringe for aspiration. Another advantage is a syringe which requires no additional training for the use thereof. An additional advantage is a syringe which can be used both for obtaining arterial blood and in an aspirating mode.
Still other objects, features, and attendant advantages of the present invention will become apparent to those skilled in the art from a reading of the following detailed description of the preferred embodiments constructed in accordance therewith, taken in conjunction with the accompanying drawings wherein like numerals designate like or corresponding parts in the several figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a syringe constructed in accordance with teachings of the present invention;
FIG. 2 is an exploded perspective view of the syringe plunger;
FIG. 3 illustrates the syringe plunger of FIG. 2 with its valve in open position; and,
FIG. 4 illustrates the plunger of FIG. 2 with its valve in closed condition.
DETAILED DESCRIPTION
Referring now to the drawings, one form of syringe, generally designated 10, includes a transparent or translucent main tubular body 11 of circular transverse section having an open end 12 and a closed end 13 having a neck 14 which protrudes axially from end 13. A hypodermic needle 15 is frictionally connected to or screwed onto neck 14 by a needle hub 16. Neck 14 is hollow and communicates with an interior chamber 17 generally defined by the space in tubular body 11, the end wall 18 of body 11 and a hollow plunger, generally designated 20, which is received in tubular body 11, through open end 12 thereof.
The plunger includes a tubular, soft rubbery plastic sealing cylinder 22 having flexible frustoconical sealing elements 24 and 26 respectively projecting axially and outwardly from the cylinder body into engagement with the interior of the main tubular syringe body 10. The tubular body 22 has a rear portion 28, adjacent the open end of the syringe body 10, formed with a relatively large diameter bore 30 and a forward portion 32 formed with a relatively smaller diameter bore 34.
A filter member 38 is formed of a relatively hard cylindrical air permeable porous plug 38 that is inserted into the relatively small diameter bore portion 34, outwardly compressing the soft material of the sealing cylinder body 22 to form a shoulder 40. By means of its inherent resilience, the sealing cylinder body firmly retains the porous filter plug 38 within its bore. The filter plug is preferably formed of a porous polyethylene that readily permits passage of air but which will present passage of blood.
The main portion of the plunger body is formed by a hard plastic rod which provides an elongated handle 42. The handle, for a major portion of its length, has a generally cross-shaped cross-section and has a flat transverse disc 44 adjacent a forward portion of the handle and which terminates in an enlarged head 45 at its rearward end. A smaller diameter handle section or handle neck 46 extends forwardly from the handle disc 44 and through a centrally located aperture in an end cap 48 that is formed at the rear end of the tubular sealing cylinder 22. The smaller diameter handle portion 46 terminates in an enlarged forward end or nipple 50 having a rearwardly facing flat surface 52 which is adapted to cooperate with a flat, forwardly facing interior face 54 of the end cap 50 to seal the interior passageway of the tubular sealing cylinder 22. The outer or rearwardly facing surface of end cap 48 is formed with a plurality of rearwardly projecting protrusions 56, 58 that are adapted to engage a forwardly facing surface of the handle disc 44 and prevent the latter from moving into sealing engagement with the outer surface of end cap 50.
The tubular sealing cylinder 22 is made of a soft rubbery plastic material such as, for example, a material known under the trademark KRATON thermoplastic rubber which comprises a mixture containing styrene ethylene/butylenestyrene block copolymer, polypropylene, process oil, filler, plus minor amounts of anti-oxidant/stabilizer and dusting agent, made by Shell under the name KRATON G7705-1001-1 Thermoplastic Rubber. The material is relatively soft, having a shore hardness of about 45, whereas the plunger is made of a rigid, considerably harder, material having a shore hardness of in excess of 250. The rod handle may be a rigid polypropylene, for example. It is preferred to employ a cylindrical filter plug made of a porous polyethylene and having a hardness considerably greater than that of the KRATON material of the tubular sealing cylinder. As previously mentioned, the filter plug permits passage of air but not blood.
The length of the intermediate reduced diameter handle section 46 is greater than the sum of the thickness of sealing cylinder end cap 48 and its protrusions 56, 58, so that, when the handle is pushed toward the sealing cylinder and the entire plunger then is moved forwardly, toward the left as viewed in FIGS. 3 and 4, sealing surface 52 of handle end 50 is displaced from the mating sealing surface 46 of the interior surface of end cap 48. Thus, as the reduced handle section 46 is also of a cross-shaped cross-section, and the diameter of handle end 50 handle is less than the diameter of the bore 30 of cylinder 22, the valve is opened and air may pass from the interior of syringe body 10 through the porous plug 38 and through the valve.
However, when the syringe is used in an aspirating mode, and the handle is pulled to the right (as viewed in FIGS. 3 and 4) so as to start withdrawal of the plunger from the syringe body, the lost motion connection between the handle section and the sealing cylinder allows the enlarged end 50 of the handle to move rearwardly relative to the tubular sealing cylinder until its rearwardly facing surface 52 abuts the interior surface 54 of the tubular sealing cylinder end cap 48 to thereby seal the valve. Accordingly, as the handle is manipulated to start retraction of the plunger, the valve automatically closes to seal the interior of the plunger sealing cylinder 22 and prevent air from passing through its passageway. This permits a syringe that is fitted with the plunger assembly of FIGS. 2, 3 and 4 to be used in either an aspirating mode or to obtain arterial blood samples.
For use in drawing an arterial blood sample, the forward end 32 of the plunger is pushed forwardly against the forward end 18 of the tubular body and the needle is inserted into an artery from which a blood sample is to be taken. Normal pressure of the arterial blood then forces the blood into the syringe, between the forward end 32 of the tubular sealing cylinder and the forward end 18 of the syringe body, driving the air out of the body through the porous plug 38 and through the open valve formed by the interengaging parts of the handle and sealing cylinder. When the blood contacts the filter member after evacuating all air out of the dead space between end wall 18 and filter member 38, the pressure of the blood causes the plunger assembly to move back into the tubular body 11, from left to right as viewed in FIGS. 3 and 4. This action will occur under arterial pressure above twenty millimeters of mercury. Blood air interface is minimized during the taking of a blood sample because the procedure is started with the plunger pushed forwardly to a position in which there is a minimum volume of air within the syringe body. Moreover, this small amount of air is rapidly discharged through the porous plug and, therefore, a minimum contact between blood and air within the syringe occurs during the remainder of the blood withdrawal.
The unique sealing elements 24 and 26 eliminate the need for separate O-rings and, moreover, provide effective sealing with a considerably decreased frictional resistance to sliding motion of the sealing cylinder along the interior surface of the syringe cylinder. Because of the axially projecting configuration of the frustoconical sealing elements, each will operate to seal primarily in only one direction. For example, as the plunger assembly is moved to the left, as viewed in FIG. 3, the rearward sealing element 26 tends to move in a direction in which it creates a lesser resistance because this direction of motion tends to move the outwardly projecting conical element 26 radially inwardly. The same direction of motion, toward the left as viewed in FIGS. 3 and 4, causes the frustoconical sealing element 24 to exert a maximum sealing contact because this direction of relative motion tends to bend the element 24 outwardly, creating an increased sealing contact. The same is true in the reverse, for motion of the plunger in the opposite direction, which is toward the right as viewed in FIGS. 3 and 4. With such motion, the sealing element 24 produces relatively little frictional resistance as it tends to collapse, whereas the sealing element 26 tends to increase its sealing contact with this motion.
To use the plunger assembly of FIGS. 3, and 4 in an aspirating mode, the plunger assembly is moved to the left to drive the plunger deeper into the syringe body, as illustrated in FIG. 3. During this motion, air trapped between the forward end of the sealing cylinder and the closed end of the plunger body, flows outwardly through the pores of sealing member 38 and through the valve which is open, having the handle disc 44 pressing against the end cap projections 56, 58.
When the handle is moved toward the right so as to tend to withdraw the plunger from the syringe body, the relatively hard enlarged handle end 50 moves to abut the relatively soft end cap 48 of the sealing cylinder, closing the valve automatically upon such motion and sealing the interior of the syringe.
It can therefore be seen that according to the present invention, there is provided a syringe which solves the problems encountered heretofore in a unique and unobvious manner.
The syringe also permits the use of dry heparin so that the problems associated with liquid heparin are also eliminated. A flake of heparin, prepared in any known manner, may be placed in a dried state within chamber 17 so that any blood received is immediately exposed to the heparin. The heparin flakes (not shown) can be stored along with the syringe for immediate use.
In addition, the syringe can be used in an aspirating mode in those situations where individuals have insufficient blood pressure to fill the body of the syringe.
The unique valve enables the syringe to operate either for withdrawal of arterial blood under its own pressure, or in an aspirating mode. The valve operates automatically as an automatically controlled manual valve. The unique integral formation of frustoconical sealing elements on the relatively soft and resilient tubular sealing cylinder of the plunger provides a simplified, inexpensive and more effective and more efficient seal.
Although the invention has been described with respect to a preferred physical embodiment constructed in accordance therewith, it will be apparent to those skilled in the art that various modifications and improvements may be made without departing from the scope of the invention. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrative embodiments, but only by the scope of the appended claims.
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A syringe comprises a main tubular body, the body being open at one end and receiving a hypodermic needle at the other end, and a plunger, one end of the plunger extending into the body, through the open end thereof, the plunger having a longitudinal passageway therein permitting air flow therethrough. A fluid-tight seal is formed between the outside surface of the plunger and the inside surface of the syringe body. An air permeable filter member extends across the first end of the plunger, in the passageway, whereby the body can fill with blood, causing the air in the body to pass through the filter member to the open end of the body. The blood does not flow through the filter. A valve extends across the passageway and allows the syringe to be used to aspirate in the absence of natural blood pressure.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Phase Application of PCT International Application PCT/EP2010/051719, filed Feb. 11, 2010, the contents of such application being incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to an injection training dummy, an injection training system and a method for training an injection process.
BACKGROUND OF THE INVENTION
A whole range of liquid drugs are already administered using injection pens and comparable administering apparatus, such as for example insulin in diabetes therapy. The apparatus allow the drug to be individually dosed, but with a high degree of operational security and operational comfort—characteristics which are required in particular in self-administering, i.e. administering to oneself. The administering apparatus can also be called an injection device.
Because of the need to reduce costs, more and more therapies are being given over to self-administering. One example is that of stimulating the ovaries and consequently, by fertilising the stimulated egg cells, pregnancy using hormone treatments. Thus, for example, EP 1 188 444 B1, which is incorporated by reference, describes liquid formulations based on FSH (follicle stimulating hormone) and FSH variants.
Further medicaments suitable for self-administering are for example neuroleptic drugs (Fluphenazini decanoas), vasodilative agents (Adrenalinum), blood products (Etamsylate, Epoetin alfa, Filgrastim (G-CSF), Nadroparinum calcium, Desmopressini acetas), drugs for treating rheumatic diseases (methotrexate, etanerceptum), oncological drugs (Cladribinum, interferonum humanum gamma-1b ADN) and drugs for treating infectious diseases (herpes simplex Type 1/Type 2, human immunoglobin). Usual or preferred active agents for each group of drugs are given in brackets. Other medicaments are insulin, heparin, growth hormones, peptide hormones or medicaments for MS treatment. In general, any kind of liquid or fluid medicament can be self-administered.
The quantity of a drug which has to be administered in an injection can vary significantly from patient to patient, such as for example in said therapy for stimulating the ovaries. It should also be borne in mind that the period of treatment in other therapies can be much shorter than for example in diabetes therapy, for example only a few days or weeks, and the patients therefore also cannot gain a sense of routine in handling the respective administering apparatus.
It is therefore essential, in particular for sensitive patients and patients being new to self-administering of injections, to practise the injection process. This process can be practiced with the actual medicament to be administered or a replacement liquid such as distilled water, a placebo or any other suitable substance.
The self-administering injection process creates two sensations for the patient. The first sensation is the skin being penetrated by the injection needle and the second sensation is the handling of and the feedback by the injection device. In particular the latter sensation can be practised before the patient actually injects the medicament for the first time. For this purpose, several injection training dummies are known from the prior art.
Document U.S. Pat. No. 3,722,138, which is incorporated by reference, discloses a training aid for use in the medical arts and simulating at least a portion of a human body. The training aid includes a skin-simulating substance enclosing a flesh-simulating substance to form a replica of an extremity of a human body such as an arm. A bone-simulating substance is embedded in the flesh-simulating substance. Flexible tubes are embedded in the flesh-simulating substance to simulate arteries and veins.
Document U.S. Pat. No. 4,481,001, which is incorporated by reference, discloses a skin model for use and demonstrating or practising intradermal injection of fluids. The model is a composite laminate of a subcutaneous tissue-simulating layer made of foamed elastomer of low compression deflection and hardness, a dermis-simulating layer that is substantially nonporous and has a slightly greater hardness than the subcutaneous tissue-simulating layer and an epidermis-simulating layer made of a high tear strength, high tensile strength elastomer.
A dummy of similar design is disclosed in document DE 20 2009 007 610 U1, which is incorporated by reference.
Document EP 0 951 003 A1, which is incorporated by reference, discloses an injection practice apparatus including a casing in a curved shape, an upper wall of which is provided with an opening, with a sponge member housed inside the casing. The patient pinches up the sponge member exposed through the opening and pricks a needle of an injection syringe into a protrusion of the sponge member formed by such a pinching to dispense injection liquid.
Document US 2009/0035737 A1, which is incorporated by reference, discloses an injection training pad including a container having an opened top and a closed bottom. A lid having a hole removably engages the opened top of the container. The pad comprises a cushion made of a solid piece of foam or a sponge-like material covered by a cap made from a flexible and nonporous material to simulate human skin.
SUMMARY OF THE INVENTION
The drawback of the aforementioned injection dummies is that their reusability and level of hygiene is unsatisfactory. An aspect of the present invention relates to an injection training dummy, an injection training system and a method for training an injection process according to the independent claims to overcome these drawbacks. Advantageous embodiments are given in the dependent claims.
An injection training dummy according to an aspect of the present invention comprises a three-dimensional shell member, which can be penetrated by an injection needle, and a closure member detachably interconnected with the shell member. The shell member and the closure member constitute a chamber into which liquid can be injected through the injection needle and the shell member and the closure member are designed such that they do not absorb the liquid. The injection needle penetrating the shell member means that the tip of the injection needle completely passes the wall of the shell member, ending in the chamber into which liquid can then be injected. The chamber is preferably unfilled, which means that it does not contain any porous or sponge-like material which soaks the injected liquid up. Instead, the injected liquid is accumulated within the chamber and the chamber can be emptied by detaching the closure member.
The connection between the shell member and the closure member is liquid-tight, at least for the liquid to be injected. With this configuration, the injection training dummy can be used repeatedly until the chamber is full. The injection training dummy can easily be emptied and cleaned. The connection is for example a positive lock in which the shell member and the closure member are held together tightly by an elastic force or elasticity, which is preferably exerted by the shell member.
The shell member and the closure member being designed such that they do not absorb the liquid can be achieved in several ways. Possible embodiments, among others, are using non-absorbing materials or coating, at least partly, the shell member and/or the closure member with an impermeable layer.
The injected liquid is sealed within the chamber of the injection training dummy. Unlike some prior art dummies comprising unsealed sponges, unintentional staining of the area surrounding the dummy can be prevented.
In a preferred utilization, the dummy is located on the part of the body at which the real injection is to be carried out later. Preferably, the closure member constitutes a lower member for facing the skin when the dummy is placed on the skin at a desired injection site when training an injection, and the shell member constitutes an upper element facing away from the skin.
In a preferred embodiment, the shell member comprises an injection wall to be penetrated by the injection needle and at least one side wall. In particular, the injection wall is opposite to the closure member, wherein the side wall connects the injection wall and the closure member. The shell member therefore has a pot-like shape or a U-shape, with the bottom of the pot or U being the injection wall and the other wall being the side wall. The opening of the shell member is then closed and/or sealed by the closure member. In a particular embodiment, the injection wall has convex shape when seen from outside of the injection training dummy. This means that the injection wall has a curvature stretching outwards. This reduces the deformation of the injection wall while forces are exerted onto it by the injection device.
Preferably, the injection wall and the closure member have congruent shapes. In a rotationally symmetric design, the injection wall and the closure member have a circular outline. In another preferred embodiment, the injection wall and the closure member have a rectangular outline.
In a preferred embodiment, the side wall is concave when seen from outside of the injection training dummy. This means that the side wall has a curvature pointing, or smoothly bulging, towards the chamber of the training dummy. With this shape of the side wall, the dummy can be easily grasped and held in place during practice.
Further preferably, the side wall is slanted. In particular, the distance between the side walls close to the closure member is wider than close to the injection wall. If the injection wall has a circular shape, then the outer diameter of the side wall at the injection wall is smaller than at the closure member. If the injection wall has a rectangular shape, then the distance between opposing side walls close to the injection wall is smaller than at the closure member. With this design, handling of the dummy is further simplified.
Preferably, the dummy is basically symmetric, for example mirror symmetric or most preferably basically rotationally symmetric. Such a symmetry eases practising with the dummy as well as disassembly and assembly.
In a preferred embodiment, the shell member has a recess for receiving the closure member, in particular in the side wall or side walls of the shell member. In such a recess, the closure member can easily be accommodated while providing a liquid-tight seal of the chamber. The recess preferably encircles a central axis of the dummy, wherein the central axis points normal to an underside of the dummy. A central axis is an axis lying in a central area of the dummy, that is within the volume enclosed by the side wall or side walls. The underside of the dummy is the side which is to be brought in contact with the skin or another surface for using the dummy. The central axis can alternatively be defined as pointing normal to a major surface, such as a disk-shaped or rectangular surface, of the closure member.
As an option, the shell member comprises an additional chamber boundary wall, or inner wall, confining the chamber and/or stiffening the dummy in its interior in a direction which is at least essentially normal to the underside of the dummy. Preferably, the additional chamber boundary wall or walls are perpendicular to the surface of the closure member. Further preferably, the inner wall extends from the injection wall to the closure member. As a result, the inner wall, as a reinforcing wall, transmits forces between the injection wall and the closure member, thus reinforcing the injection wall against forces exerted when the shell member is penetrated by the injection needle. In addition, the inner wall can exert a force onto the closure member, thus pressing the closure member against the shell member, in particular a sealing surface such as a lip, for sealing the chamber. Preferably, the height of the inner wall is slightly larger than the distance between the injection wall and the closure member. If the inner wall is a chamber boundary wall, only a part of the volume defined by the shell member is used as the chamber for holding the liquid. If the inner wall is just a reinforcement wall, then it can have any suitable shape. For example, it could comprise one or more planar walls or ribs.
Preferably, the shell member is flexible, and further preferably resiliently flexible. This means that the shell member can be (elastically) deformed for removing or installing the closure member. For example, the shell member can be widened such that the closure member can be removed from or installed into the recess in the shell member. If the shell member is resiliently flexible, it automatically returns to its original shape when the closure member was removed or installed, thus sealing the chamber. Suitable materials for the shell member are an elastomer or natural rubber. Preferably, the material is injection mouldable, such as a thermoplastic elastomer. Further preferably, the material can endure a large number of penetrations, for example more than 1000 penetrations, without (significant or permanent) damage. In an advantageous manner, the material has the property of automatically closing the cut-in caused by the penetration once the injection needle is removed.
As a further option, the shell member comprises a chamfer or grove. This chamfer or grove preferably encircles the recess in the shell structure in close vicinity and/or is located at the underside of the dummy. In an embodiment, the chamfer or grove is circular with a diameter slightly larger than the diameter of the recess in the shell member for the closure member. With the width and depth of the chamfer, the flexibility of the shell member in the area where the closure member is installed can be influenced by structural measures without modifying the properties of the shell member material. This is particularly advantageous if the shell member is formed integrally, that is as one single piece from just one material in one production step. This simplifies removal and installation of the closure member. In addition, this is advantageous for the production of the shell member, for example reducing cycle time of an injection molding.
In a preferred embodiment, the shell member comprises a strap for widening the shell member. This strap eases handling of the dummy for removing/disconnecting and installing the closure member.
In a further preferred embodiment, the closure is stiff. This means that the resilience of the closure member is higher than the resilience of the shell member, for example 10 times, 20 times, 50 times or 100 times higher. This means that the closure member is not deformed when opening or closing the dummy. Further preferably, the closure member is plain, for example disk-shaped.
In another preferred embodiment, the dummy comprises a ventilation opening for the volume enclosed by the shell member, the closure member and a surface on which the dummy is placed. This is to prevent a vacuum in this volume if the dummy is placed on a surface such as a table top, causing adherence of the dummy on the surface. Preferably, the opening is a radial cut in the shell member at the underside of the dummy, for example in the end face of the shell member.
An injection training system according to the present invention comprises an injection training dummy as described above and an injection device having an injection needle. Preferably, the injection device is the device used by the patient later on to administer the actual medicament. Further preferably, the injection device of the injection training system does not contain the actual medicament, but a replacement substance. The replacement substance can have the same properties, such as viscosity, as the actual medicament. Preferably, the viscosity of the replacement substance is (slightly) higher than the viscosity of the actual medicament. This is to compensate for the fact that the replacement substance is injected into a hollow chamber instead of into tissue.
According to the present invention, a method for training the injection process with an injection device having an injection needle comprises the steps of penetrating a shell member of an injection training dummy with the injection needle such that the tip of the injection needle extends into a chamber of the injection training dummy and injecting a liquid from the injection device into the chamber. This means that the present invention encompasses the use of an injection training dummy comprising an unfilled chamber for training or practising an injection process.
It is within the scope of the present invention to combine single or all features of the embodiments and examples given in this document to form another embodiment. Further, features not essential for performing the present invention can be omitted.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the injection training dummy shall be described with reference to the accompanying drawings. The figures show:
FIG. 1 a a bottom view of an injection training dummy,
FIG. 1 b a cross-sectional view,
FIG. 1 c a top view,
FIG. 2 an inclined top view of the shell member and
FIG. 3 an inclined bottom view of the shell member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 a to 1 c show different views of an exemplary injection training dummy 1 . FIG. 1 a shows a bottom view, FIG. 1 c shows a top view and FIG. 1 b shows a cross-sectional view along the intersection line A-A shown in FIG. 1 c.
The injection training dummy 1 consists of a shell member 2 made of a flexible material, like an elastomer or natural rubber, and a closure member 3 . The closure member is a circular disc made from a stiff material such as metal or plastic.
The exemplary injection training dummy 1 is basically rotationally symmetric. This means that the shell member 2 has a pot-like or bell-like outer shape. The shell member 2 comprises an injection wall 4 , which can be compared to the bottom of the pot, and a circular side wall 5 , as can be seen from FIGS. 2 and 3 . The injection wall 4 has a convex shape, which means that it is curved outwards. The side wall 5 , which can also be called lateral surface, is concave, which means that it is curved inwards. In addition, the side wall 5 is slanted, which means that the outer diameter of the side wall near the injection wall is smaller than at the other end where the closure member 3 is located. With this design, the injection training dummy can easily be grasped and handled.
At the end of the side wall 5 facing away from the injection wall 4 , the shell member 2 has a recess 6 shaped like a grove to receive the closure member 3 . The recess 6 is bordered on one side by the side wall 5 and on the other side by a ring-like lip 7 . As can be seen in FIG. 1 b , the lip 7 extends radially inward along the surface of the closure member 3 and has an inner diameter slightly smaller than the diameter of the closure member 3 . The closure member 3 is therefore embraced by the lip 7 , thus being interconnected with the shell member 2 in liquid-tight manner.
As can be best seen from FIGS. 1 b and 3 , the shell member 2 also comprises an optional inner wall or reinforcement wall 8 having the shape of a hollow cylinder. As an alternative, the reinforcement wall 8 could have the shape of a truncated hollow cone or any other shape. In the present embodiment, the height of the reinforcement wall 8 is slightly larger than the distance between the facing sides of the injection wall 4 and the closure member 3 . One end of the reinforcement wall 8 is supported by the closure member 3 , while the other end reinforces the injection wall 4 to generate a suitable resistance of the injection wall 4 against the injection needle of an injection device over its whole surface. At the same time, the reinforcement wall 8 presses the closure member 3 against the lip 7 to ensure that there is a tight seal between them. As an alternative, the height of the reinforcement wall 8 could be equal to or smaller than the distance between the facing sides of the injection wall 4 and the closure member 3 . In this case, the injection wall 4 moves the reinforcement wall 8 against the closure member before it supports the injection wall 4 . The injection wall is therefore slightly deformed before the reinforcement becomes effective.
The shell member 2 and the closure member 3 constitute a chamber 9 into which a liquid can be injected through the injection wall 4 . In the present embodiment, the chamber 9 is divided into a first volume 9 a within the reinforcement wall 8 and a second volume 9 b between the side wall 5 and the reinforcement wall 8 . The two volumes 9 a and 9 b can optionally be connected by apertures in the reinforcement wall 8 .
As can be best seen in FIGS. 1 a and 3 , the rotational symmetry of the injection training dummy 1 is broken by a strap 11 and a cut 12 . The strap 11 is an extension of the lip 7 facing radially inwards. By handling the strap 11 , the shell member 2 can be deformed to remove or install the closure member 3 . The cut 12 is a radial cut in the end face of the shell member 2 opposite to the injection wall 4 . Optionally, the radial cut 12 is located radially opposite to the strap 11 as in the present embodiment. This cut 12 enables ventilation and inhibits the formation of a vacuum between the dummy 1 and a surface on which the dummy 1 is placed, thus preventing suction forces that could impair the handling of the dummy.
In the end face of the shell member 2 opposite to the injection wall 4 , there is a circular grove or chamfer 10 between the lip 7 and the outer circumference of the shall member 2 . At this end, the side wall 5 widens so the dummy 1 can be safely pressed against a surface such as skin. If the area between the side wall 5 and the lip 7 was completely filled and there was no chamfer 10 , the shell member 2 would be rather stiff in this section. With the chamfer 10 , the lower end of the shell member 2 remains flexible enough to be deformed for removing and installing the closure member 3 in the recess 6 . In addition, if the shell member 2 is produced by injection molding, the cycle time can be reduced and the fabrication of the undercut is simplified.
Together with an injection device having an injection needle, the injection training dummy forms an injection training system. For training the injection process, the user or patient penetrates the shell member 2 of the injection training dummy 1 with the injection needle such that the tip of the injection needle extends into the chamber 9 . He then injects a liquid from the injection device into the chamber 9 . This can be done repeatedly, thus accumulating the injected liquid in the chamber 9 . Since the shell member 2 and the closure member 3 are impermeable to the liquid, the liquid cannot leak out of the injection training dummy 1 . This prevents a smell as well as staining of the area surrounding the injection training dummy, in particular the clothing of the user or patient.
In general, any king of injection device can be used with the injection training system. Injection devices can range from simple, manually operated syringes to complex auto injectors with an automated control of the injection process steps. In particular, the injection devices as described in the Patent Application PCT/EP2009/057934, filed on Jun. 24, 2009, and published as WO 2010/149214 A1, or the Patent Application PCT/EP2010/050642, filed on Jan. 20, 2010, and published as WO 2011/088894 A1, can be used. Both applications, filed by the applicant of the present application, are hereby incorporated by reference.
For emptying the chamber 9 , the user pulls the strap 11 and therefore deforms the shell member 2 . The closure member 3 can then be removed from the recess 6 in the shell member. The liquid accumulated in the chamber 9 can then be disposed and the injection training dummy 1 can be cleaned. The injection training dummy 1 can then be reassembled for further use.
Though the injection training dummy 1 of the exemplary embodiment is described as having a circular basic shape, any other suitable shape is within the scope of the present invention. In particular, the basic shape, i.e. the shape of the injection wall 4 and the closure member 3 , can be rectangular or triangular.
Preferably, the thickness of the injection wall 4 and/or the side wall 5 is less than or equal to 3 mm. The height of the injection training dummy 1 , that is the extent perpendicular to the surface, parallel or along the side walls 5 , of the closure member 3 , is preferably between 2 and 5 cm, preferably 3 cm. The diameter of the injection training dummy 1 , that is the extent perpendicular to the height dimension, is preferably between 5 and 15 cm, for example 8.8 cm.
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An injection training dummy, including a) a three-dimensional shell member which can be penetrated by an injection needle, and b) a closure member detachably interconnected with the shell member, wherein c) the shell member and the closure member constitute a chamber into which liquid can be injected through the injection needle, and d) the shell member and the closure member are designed such that they do not absorb the liquid.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/037,256 filed on Feb. 28, 2011, the entire content of which is incorporated by reference herein.
TECHNICAL FIELD
[0002] Embodiments of the present invention relate to peer-to-peer systems, and more specifically to peer discovery in a peer-to-peer system.
BACKGROUND
[0003] A peer-to-peer system is a distributed service architecture in which resources such as processing power, memory, disk storage, network bandwidth, etc. are partitioned and divided among peers. Each peer in a peer-to-peer system may be both a consumer and supplier of resources.
[0004] Peer-to-peer systems provide mechanisms for peer discovery to enable nodes to join the peer-to-peer system. One conventional mechanism for peer discovery is the use of a static list. The static list is a list of nodes in the peer-to-peer system. A new node uses the network addresses of nodes in the static list to determine system membership. Static lists provide a very fast discovery. However, static lists do not work well when membership in the peer-to-peer system is dynamic. Additionally, static lists are cumbersome for large numbers of nodes.
[0005] Due to the limitations of static lists, most peer-to-peer systems use user datagram protocol (UDP) multicast to perform peer discovery. Multicast is the delivery of a message or data to multiple destination computing devices simultaneously in a single transmission. With multicast, as a node joins a peer-to-peer system, the node announces its address to existing nodes in the peer-to-peer system. The nodes (each of which is a peer in the peer-to-peer system) then respond by sending their addresses to the new node. Multicast enables peer discovery in a peer-to-peer system that has a dynamic membership. However, multicast can require multiple round trip messages to perform discovery. Additionally, many cloud computing platforms (e.g., Amazon® Elastic Compute Cloud (EC2), Rackspace® Cloud, etc.) do not permit multicasts. Therefore, peer-to-peer systems running on cloud computing platforms often cannot use multicast for peer discovery.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which:
[0007] FIG. 1 illustrates an exemplary peer-to-peer network architecture, in which embodiments of the present invention may operate;
[0008] FIG. 2 illustrates a block diagram of a peer-to-peer system joiner for a node in a peer-to-peer system, in accordance with one embodiment of the present invention;
[0009] FIG. 3 illustrates a flow diagram of one embodiment for a method of discovering nodes of a peer-to-peer system;
[0010] FIG. 4 illustrates a flow diagram of one embodiment for a method of joining a peer-to-peer system; and
[0011] FIG. 5 illustrates a block diagram of an exemplary computer system, in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
[0012] Described herein are a method and apparatus for using a shared data store to perform peer discovery for a peer-to-peer system. In one embodiment, after acquiring a network address a machine accesses a shared data store and writes the network address to the shared data store. The computing device additionally reads other network addresses from the shared data store. Each network address in the shared data store may be for a member node (peer) of a peer-to-peer system. Accordingly, the machine may determine group membership of the peer-to-peer system based on the contents of the shared data store. The computing device then joins the peer-to-peer system. This may include exchanging messages with one or more of the existing member nodes in the peer-to-peer system using their network addresses.
[0013] Embodiments of the present invention enable machines to perform shared data store based peer discovery in a peer-to-peer system that has dynamic membership. Shared data store based peer discovery may be used for peer-to-peer systems that operate on cloud computing platforms that prohibit multicast (e.g., Amazon EC2 and Rackspace Cloud). Additionally, unlike static list peer discovery, shared data store based peer discovery can be used for peer-to-peer systems that have dynamic membership.
[0014] FIG. 1 illustrates an exemplary peer-to-peer network architecture 100 , in which embodiments of the present invention may operate. The peer-to-peer network architecture 100 includes multiple machines 105 , 110 , 115 connected via a network 120 . The network 120 may be a public network (e.g., Internet), a private network (e.g., a local area Network (LAN)), or a combination thereof.
[0015] Machines 105 , 110 , 115 may be hardware machines such as desktop computers, laptop computers, servers, or other computing devices. Additionally, machines 105 , 110 , 115 may also be hardware machines such as routers, switches, gateways, storage servers, or other network attached devices. Each of the machines 105 , 110 , 115 may include an operating system that manages an allocation of resources of the computing device (e.g., by allocating memory, prioritizing system requests, controlling input and output devices, managing file systems, facilitating networking, etc.). In one embodiment, one or more of the machines 105 , 110 , 115 is a virtual machine. For example, machines 105 may be a virtual machine provided by Amazon EC2. In some instances, some machines may be virtual machines running on the same computing device (e.g., sharing the same underlying hardware resources).
[0016] Each of the machines 105 , 110 , 115 includes a peer-to-peer (P2P) application 123 that runs on the machine. The peer-to-peer application may be a file sharing application, grid computing application, distributed data grid application, distributed search application, or any other type of application that uses a clustering protocol. The peer-to-peer applications 123 may communicate via the network 120 to form a peer-to-peer system 140 . The peer-to-peer system 140 may be a peer-to-peer file sharing system, a distributed computing grid, a distributed data grid, a computing cluster, or other type of peer-to-peer system.
[0017] In one embodiment, the peer-to-peer system 140 provides one or more services that clients and/or peers can access. A service is a discretely defined set of contiguous and autonomous functionality (e.g., business functionality, technical functionality, etc.). A service may represent a process, activity or other resource that can be accessed and used by other services or clients (not shown) on network 120 . In one embodiment, peers of the P2P system 140 can access the service provided by the P2P system 140 . In another embodiment, the P2P system 140 acts as a distributed server, and clients may connect to any of the machines 105 , 110 , 115 in the P2P system 140 to access the service. For example, the P2P system 140 may be a distributed data grid that provides a distributed cache to a client such as a web application.
[0018] To join the P2P system 140 , a machine initially performs peer discovery to find other nodes (e.g., machines) that are members in the peer-to-peer system 140 . In one embodiment, the P2P application 123 includes a peer-to-peer (P2P) system joiner 125 that performs peer discovery and tracks group membership. In one embodiment, P2P system joiner 125 is preconfigured with a network address for a shared data store 118 that contains network addresses for current members of the P2P system 140 .
[0019] Shared data store 118 is a network-available storage connected to network 120 . Shared storage 118 may include volatile storage (e.g., memory), non-volatile storage (e.g., disk storage), or a combination of both. In one embodiment, the shared data store 118 is a network storage device managed by a storage server. For example, the shared data store 118 may be a storage area network (SAN), a network attached storage (NAS), or a combination of both. The shared data store 118 may be a shared folder or directory within a network storage device. If the shared data store is a network storage device, P2P system joiner 125 may access the shared data store 118 using a storage network communication protocol such as internal small computer interface (iSCSI), common internet file system (CIFS), network file system (NFS), direct access file systems (OAFS), and so on.
[0020] In another embodiment, shared data store 118 is a container in a storage cloud. Some examples of storage clouds include Amazon's® Simple Storage Service (S3), Nirvanix® Storage Delivery Network (SON), Windows® Live SkyDrive, Ironmountain's® storage cloud, Rackspace® Cloudfiles, AT&T® Synaptic Storage as a Service, Zetta® Enterprise Cloud Storage On Demand, IBM® Smart Business Storage Cloud, and Mosso® Cloud Files. Most storage clouds provide unlimited storage through a simple web services interface (e.g., using standard HTTP commands or SOAP commands). However, most storage clouds are not capable of being interfaced using standard file system protocols. Accordingly, if the shared data store 118 is a container in a storage cloud, P2P system joiner 125 may access shared data store 118 using cloud storage protocols such as hypertext transfer protocol (HTTP), hypertext transport protocol over secure socket layer (HTTPS), simple object access protocol (SOAP), representational state transfer (REST), etc. Thus, P2P system joiner
[0000] 125 may store data in the shared data store 118 using, for example, common HTTP POST or PUT commands, and may retrieve data using HTTP GET commands.
[0021] In one embodiment, shared data store 118 is encrypted and/or protected by an authentication mechanism to ensure that only authenticated machines can join the peer-to-peer system. Accordingly, P2P system joiner 125 may be challenged to provide authentication credentials (e.g., a login and password, a secure sockets layer (SSL) certificate, etc.) before gaining access to the shared data store 118 . Alternatively, shared data store 118 may be public, so that any machine can join the peer-to-peer system 140 .
[0022] Shared data store 118 holds one or more membership data structures 135 . A membership data structure 135 may be a file, database, table, list or other data structure. In one embodiment, shared data store 118 includes a separate membership data structure (e.g., a separate file such as a text file, XML file, etc.) for each node that is a member of the P2P system 140 . Alternatively, shared data store 118 may include a single membership data structure (or a few membership data structures) that contains multiple entries, where each entry corresponds to a separate member node. In one embodiment, each entry includes an address of a particular member node. The address may include an internet protocol (IP) address and a port number. For example, the address may be a tuple (IP address, port number) that enables the P2P application 123 to communicate with other nodes in the P2P system 140 .
[0023] In one embodiment, each machine 105 , 110 , 115 that joins P2P system 140 accesses shared data store 118 and writes the machine's network address to the shared data store 118 (e.g., by adding an entry to an existing membership data structure 135 or adding a new membership data structure 135 ). In addition to writing to the shared data store 118 , a P2P system joiner 125 may read the one or more membership data structures 135 in the shared data store 118 to identify network addresses of the member nodes in the peer-to-peer system 140 . Once a P2P application 123 has the network addresses of the other nodes in the P2P system 140 , and those other nodes have the network address of the P2P application 123 and/or its host machine, that P2P application 123 has joined the P2P system 140 .
[0024] FIG. 2 illustrates a block diagram of a P2P system joiner 205 for a node in a peer-to-peer system, in accordance with one embodiment of the present invention. In one embodiment, the P2P system joiner 205 corresponds to P2P system joiner 125 of FIG. 1 . The P2P system joiner 205 may be installed on each machine (e.g., each hardware machine and each virtual machine) that will participate in a peer-to-peer system.
[0025] P2P system joiner 205 joins a peer-to-peer system and tracks P2P system membership for a peer-to-peer application. In one embodiment, P2P system joiner 205 includes a data store discovery module 210 , a multicast discovery module 215 , a static list discovery module 220 and a membership tracker 225 . Data store discovery module 210 accesses a shared data store to determine group membership in the peer-to-peer system. Data store discovery module 210 uses shared data store access information 235 to access the shared data store. The shared data store access information 235 may include an address (e.g., a network address) of the shared data store, identification of a protocol to use to access the shared data store (e.g., CIFS, HTTP, NFS, SOAP, etc.), and authentication credentials (e.g., login, password, digital certificates, etc.) for accessing the shared data store. If the shared data store is a network storage device, the address may include a directory of a mapped drive. If the shared data store is a container of a storage cloud, the address may include a universal resource locator (URL).
[0026] In one embodiment, data store discovery module 210 writes a network address for its host machine and/or P2P application to the shared data store. Data store discovery module 210 additionally reads network addresses for other nodes in the peer-to-peer system from the shared data store. In one embodiment, data store discovery module 210 downloads one or more membership data structures (e.g., files containing membership lists) from the shared data store. Alternatively, data store discovery module 210 may query the shared data store for network addresses of member nodes. For example, if the shared data store is a database, data store discovery module 210 may query the database using a structured query language (SQL) query. Data store discovery module 210 may generate a membership data structure 240 based on the received network address data. Alternatively, data store discovery module 210 may save a received membership data structure.
[0027] In one embodiment, after acquiring the network addresses for the nodes in the peer-to-peer system, the data store discovery module 210 queries one or more of the nodes for their group membership data structures. Data store discovery module 210 may then receive group membership data structures from the nodes and compare the received group membership data structures to the group membership data structure that the data store discovery module 210 previously generated or stored. Data store discovery module 210 may update its group membership data structure 240 based on entries in the received group membership data structures.
[0028] In some instances, data store discovery module 210 may not be able to successfully access the shared data store. This may occur, for example, if there is a network partition or if the shared data store has stopped working. In one embodiment, if data store discovery module 210 is unable to perform peer discovery, multicast discovery module 215 and/or static list discovery module 220 perform peer discovery. Multicast discovery module 215 may perform peer discovery using multicast. Static list discovery module 220 may perform peer discovery using a default group membership list 240 .
[0029] After data store discovery module 210 has performed discovery and joined the P2P system, membership tracker 225 tracks membership of the P2P system and maintains the group membership data structure 240 . In one embodiment, membership tracker 225 periodically accesses the shared data store to determine whether network addresses for any new nodes have been added to the shared data store and/or if any network addresses have been removed from the shared data store. This may ensure that P2P system joiner 205 maintains an updated membership view in light of dynamic changes to the P2P system or cluster (e.g., as new peers are added, and existing peers go offline). If new network addresses are included in the shared data store, membership tracker 225 may write those new network addresses to the group membership data structure 240 . Alternatively, membership tracker 225 may replace a previous version of the membership data structure 240 with a newly received membership data structure. Therefore, membership tracker 225 ensures that the group membership data structure 240 does not become stale.
[0030] The group membership data structure 240 maintained by membership tracker 225 may include every member of the peer-to-peer system, which gives the P2P system joiner 205 a full view of the peer-to-peer system. Alternatively, the group membership data structure 240 may include a subset of the total membership, which provides a partial view of the peer-to-peer system. Note that if the group membership data structure 240 includes a partial view of the total membership in the P2P system, then different P2P system joiners 205 in the peer-to-peer system may have different group membership data structures.
[0031] In one embodiment, the peer-to-peer system is divided into multiple clusters. Each cluster may have its own group membership that is maintained in a distinct shared data store. In one embodiment, the P2P system joiner 205 joins a specific cluster of the peer-to-peer system by accessing a specific shared data store associated with that specific cluster.
[0032] FIG. 3 illustrates a flow diagram of one embodiment for a method 300 of discovering nodes of a peer-to-peer system. The method may be performed by processing logic that may comprise hardware (e.g., circuitry, dedicated logic, programmable logic, microcode, etc.), software (such as instructions run on a processing device), or a combination thereof. In one embodiment, method 300 is performed by a machine that includes a P2P system joiner 125 , as shown in FIG. 1 .
[0033] Referring to FIG. 3 , at block 305 processing logic acquires a network address. At block 310 , processing logic attempts to access a shared data store. The shared data store may be a directory in a shared network storage device or a container in a storage cloud (e.g., a bucket of Amazon's 83 storage cloud). If the shared data store is a container in a storage cloud, then an HTTP or SOAP message may be sent to the storage cloud to access the shared data store. If the shared data store is a directory in a network storage device, then a CIFS or NFS message may be sent to the network storage device to access the shared data store. In one embodiment, accessing the shared data store includes performing authentication (e.g., by login and password information and/or by providing SSL authentication credentials). If processing logic can access the shared data store, the method continues to block 315 . Otherwise, the method continues to block 330 .
[0034] At block 315 , processing logic writes the acquired network address to the shared data store. In one embodiment, processing logic writes the network address to an existing membership data structure in the shared data store. Alternatively, processing logic may generate a new membership data structure and add it to the shared data store.
[0035] At block 320 , processing logic reads network addresses from the shared data store. This may include downloading one or more membership data structures from the shared data store and/or querying the shared data store. Each read network address may be for a node of a peer-to-peer system. Each such node may be configured to write its network address to the shared data store. Therefore, the shared data store may contain entries for every active node in the peer-to-peer system.
[0036] At block 325 , processing logic joins the peer-to-peer system. Joining the peer-to-peer system may include communicating with the nodes using their network addresses.
[0037] At block 330 , processing logic determines whether a backup peer discovery mechanism is available. Examples of backup peer discovery mechanisms include a multicast discovery mechanism and a static list discovery mechanism. If a backup discovery mechanism is available, processing logic uses the backup discovery mechanism to determine group membership for the peer-to-peer system. If no backup peer discovery mechanism is available, processing logic is unable to join the peer-to-peer system, and the method ends.
[0038] FIG. 4 illustrates a flow diagram of one embodiment for a method 400 of joining a peer-to-peer system. The method may be performed by processing logic that may comprise hardware (e.g., circuitry, dedicated logic, programmable logic, microcode, etc.), software (such as instructions run on a processing device), or a combination thereof. In one embodiment, method 400 is performed by a machine that includes a P2P system joiner 125 , as shown in FIG. 1 . In one embodiment, method 400 corresponds to block 325 of method 300 .
[0039] Referring to FIG. 4 , at block 405 processing logic generates and/or stores a membership data structure for a peer-to-peer system. The membership data structure may be a list, table, etc. that includes an entry for each active node of the peer-to-peer system. In one embodiment, the membership data structure is generated based on network addresses retrieved from a shared data store. The generated membership data structure may then be stored. Alternatively, a membership data structure may be received from the shared data store and then stored.
[0040] At block 410 , processing logic queries some or all of the nodes included in the membership data structure using the their network addresses. At block 415 , processing logic receives membership data structures from the queried nodes. At block 420 , processing logic determines whether the received membership data structures match the stored membership data structure. If any of the received membership data structures fails to match the stored membership data structure, the method continues to block 423 . Once processing logic has identified member nodes in the P2P system and notified the member nodes of the network address associated with processing logic's host machine, the processing logic has joined the P2P system.
[0041] At block 423 , processing logic identifies differences between the received membership data structures and the stored membership data structure. At block 425 , processing logic then updates the stored membership data structure. In one embodiment, any network addresses from the received membership data structures that are not in the stored membership structure are added to the stored membership data structure. In one embodiment, network addresses that are in the stored membership data structure but not in the received membership data structure are removed from the stored membership data structure. This ensures that processing logic does not use stale membership information. The method then ends.
[0042] FIG. 5 illustrates a diagrammatic representation of a machine in the exemplary form of a computer system 500 within which a set of instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed. In alternative embodiments, the machine may be connected (e.g., networked) to other machines in a LAN, an intranet, an extranet, and/or the Internet. The machine may operate in the capacity of a server or a client machine in client-server network environment, or as a peer machine in a peer-to-peer (or distributed) network environment.
[0043] The machine may be a personal computer (PC), a tablet PC, a set-top box (STB), a Personal Digital Assistant (PDA), a cellular telephone, a web appliance, a server, a network router, a switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while only a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein.
[0044] The exemplary computer system 500 includes a processing device 502 , a main memory 504 (e.g., read-only memory (ROM), flash memory, dynamic random access memory (DRAM) such as synchronous DRAM (SDRAM) or Rambus DRAM (RDRAM), etc.), a static memory 506 (e.g., flash memory, static random access memory (SRAM), etc.), and a data storage device 518 , which communicate with each other via a bus 530 .
[0045] Processing device 502 represents one or more general-purpose processing devices such as a microprocessor, a central processing unit, or the like. More particularly, the processing device may be complex instruction set computing (CISC) microprocessor, reduced instruction set computing (RISC) microprocessor, very long instruction word (VLIW) microprocessor, or processor implementing other instruction sets, or processors implementing a combination of instruction sets. Processing device 502 may also be one or more special-purpose processing devices such as an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a digital signal processor (DSP), network processor, or the like. The processing device 502 is configured to execute instructions 522 for performing the operations and steps discussed herein.
[0046] The computer system 500 may further include a network interface device 508 . The computer system 500 also may include a video display unit 510 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)), an alphanumeric input device 512 (e.g., a keyboard), a cursor control device 514 (e.g., a mouse), and a signal generation device 516 (e.g., a speaker).
[0047] The data storage device 518 may include a machine-readable storage medium 528 (also known as a computer-readable medium) on which is stored one or more sets of instructions or software 522 embodying any one or more of the methodologies or functions described herein. The instructions 522 may also reside, completely or at least partially, within the main memory 504 and/or within the processing device 502 during execution thereof by the computer system 500 , the main memory 504 and the processing device 502 also constituting machine-readable storage media.
[0048] In one embodiment, the instructions 522 include instructions for a P2P system joiner (e.g., P2P system joiner 205 of FIG. 2 ) and/or a software library containing methods that call a P2P system joiner. While the machine-readable storage medium 528 is shown in an exemplary embodiment to be a single medium, the term “machine-readable storage medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions. The term “machine-readable storage medium” shall also be taken to include any medium that is capable of storing or encoding a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present invention. The term “machine-readable storage medium” shall accordingly be taken to include, but not be limited to, solid-state memories, optical media and magnetic media.
[0049] Thus, techniques for using a shared data store for peer discovery in a peer-to-peer system are described herein. Some portions of the preceding detailed descriptions have been presented in terms of algorithms and symbolic representations of operations on data bits within a computer memory. These algorithmic descriptions and representations are the ways used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. An algorithm is here, and generally, conceived to be a self-consistent sequence of operations leading to a desired result. The operations are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, combined, compared, and otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
[0050] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the above discussion, it is appreciated that throughout the description, discussions utilizing terms such as “acquiring” or “writing” or “reading” or “joining” or “querying” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage devices.
[0051] The present invention also relates to an apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may comprise a general purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but not limited to, any type of disk including floppy disks, optical disks, CO-ROMs, and magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, or any type of media suitable for storing electronic instructions, each coupled to a computer system bus.
[0052] The algorithms and displays presented herein are not inherently related to any particular computer or other apparatus. Various general purpose systems may be used with programs in accordance with the teachings herein, or it may prove convenient to construct a more specialized apparatus to perform the required method steps. The required structure for a variety of these systems will appear as set forth in the description below. In addition, the present invention is not described with reference to any particular programming language. It will be appreciated that a variety of programming languages may be used to implement the teachings of the invention as described herein.
[0053] The present invention may be provided as a computer program product, or software, that may include a machine-readable medium having stored thereon instructions, which may be used to program a computer system (or other electronic devices) to perform a process according to the present invention. A machine-readable medium includes any mechanism for storing information in a form readable by a machine (e.g., a computer). For example, a machine-readable (e.g., computer-readable) medium includes a machine (e.g., a computer) readable storage medium such as a read only memory (“ROM”), random access memory (“RAM”), magnetic disk storage media, optical storage media, flash memory devices, etc.
[0054] In the foregoing specification, embodiments of the invention have been described with reference to specific exemplary embodiments thereof. It will be evident that various modifications may be made thereto without departing from the broader spirit and scope of embodiments of the invention as set forth in the following claims. The specification and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense.
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An example method includes: identifying, by a new node, an address of a shared data store comprising information on a current membership in a peer-to-peer system, wherein the shared data store is shared by a plurality of nodes that are current members of the peer-to-peer system, wherein the shared data store is a container for storing data in a storage cloud; sending, by the new node, a first message comprising an address of the new node to the shared data store; requesting, by the new node, at least one membership data structure from the shared data store; receiving, by the new node, a second message comprising the at least one membership data structure; generating, by the new node, a new membership data structure comprising the address of the new node and the plurality of addresses for the plurality of nodes identified in the at least one membership data structure; sending, by the new node, a third message comprising the new membership data structure to the shared data store; and joining, by the new node, the peer-to-peer system, wherein the joining comprises using the new membership data structure to identify nodes of the plurality of nodes to receive a plurality of messages from the new node.
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REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/237,954, filed Aug. 28, 2009, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to surgical tools for use in endoscopic procedures. In specific embodiments, multifunctional surgical tools for use in endoscopic procedures are described.
BACKGROUND OF THE INVENTION
[0003] Demand for surgical procedures which drastically reduce patient recovery time and discomfort has led to a paradigm shift in modern medicine. Minimally invasive surgery (MIS) is a rapidly developing medical practice and is constantly being advanced through the introduction of novel experimental procedures. MIS procedures require smaller external incisions than traditional surgery, or are completely devoid of external incisions. The benefits of such procedures from a patient care perspective include less discomfort and scaring, shortened recovery time and decreased chance of surgical infections. These benefits have caused an extremely high demand for MIS over traditional surgery, resulting in the introduction of several groundbreaking procedures.
[0004] The scope of endoscopic therapy for diseases has significantly broadened with the use of techniques allowing dissection of the layers of the stomach and selective removal of superficial layers. Several previously open surgical procedures can now be accomplished through minimally invasive endoscopic procedures. Furthering of this field requires tools adapted for flexible endoscopic application.
[0005] A procedure known as natural orifice transluminal endoscopic surgery (NOTES) is particularly promising as a minimally invasive technique. During NOTES, the surgeon passes a flexible endoscope through a natural orifice, e.g. the mouth or anus, in order to access an internal surgical site.
[0006] A novel NOTES procedure for transgastric access is currently under development. During this experimental procedure, the endoscope is inserted through the esophagus and a small internal incision is made in the inner lining of the stomach. The surgeon then passes a forceps tool through the endoscope and tunnels between the layers of the stomach wall, subsequently making a second incision in the outer layer of the stomach. Tunneling between the layers of the stomach wall creates an effective seal between the acidic inside of the stomach and the abdominal cavity, preventing unwanted leakage. After the procedure has concluded, no external incisions are present, and the internal incisions are sutured.
[0007] The tunneling procedures and dissection of tissue using millimeter scale has proven to be extremely tedious using modern endoscopic tools. At small scales, such as 1-5 mm diameter or less, current tool designs are not capable of applying large spreading forces, thereby greatly impeding the ability to separate and dissect tissue. Dissection of tissue is key in any surgery and irrespective of the location and minimally invasive technique, small tools capable of tissue dissection and separation, that pass through the small channels of the current and envisioned endoscopes and other surgical devices are needed. Without these minimally invasive and NOTES procedures cannot to develop and advance effectively.
[0008] There is presently a dearth of multifunctional surgical tools for use in endoscopy. Exchanging the tool tip at the distal end of an endoscope is not only tedious but also undesirably extends the length of a surgical procedure. There is a continuing need for multifunctional surgical tools for use in endoscopy.
SUMMARY OF THE INVENTION
[0009] Surgical tools are provided according to embodiments of the present invention which include a first elongated member and a second elongated member, each of the first and second elongated members having a proximal end, a distal jaw end, the first and second elongated members pivotally attached at a pivotal attachment, each of the first and second elongated members having a first actuator connection disposed between the proximal end and the pivotal attachment and a second actuator connection disposed between the distal end and the pivotal attachment; a pair of first actuators, one of the pair of first actuators connected to the first actuator connection of the first elongated member and the second of the pair of first actuators connected to the first actuator connection of the second elongated member; a pair of second actuators, one of the pair of second actuators connected to the second actuator connection of the first elongated member and the second of the pair of second actuators connected to the second actuator connection of the second elongated member, such that activation of the pair of first actuators urges pivotal movement of the first and second elongated members to bring the distal jaw ends closer together and activation of the pair of second actuators urges pivotal movement of the first and second elongated members to move the distal jaw ends apart; and a housing supporting the pivotally attached elongated members.
[0010] Surgical tools are provided according to embodiments of the present invention which include a first elongated member and a second elongated member, each of the first and second elongated members having a proximal end, a distal jaw end, the first and second elongated members pivotally attached at a pivotal attachment, each of the first and second elongated members having a first actuator connection disposed between the proximal end and the pivotal attachment and a second actuator connection disposed between the distal end and the pivotal attachment; a pair of first actuators, one of the pair of first actuators connected to the first actuator connection of the first elongated member and the second of the pair of first actuators connected to the first actuator connection of the second elongated member; a pair of second actuators, one of the pair of second actuators connected to the second actuator connection of the first elongated member and the second of the pair of second actuators connected to the second actuator connection of the second elongated member, such that activation of the pair of first actuators urges pivotal movement of the first and second elongated members to bring the distal jaw ends closer together and activation of the pair of second actuators urges pivotal movement of the first and second elongated members to move the distal jaw ends apart; a housing supporting the pivotally attached elongated members and a flexible or non-flexible tool shaft attached to the housing supporting the pivotally attached elongated members.
[0011] A controller in operable connection with the pair of first actuators and/or the pair of second actuators is included according to embodiments of surgical tools of the present invention
[0012] A wire in electrical communication with a power source and with the distal jaw end of at least one of the first and second elongated members, the power source operable to deliver an electrical current via the wire to the distal jaw end of at least one of the first and second elongated members. Delivery of the electrical current to the distal jaw end of at least one of the first and second elongated members is useful, for example, to cauterize a tissue.
[0013] Optionally, an included tool shaft is an articulated tool shaft.
[0014] Surgical tools according to embodiments of the present invention are provided that include a housing having a first connecting pin opening and a second connecting pin opening; a first elongated member and a second elongated member, each of the first and second elongated members having a proximal end, a distal jaw end and a connecting pin opening disposed therebetween for pivotal attachment of the first and second elongated members, each of the first and second elongated members having a first actuator connection disposed between the proximal end and the connecting pin opening and a second actuator connection disposed between the distal end and the connecting pin opening; a connecting pin attaching the first elongated member, second elongated member and the housing; a pair of first actuators, one of the pair of first actuators connected to the first actuator connection of the first elongated member and the second of the pair of first actuators connected to the first actuator connection of the second elongated member; and a pair of second actuators, one of the pair of second actuators connected to the second actuator connection of the first elongated member and the second of the pair of second actuators connected to the second actuator connection of the second elongated member, such that activation of the pair of first actuators urges pivotal movement of the first and second elongated members to bring the distal jaw ends closer together and activation of the pair of second actuators urges pivotal movement of the first and second elongated members to move the distal jaw ends apart.
[0015] Surgical tools according to embodiments of the present invention are provided that include a housing having a first connecting pin opening and a second connecting pin opening; a first elongated member and a second elongated member, each of the first and second elongated members having a proximal end, a distal jaw end and a connecting pin opening disposed therebetween for pivotal attachment of the first and second elongated members, each of the first and second elongated members having a first actuator connection disposed between the proximal end and the connecting pin opening and a second actuator connection disposed between the distal end and the connecting pin opening; a connecting pin attaching the first elongated member, second elongated member and the housing; a pair of first actuators, one of the pair of first actuators connected to the first actuator connection of the first elongated member and the second of the pair of first actuators connected to the first actuator connection of the second elongated member; and a pair of second actuators, one of the pair of second actuators connected to the second actuator connection of the first elongated member and the second of the pair of second actuators connected to the second actuator connection of the second elongated member, such that activation of the pair of first actuators urges pivotal movement of the first and second elongated members to bring the distal jaw ends closer together and activation of the pair of second actuators urges pivotal movement of the first and second elongated members to move the distal jaw ends apart, wherein the housing is attached to a distal functional end of a flexible insertion portion of an endoscopic instrument and/or to a flexible sheath of a flexible insertion portion of an endoscope.
[0016] Methods are provided according to embodiments of the present invention which include providing a surgical tool described herein, inserting the surgical tool into the body of a surgical patient; and activating the first pair of actuators to grasp a tissue of the surgical patient and/or activating the second pair of actuators to spread a tissue of the surgical patient.
[0017] Methods are provided according to embodiments of the present invention which include providing a surgical tool described herein, inserting the surgical tool into the body of a surgical patient; and activating the first pair of actuators to grasp a tissue of the surgical patient and/or activating the second pair of actuators to spread a tissue of the surgical patient, and delivering and electrical current to the distal jaw end of at least one of the first and second elongated members in contact with a tissue of the surgical patient, thereby cauterizing the tissue of the surgical patient.
DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a surgical tool according to an embodiment of the present invention disposed through an endoscope, with the endoscope extending into the stomach of a surgical patient;
[0019] FIG. 2 is a perspective view of a surgical tool according to an embodiment of the present invention extending from the end of an endoscope;
[0020] FIG. 3 is a perspective view of a surgical tool according to an embodiment of the present invention;
[0021] FIG. 4 is a perspective view of a surgical tool according to an embodiment of the present invention; and
[0022] FIG. 5 is a perspective view of one arm of a surgical tool according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] A multifunctional grasper/spreader surgical tool which can be used via minimally invasive surgery platforms like endoscopes, including laparoscopes etc, such as through the working channel of endoscopes, and which can apply appreciable grasping and spreading forces to tissue is provided according to embodiments of the present invention.
[0024] Flexible endoscopes are generally characterized by an elongated flexible insertion portion which can be inserted into a patient's body. The elongated flexible insertion portion generally includes a functional distal end, for instance having an attached imaging device and/or surgical tool and a controller disposed at the proximal end of the elongated flexible insertion portion for control of the functional distal end by a user.
[0025] A multifunctional grasper/spreader surgical tool, referred to as a “surgical tool” herein according to embodiments of the present invention includes a housing and two mating jaws supported in the housing.
[0026] According to embodiments of the present invention, the surgical tool includes two pivotally connected elongate members, each having a distally located mating jaw. Any of various pivotal connectors can be used to pivotally connect the elongate members, exemplified by, but not limited to, a pivot pin or compliant mechanism.
[0027] An actuation mechanism for opening and closing the two mating jaws to perform tissue grasping and spreading functions of the surgical tool is included. Prior art forceps designs include a single set of 2 wires which control both the opening and closing of the forceps, resulting in very poor mechanical advantage in one loading direction. In contrast, according to embodiments of the present invention, the actuation mechanism includes a first actuator for opening the jaws to accomplish a tissue spreading function of the surgical tool and a second actuator to close the jaws and accomplish a tissue grasping function of the surgical tool.
[0028] Actuators for opening and closing the two mating jaws can include any actuator capable of urging movement of the two mating jaws. Exemplary actuators include, but are not limited to, wires. The teims “wire” and “wires” as used herein encompass single strands, multiple entwined strands, rods, cables.
[0029] Actuators can be made of materials compatible with surgical use, including but not limited to, metals such as stainless steel or plastics such as polytetrafluoroethylene. Actuators are operably connected to an endoscope handle or controller which allows a user to activate the actuators and control the opening and closing of the mated jaws.
[0030] According to embodiments of the present invention, mechanically controlled wire-actuators are included. Embodiments of a surgical tool of the present invention incorporate as a first actuator a first set of actuating wires for opening the mating jaws of the tool and a second set of actuating wires for closing the mating jaws of the tool as a second actuator.
[0031] The pivotally connected elongate members having distally located mating jaws are supported in a housing. The elongate members are pivotally attached to the housing by any of various pivotal connectors, exemplified by, but not limited to, a pivot pin or compliant mechanism. The housing is adapted to allow for opening and closing of the mating jaws and movement of the elongate members.
[0032] As noted above, a surgical tool according to embodiments of the present invention is useful in conjunction with an endoscope in performing endoscopic surgery. As is well-known, endoscopes for use in surgical procedures typically have several channels including light transmission, image transmission, air and water, and one or more “working channels” through which surgical instruments are inserted.
[0033] A surgical tool of the present invention can be reversibly or permanently attached to a tool shaft which supports the surgical tool. The tool shaft can be flexible or rigid depending on the intended application. In endoscope embodiments, the tool shaft is flexible and extends through the working channel of the endoscope. The housing of an inventive surgical tool optionally includes a connector adapted to reversibly attach the housing to the tool shaft.
[0034] The housing optionally includes a base having a channel therethrough such that actuators attached to the elongate members and operably connected to the endoscope handle or controller are disposed in the channel. The tool shaft may be hollow such that actuators can be disposed in the tool shaft.
[0035] Optionally, at least a portion of the tool shaft is articulated to allow for flexible and/or directed movement of the surgical tool at the distal end of the endoscope.
[0036] In a further option, a surgical tool according to embodiments of the present invention is in electrical communication with a power source to provide electrocautery functionality to the surgical tool.
[0037] FIG. 1 shows an endoscope including a surgical tool of the present invention, 2 . The endoscope extends between two ends 4 and 6 with the end 6 inserted into the body of a subject. The illustrated endoscope includes a handle or control, such as shown at 12 , which is operably connected to an embodiment of a surgical tool of the present invention, 10 . Surgical tool 10 is shown attached to a shaft 9 .
[0038] A detailed view of the end 6 is provided in FIG. 2 . As shown, the endoscope has a working channel 8 defined therethrough. Typically, this channel has a diameter in the range of 0.5 to 6 millimeters, and the diameter can be smaller or larger depending on the application.
[0039] FIG. 2 shows an embodiment of a surgical tool of the present invention, 10 attached to a shaft 9 which is removably disposed in working channel 8 of the endoscope. The illustrated surgical tool includes a first elongated member 12 and a second elongated member 14 . Each of the first and second elongated members have a distal jaw end 16 and a proximal end 18 . The lower sections of the elongated members incorporate an offset design to enable mating of the gripping surfaces of the jaws 20 . The upper sections of the elongated members are stepped up and tapered to provide grasping/spreading areas and prevent tissue puncturing.
[0040] The first and second elongated members 12 and 14 are pivotally attached in an embodiment shown in FIG. 2 . Each of the first and second elongated members 12 and 14 has a connecting pin opening disposed between the distal jaw end 16 and the proximal end 18 for insertion of a connecting pin therethrough. A connecting pin 26 pivotally attaching the first and second elongated members 12 and 14 to each other and to a housing 28 is illustrated.
[0041] Each of the first and second elongated members 12 and 14 has a first actuator connection 22 disposed between the distal jaw end 16 and the connecting pin opening and a second actuator connection 24 disposed between the proximal end 18 and the connecting pin opening.
[0042] A pair of first actuators 32 is shown. One of the pair of first actuators 32 is connected to the first actuator connection 22 of the first elongated member 12 and the second of the pair of first actuators 32 is connected to the first actuator connection 22 of the second elongated member 14 . A pair of second actuators 34 is illustrated. One of the pair of second actuators 34 is connected to the second actuator connection 24 of the first elongated member 12 and the second of the pair of second actuators 34 is connected to the second actuator connection 24 of the second elongated member 14 . Activation of the pair of first actuators 32 urges pivotal movement of the first and second elongated members 12 and 14 to bring the distal jaw ends 16 closer together to provide the tissue grasping function. Activation of the pair of second actuators 34 urges pivotal movement of the first and second elongated members 12 and 14 to move the distal jaw ends 16 apart, providing the tissue spreading function.
[0043] FIG. 3 shows an embodiment of a surgical tool of the present invention, 10 . The illustrated surgical tool includes a first elongated member 12 and a second elongated member 14 . Each of the first and second elongated members have a distal jaw end 16 and a proximal end 18 .
[0044] Each of the first and second elongated members 12 and 14 has a connecting pin opening disposed between the distal jaw end 16 and the proximal end 18 for insertion of a connecting pin therethrough. A connecting pin 26 pivotally attaching the first and second elongated members 12 and 14 to each other and to a housing 28 is illustrated.
[0045] Housing 28 includes a channel 30 for reversible attachment of the housing 28 to a tool shaft. Optionally actuators 32 and 34 are disposed in the channel.
[0046] Each of the first and second elongated members 12 and 14 has a first actuator connection 22 disposed between the distal jaw end 16 and the connecting pin opening and a second actuator connection 24 disposed between the proximal end 18 and the connecting pin opening.
[0047] Actuators attached at first actuator connections 22 and second actuator connections 24 can be any actuator capable of urging movement of the attached distal jaw ends of the first and second elongated members.
[0048] A pair of first actuators 32 is shown in FIG. 3 . One of the pair of first actuators 32 is connected to the first actuator connection 22 of the first elongated member 12 and the second of the pair of first actuators 32 is connected to the first actuator connection 22 of the second elongated member 14 . A pair of second actuators 34 is illustrated. One of the pair of second actuators 34 is connected to the second actuator connection 24 of the first elongated member 12 and the second of the pair of second actuators 34 is connected to the second actuator connection 24 of the second elongated member 14 , such that activation of the pair of first actuators 32 urges pivotal movement of the first and second elongated members 12 and 14 to bring the distal jaw ends 16 closer together and activation of the pair of second actuators 34 urges pivotal movement of the first and second elongated members 12 and 14 to move the distal jaw ends 16 apart.
[0049] Distal jaw ends of the first and second elongated members can have various shapes.
[0050] FIG. 4 shows a “wide-jaw” embodiment of a surgical tool of the present invention, 40 . The illustrated surgical tool includes pivotally attached first and second elongated members 12 and 14 . Each of the first and second elongated members have a distal jaw end 16 and a proximal end 18 . The distal jaw ends 16 include opposing gripping surfaces of the jaws 20 .
[0051] Each of the first and second elongated members 12 and 14 has a connecting pin opening disposed between the distal jaw end 16 and the proximal end 18 for insertion of a connecting pin therethrough. A connecting pin 26 pivotally attaching the first and second elongated members 12 and 14 to a housing 28 is illustrated.
[0052] Each of the first and second elongated members 12 and 14 has a first actuator connection 22 disposed between the distal jaw end 16 and the connecting pin opening and a second actuator connection 24 disposed between the proximal end 18 and the connecting pin opening.
[0053] FIG. 5 shows a first elongated member 12 having a distal jaw end 16 and a proximal end 18 , connecting pin opening 36 disposed between the distal jaw end 16 and the proximal end 18 for insertion of a connecting pin therethrough. A gripping surface of a jaw is illustrated at 20 .
[0054] The first elongated members 12 has a first actuator connection 22 disposed between the distal jaw end 16 and the connecting pin opening 36 and a second actuator connection 24 disposed between the proximal end 18 and the connecting pin opening 36 .
[0055] According to embodiments of the present invention, a surgical tool described herein is used through the working channel of an endoscope and is sized accordingly. For example, tool insertion ports on standard endoscopes do not allow long rigid sections to pass through, therefore a surgical tool tip according to embodiments of the present invention has a maximum length of about 10.0 mm. Further aspects of a surgical tool according to embodiments of the present invention include (1) an open jaw-to-jaw angle of 90 degrees, (2) a length of least 5.0 mm from pivot point to tip and (3) at least 3.25 mm of unobstructed external jaw length.
[0056] In particular embodiments, a surgical tool of the present invention is used in a 3.3 mm working channel of a flexible endoscope and therefore the outer diameter of the surgical tool has a maximum dimension equal to or less than about 3.0 millimeters.
[0057] Particular sizes of surgical tools and/or components of surgical tools according to the present invention described herein are intended as exemplary and are considered non-limiting.
[0058] Surgical tools of the present invention are made of any of various materials used in manufacture of surgical tools, including both rigid and flexible materials, exemplified by, but not limited to, surgical steel and flexible plastics.
[0059] Any of various well-known methods can be used to manufacture a surgical tool of the present invention, such as wire electrical discharge machining (EDM).
[0060] Optionally, methods used to manufacture a surgical tool are those described in U.S. Patent Application Publication 2010/0075170. Briefly described, a manufacturing process described in U.S. Patent Application Publication 2010/0075170 includes a) mold fabrication; b) colloid preparation; c) gel-casting slurry preparation; d) mold infiltration, gel-casting, and planarization; and e) mold removal and sintering. The final parts manufactured according to this method are filtered and cleaned and assembled if necessary.
[0061] Surgical tools of the present invention can be used in any of various medical procedures, including, but not limited to MIS and NOTES.
[0062] A surgical tool described herein is used in a surgical procedure on a subject, such as, but not limited to, a human. Surgical tools described herein are used in surgical procedures on non-human subjects according to embodiments of the present invention, such as a companion animal including but not limited to dogs and cats; livestock including but not limited to cattle, horses, sheep, goats and poultry; and laboratory animals including but not limited to rodents.
[0063] Any patents or publications mentioned in this specification are incorporated herein by reference to the same extent as if each individual publication is specifically and individually indicated to be incorporated by reference.
[0064] The devices and methods described herein are presently representative of preferred embodiments, exemplary, and not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art. Such changes and other uses can be made without departing from the scope of the invention as set forth in the claims
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Recent advances in minimally invasive surgical procedures have created a demand for smaller scale tools with improved performance characteristics. Attempts to scale down modern tools to the meso level (1-5 mm) have caused severe performance losses. Surgical tools of the present invention provide significant improvements in operable range and force application for both grasping and spreading when compared to currently used endoscopic forceps.
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This is a continuation of application Ser. No. 08/184,490, filed Jan. 21, 1994, which was abandoned upon the filing hereof.
BACKGROUND OF THE INVENTION
The instant invention relates to a process for the installation and interconnection of drafting units of a single-head or two-head draw frame, whereby each drafting unit is provided with drafting rollers supported in pillow blocks and with interconnected shafts provided in the case of a two-head draw frame. The invention furthermore relates to a draw frame with a frame having at least one drafting unit placed on the frame on top of pillow blocks.
Single-head draw frames, i.e. draw frames using one single drafting unit for the drafting of fiber slivers, in which the drafting rollers are installed in pillow blocks directly on the frame of the draw frame are known. For the horizontal and vertical alignment of the drafting units or of the pillow blocks on the frames, washers are used between the pillow blocks and the frame, said washers having a thickness sufficient to lift the drafting unit into the desired position. Washers of different thicknesses are selected in order to achieve proper alignment of the drafting units. This type of assembly is time-consuming, since the pillow blocks must be disassembled again if the selection of washers is not correct, and must be assembled again with washers of a different height. Also known is a two-head draw frame, i.e. a draw frame in which two drafting units which are parallel to each other draw fiber slivers. In addition to the alignment of the individual drafting units, similarly as with the single-head draw frame, it is furthermore necessary to align the two parallel drafting units so that they are precisely flush in relation to each other. This is necessary as the two drafting units are generally driven by one single drive so that the drafting rollers of the two drafting units which correspond to each other are rigidly connected to each other. To achieve this rigid connection of the drafting rollers with each other, it is necessary to bring the two drafting units into vertical as well as horizontal alignment with each other, so that the shafts of the drafting rollers may be connected to each other.
OBJECTS AND SUMMARY OF THE INVENTION
It is a principal object of the instant invention to create a process and a device by means of which the assembly of the drafting units of a draw frame can be carried out rapidly, at low cost, and with precise positioning. Additional objects and advantages of the invention will be set forth in part in the following description or may be obvious from the description, or may be learned through practice of the invention.
According to the invention, if the pillow block is placed on a table, and if the height is adjusted by means of a first adjusting device and the table pitch in relation to the frame by means of a second adjusting device, the adjustment of the pillow block of the drafting unit can be effected easily and rapidly. Repeated disassembly of the pillow block in order to insert different washers until the height and pitch of the pillow block in relation to the other components of the draw frame are correct is thus avoided. By adjusting the adjusting devices until the desired position has been achieved, assembly is facilitated considerably.
In an advantageous embodiment, the horizontal alignment of the pillow blocks is adjusted in relation to the table by means of adjusting devices. This has the advantage that the horizontal position of the pillow blocks on the table can be changed after proper position adjustment of the table.
The device according to the invention can be used to special advantage in a process for the adjustment and interconnection of drafting units of a two-head draw frame. If the pillow blocks of the drafting rollers are installed on a table, the height of the table in relation to the frame can be adjusted by means of first adjusting devices, and the vertical alignment of the shafts can be changed by means of second adjusting devices until they face each other in vertical flush adjustment. The desired height of the drafting units is adjusted by means of the first adjusting devices so that the fiber slivers going through the draw frame are transferred to the drafting units and from the drafting units to the components downstream of the drafting units without any deflection away from the components located before the drafting units.
To achieve additional horizontal alignment of the shafts in relation to each other, it is advantageous to adjust the pillow blocks of the drafting units in relation to each other by means of additional adjusting devices until the alignment of the shafts is such that they face each other horizontally. Following this adjustment, the shafts of the drafting rollers can be connected to each other by means of a coupling without tension.
If a table is provided between the pillow blocks and the frame for position adjustment of the pillow blocks on which the drafting rollers of the drafting units are mounted, the adjusting of the pillow blocks can be effected rapidly, easily and precisely. The pillow blocks need not be disassembled for precise position adjustment if the table is connected to the frame by means of adjusting screws.
It is especially advantageous if the height adjustment, as well as the vertical alignment of the pillow blocks, can be carried out with the help of the table. In this manner a precise adjustment of the drafting units, in particular with a two-head draw frame where two drafting units must be aligned with each other, is advantageous.
For horizontal adjustment of the pillow blocks, they are adjusted on the table by means of eccentric collar bolts. The advantage in this method consists in the fact that the vertical alignment of the pillow blocks has already been achieved and only a horizontal adjustment is therefore made by shifting the eccentric collar bolts. By thus separating the horizontal and the vertical adjustability of the pillow blocks, rapid and reliable adjustment of the pillow blocks and thereby of the drafting units is ensured.
It is especially advantageous if the pillow block is equipped with two collar bolt, one being eccentric and the other one round. In this case the pillow block can be swivelled around the round collar bolt by rotating the eccentric collar bolt, so that a good horizontal adjustment of the pillow block on the table is ensured.
Embodiments of the invention are described below through the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a frontal view of a single-head draw frame;
FIG. 2 shows a frontal view of a two-head draw frame;
FIG. 3 shows a top view of a two-head draw frame;
FIG. 4a is an enlarged cutaway view of the pillow block and table shown in FIG. 2, particularly illustrating the eccentric bolt; and
FIG. 4b is a top view of the embodiment shown in FIG. 4a.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not a limitation of the invention. The numbering of components throughout the drawings and description with the same components having the same number throughout.
FIG. 1 shows a frontal view of a single-head draw frame 1. The bearing structure of the draw frame 1 is a frame 2. The different operational components of the draw frame 1, such as e.g. control devices, motor, draw-off rollers and fiber sliver depositing devices are installed on this frame 2. In addition, a table 10 is attached on the frame 2, the table 10 supporting a pillow block 4 with drafting rollers 5. The pillow block 4, together with the drafting rollers 5, constitutes a drafting unit 3.
The table 10 is attached to the frame 2 by means of adjusting screws 11 and 12. The drafting unit 3 is adjusted on the table 10 by means of an eccentric collar bolt 15 and a round collar bolt 16. The drafting unit 3 can be furthermore attached to the table 10 by means of screws.
To adjust the height, pitch, and position of the drafting unit 3 in relation to the other components of said drafting unit 3, the following procedure is followed. The frame 2 is anchored to the floor of the shop in which the draw frame is to be set up. Precise height adjustment of the frame 2 is not required here. The precise adjustment is carried out by means of table 10. The table 10 is then used as an adjusting platform for the drafting unit 3. The table 10 is attached to the frame 2 by means of adjusting screws 11 and 12. The table 10 is first moved to the desired height H by means of the setting screw 11. Here it is possible to move the table 10 up or down as indicated by the double arrow H. Using the setting screw 11, the pitch of the table 10 is then adjusted according to double arrow N. The table is here rotatable around a pivot point in the area of the setting screw 11. The rotation can be effected either by means of an articulation which is not shown here, or by winding the table 10. Most often it suffices to carry out this pitch adjustment by winding the table 10.
When the height and the pitch of table 10 has been adjusted, the alignment of the drafting unit 3 in its horizontal position is adjusted. This is done by means of collar bolts 15 and 16. It has been shown to be advantageous for the collar bolt 16 to be round, and the collar bolt 15 to be eccentric. This makes it possible to swivel the drafting unit 3 or the pillow block 4 around the round collar bolt 16 by means of the eccentric collar bolt 15. Precise adjustment of the pillow block 4 is thus easily achieved.
This device according to the invention makes it possible to adjust the drafting equipment easily and rapidly. The position of the drafting unit 3 can be adjusted very precisely without having to undo the attachments again if the position of the drafting unit 3 has proven to be unsuitable after a first adjustment.
FIG. 2 shows a two-head draw frame 1' in frontal view. As in the case of the single-head draw frame 1, the draw frame 1' consists of a frame 2, a table 10, drafting units 3 and 3' with pillow blocks 4 and 4' and drafting rollers 5 and 5', as well as of other components not shown here The drafting units 3 and 3' are placed next to each other on the table 10. The drafting rollers 5, 5' are connected to each other via shafts 20, 20' and a coupling 21. Thus it is possible to drive both drafting units 3, 3' with one single motor.
To adjust the drafting units 3, 3' the following procedure is followed. The height of the table 10 and thereby of the drafting units 3, 3' is adjusted by means of the inner adjusting screws 12. By turning the adjusting screw 12 the height of table 10 is changed as indicated by the double arrow H. This is done until the drafting units 3, 3' are at the desired height.
When height H has been reached, the pitch of the drafting units 3, 3' is adjusted. Using the adjusting screws 11 and 13 which are advantageously located as far as possible from the height adjusting screw 12, the pitch of the drafting units 3 in relation to each other is adjusted. By adjusting the adjusting screw 11, the pitch is changed as indicated by double arrow N 1 of the drafting unit 3. The adjusting screw 13 produces a pitch as indicated by double arrow N 2 of the drafting unit 3'. The change in pitch in either case is effected around a pivot point near the height adjusting screw 12. For this, it is advantageous if the table 10 can be rotated or can at least be slightly twisted in the area of the adjusting screw 12. The adjustment by means of the adjusting screws 11 and 13 continues until the shafts 20 and 20' are precisely and vertically across from each other.
The horizontal coincidence of the shafts 20 and 20' is obtained by means of the collar bolts 15, 16 and 15', 16'. Referring to FIG. 1 and 4a and 4b, by rotating the eccentric collar bolts 15, 15' the adjustment of the pillow blocks 4, 4' in relation to each other can be effected in such manner that the shafts 20, 20' are flush with each other as they face each other. The rotation of the pillow blocks 4, 4' is produced by a rotation of the eccentric collar bolts 15 and 15' such that the pillow blocks 4, 4' rotate around the round collar bolts 16, and 16'. When the shafts 20 and 20' are flush and precisely across from each other, they can be connected to each other by means of a coupling 21.
The proper positioning of the drafting units 3 and 3' is important in particular with two-head draw frames. For uniform drafting of the fiber slivers it is necessary for the two drafting units 3 and 3' to be driven uniformly. This is only possible if the shafts 20 and 20' face each other in a flush manner and can be connected without offset or pitch of the shaft axes. The device according to the invention and the adjusting process according to the invention make it possible to adjust the two drafting units 3 and 3' precisely and easily. A uniform and good fiber sliver quality can thereby be achieved with a draw frame 1' by using the process and the device according to the invention.
To clarify the invention, FIG. 3 shows a top view of the two-head draw-frame 1'. It can be seen in FIG. 3 that the table 10 supports the two drafting units 3 and 3'. Several drafting rollers 5 and 5' are installed in each of the pillow blocks 4 and 4'. Each of these drafting rollers 5 and 5' is connected via shafts 20 and 20' and via a coupling 21 to its corresponding drafting roller.
To ensure the stability of the adjustment of table 10 it is advantageous if two of the adjusting screws 11, 12 and 13 are used in each instance. This minimizes the requirements for precise positioning when assembling the frame 2. The adjustment possibilities of table 10 are again increased thereby, as a pitch adjustment orthogonal to the pitches N 1 and N 2 is possible.
Referring particularly to FIGS. 3 through 4b, it can furthermore be seen from the drawing in FIG. 3 that a swivelling movement of the pillow blocks 4, 4' as indicated by the double arrow D, D' is achieved by means of the eccentric collar bolts 15, 15' and the round collar bolts 16, 16' which serve as pivot points. This makes it possible to adjust the drafting units 3, 3' in relation to each other and thereby also to achieve flush alignment of the shafts 20, 20' in relation to each other.
The invention is not limited to the embodiments shown. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the invention without departing from the scope or spirit of the invention. For example, features illustrated as part of one embodiment can be used on another embodiment to yield a still further embodiment. It is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents.
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The instant invention relates to a process for the adjustment of a drafting unit of a draw frame. The drafting unit is equipped with drafting rollers (5, 5') supported in a pillow block (4, 4'). The pillow block (4, 4') is installed on a table (10). The height of the table (10) is adjusted by a first set of adjusting devices and the pitch of the table (10) is adjusted by a second set of adjusting device in relation to the frame (2). The table (10) is installed between the pillow block (4, 4') and the frame (2) for the positional adjustment of the pillow block (4, 4').
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/565,232, filed on Nov. 30, 2011. The entire teachings of the above application are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates in general to the field of electronics. Without limitation, in some aspects it relates to frequency-division; in some others to the provision of quadrature signals.
BACKGROUND
[0003] In electronics, frequency dividers are used to convert a signal at a given frequency to a signal at an (usually even) integer sub-harmonic of that frequency. A specific example is that of divide-by-two circuitry. Each divider has an essentially random state variable that determines the phase of the outputs. Therefore, when two divide-by-two circuits are driven by the same input signal, the outputs of those circuits may be in-phase or anti-phase.
[0004] Referring to FIG. 1 , an example of a divide-by-two circuit ( 10 ) is shown. It consists in this example of two D-type flip-flops ( 12 , 14 ), both clocked at a common clock node ( 15 ). The second flip-flop ( 14 ) has an inverse clock input ( 16 ). The Qbar output of the second flip-flop 14 is connected to the D input of the first flip-flop 12 , and the Q output of the first flip-flop ( 12 ) is connected to the D input of the second flip-flop ( 14 ). I and Q outputs are derived from the Q output of the first flip-flop ( 12 ) and of the second flip-flop ( 14 ) respectively. The I and Q outputs provide outputs 90 degrees phase apart, at half the clock rate. Other circuits for divide-by-two operation are known in the art.
[0005] Similarly, logic and other circuits for divide-by-n operation are well-known in the art.
[0006] Divide-by-two circuitry is used in many applications. A notable one concerns radio transceivers to generate quadrature local oscillator (LO) signals for use in mixers.
[0007] In such an application, the phase of the local oscillator signal input to a mixer is transferred to the mixer output; therefore, a randomly occurring 180 degree phase relationship between local oscillator signals leads to a randomly occurring 180 degree phase difference in the transfer function of the transmit or receive chains being driven by those local oscillator signals. Some transceiver operations, such as beam-forming, require that the phase relationships between two transmit or receive paths stays constant over some period. If the dividers are reset or powered down during that period, it is possible for them to start up with the opposite phase relationship than they had previously. This randomly occurring 180 degree phase shift between the transmit or receive chains may be detrimental or even catastrophic to schemes that require knowledge of the phase relationship between those chains.
[0008] Additionally, there may be coupling of the divider outputs to the signal paths in the transceiver, leading to local oscillator radiation in the transmitter or DC offset in the receiver. If the phase relationship between the divider outputs is stable over time, calibration may be used to remove the effect of that coupling. However, if the phase relationship between the divider output changes from time to time, such calibration must be performed each time the dividers have an opportunity to change their phase relationship.
[0009] One solution would be to keep the dividers enabled over any period in which the phase relationship must stay constant. A shortcoming is that the circuits which generate and distribute the divider input signal, and the dividers themselves, may consume significant power. The inability to disable these blocks to save power during idle periods is a significant cost.
[0010] An alternative solution to this issue is to share a divider between the two mixers so as to guarantee a fixed phase relationship for all mixers each time the divider starts up. There are a number of potential issues with this solution. The first is that the quadrature local oscillator signal then needs to be routed from the shared divider to each of the mixers where it is used. This may necessitate long routes to one or more mixers. These long routes may require significant buffering to drive, which may consume a significant amount of power. The second issue is that long routing of quadrature signals may lead to quadrature mismatch. However, this issue is mitigated by any quadrature mismatch calibration that is performed. The third issue is that sharing a divider between several mixers is liable to increase coupling between the mixers, leading to unwanted signal coupling between transmit or receive paths. Separate dividers provide a level of isolation between paths.
SUMMARY
[0011] Some embodiments aim to address the problems set out above.
[0012] In one aspect there is provided an operating arrangement for a circuit, the circuit having plural circuit portions, the arrangement comprising a node for a frequency source coupled to plural frequency dividers, each frequency divider having an output connected to provide a respective divided frequency to a respective portion of the circuit, the arrangement comprising phase comparison circuitry connected to the outputs of the frequency dividers and correction circuitry responsive to an output of the phase comparison circuitry to act upon at least one frequency divider to cause the outputs of the frequency dividers to assume a desired phase relationship.
[0013] In an embodiment, each frequency divider is a divide-by-two circuit, there are two divide-by-two circuits and the correction circuitry is operable to cause the outputs of the divide-by-two circuits into phase parity.
[0014] In another embodiment, each frequency divider is a divide-by-two circuit, there are two divide-by-two circuits and the correction circuitry is operable to cause the outputs of the divide-by-two circuits into phase opposition.
[0015] In yet other embodiments, each frequency divider is a divide-by-two circuit, there are more than two divide-by-two circuits and the correction circuitry is operable to cause the outputs of the divide-by-two circuits into phase parity.
[0016] Arrangements where the desired phase relationship is other than all the same, for example one from N divide-by-two circuits different to the remaining (N−1) are envisaged.
[0017] In other embodiments, each frequency divider is a divide by M.
[0018] In some embodiments, each divide-by-two circuit provides first and second quadrature outputs and each circuit portion has first and second inputs for quadrature signals, the correction circuitry is operable to select between a first configuration in which the first and second outputs are connected to the first and second inputs and a second configuration in which the first and second outputs are connected to the second and first inputs respectively.
[0019] The phase comparison circuitry may be operable to compare one of the first and second quadrature outputs of each divide-by-two circuit.
[0020] The phase comparison circuitry may be operable to compare both of the first and second quadrature outputs of each divide-by-two circuit.
[0021] The phase comparison circuitry may be operable to compare the sums of the first and second quadrature outputs of each divide-by-two circuit.
[0022] In an embodiment there is a blocking circuit having an enable input for selectively permitting a signal at the output of the correction circuitry to act upon said at least one frequency divider.
[0023] In another aspect there is provided a radio transceiver comprising an operating arrangement for the transceiver, the transceiver having plural mixers, the arrangement comprising a node for a frequency source coupled to plural two divide-by-two circuits, each divide-by-two circuit operable to provide quadrature outputs to a respective mixer as quadrature local oscillator signals, the arrangement comprising phase comparison circuitry connected to the outputs of the divide-by-two circuits and correction circuitry responsive to an output of the phase comparison circuitry to act upon at least one divide-by-two circuit to cause the outputs of the divide-by-two circuits to assume a desired phase relationship.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 shows block diagram of an example of a divide-by-two circuit.
[0025] FIG. 2 shows a block diagram of a first example of a circuit for providing two quadrature local oscillator signals from an input frequency node, incorporating phase detection and correction.
[0026] FIG. 3 shows a schematic diagram of one example of an output inverter circuit for a divide-by-two.
[0027] FIG. 4 shows a block diagram of a first example of a circuit for providing two quadrature local oscillator signals from an input frequency node, incorporating phase detection and correction in which both quadrature signals are sensed.
[0028] FIG. 5 shows a block diagram of a first example of a circuit for providing two quadrature local oscillator signals from an input frequency node, incorporating phase detection and correction, in which the quadrature outputs are summed for use in comparison.
[0029] FIG. 6 shows a modified version of FIG. 5 having additional circuitry for controlling the application of a correction signal.
[0030] In the various figures, like reference signs refer to like parts.
DETAILED DESCRIPTION
[0031] Referring to FIG. 2 , a first example of a circuit ( 100 ) for providing two quadrature local oscillator signals has a frequency reference node ( 101 ) providing clock pulses to the clock nodes ( 108 , 109 ) of two divide-by-two circuits ( 110 , 120 ). Each of the divide-by-two circuits ( 110 , 120 ) provides a respective pair of quadrature outputs ( 111 , 112 ; 121 , 122 ). Of these, a respective one ( 111 , 121 ) is considered “in-phase” and the respective other ( 112 , 122 ) is considered to be the quadrature output, at 90 degrees phase to the “in-phase” output. These signals are used to supply quadrature signals in demodulation (to mixers, not shown).
[0032] A low frequency sample clock input ( 180 ) is connected to the clock nodes of two D-type flip-flops ( 115 , 116 ), whose D inputs are connected to receive the divided frequency inphase outputs ( 111 , 121 ) from the respective divide-by-two circuits ( 110 , 120 ).Typically “low frequency” means of the order of 1/80 to 1/240 the frequency applied to the frequency reference node ( 101 ). In a consumer electronics transceiver environment, the frequency of the frequency reference node may of the order of 800 MHz to 12 GHz.
[0033] The Q outputs of the two D-type flip-flops are connected as inputs to an XOR gate ( 130 ). As is known to those skilled in the art, XOR functionality means that the gate ( 130 ) provides a logical one output only when the two inputs are contrary, i.e. 1,0 or 0,1. Dummy loads ( 118 , 119 ) are connected to the quadrature outputs ( 112 , 122 ) of the divide-by-two circuits ( 10 , 120 ) to compensate for the loading of the D flip-flops ( 115 , 116 ), typically for their capacitance.
[0034] The output of the XOR gate ( 130 ) is passed to a low pass filter ( 135 ) whose output is fed to a thresholding circuit ( 140 ). The output ( 141 ) of the thresholding circuit ( 140 ), forming an “invert” signal is shown as being fed back to an invert input of one ( 120 ) of the divide-by-two circuits ( 110 , 120 ). It could of course go instead to the invert input of the other ( 110 ) divide-by-two circuit.
[0035] Initially the frequency reference node ( 101 ) is maintained at a quiescent level while the mixers are not required. When the node ( 101 ) is supplied with the double local oscillator signal, the divide-by-two circuits ( 110 , 120 ) may start in phase parity or phase opposition.
[0036] Assuming the phase parity state: the in-phase outputs ( 111 , 121 ) will be mutually in-phase.
[0037] While the inputs to the XOR gate are the same, the gate produces a logic zero; while the inputs differ the gate produces a logic one. The output of the gate goes to the low pass filter ( 135 ) which operates to prevent rapid or erroneous switching between states. The filter output is compared by the thresholding device ( 140 ) against a threshold. The value of the threshold is determined so that if the outputs of the two divide-by-two circuits ( 110 , 120 ) are in phase parity, the threshold is not reached regardless of the existence of any short periods where one sampled output is different to the other. Thus the output of the thresholding circuit ( 140 ) remains at logic zero.
[0038] Then, assuming the phase opposition state, the in-phase outputs ( 111 , 121 ) will be mutually out of phase. The XOR gate ( 130 ) provides a logic one which is passed by the low pass filter ( 135 ) whose output reaches the threshold of the thresholding circuit ( 140 ). The output of the thresholding circuit ( 140 ) switches to logic one, the rising edge of the transition resets the low pass filter and acts on one of the divide-by-two circuits ( 120 ) to invert its outputs so that its so-called “in phase output” assumes the opposite state to the previous state whereby both in-phase outputs of the two divide-by-two circuits come into phase parity.
[0039] Referring to FIG. 3 , a schematic diagram of circuitry ( 262 ) for inverting the output of the divide-by-two ( 120 ) consists of a first and a second two-input XOR gate ( 260 , 261 ). As is well-known, the XOR function dictates that the output of the gate will be at logic 1 if, and only if, one of the inputs is at logic 1.
[0040] The first gate ( 260 ) receives the I output of the divide-by-two ( 120 ) at one of its inputs, and the second gate ( 261 ) receives the Q output of the divide-by-two ( 120 ) at one of its inputs. The second input of each gate ( 260 , 261 ) receives the invert signal ( 141 ).
[0041] In operation, assume the invert signal is low (logic 0). Then, in one state, the I input to first gate ( 260 ) is logic 1, and the output (by virtue of the XOR function) will be logic 1. In the other state the I input will be logic 0 and the output is thus logic 0.
[0042] The second gate operates in the same way, and hence the circuitry ( 262 ) for inverting has no effect while the “invert” input is low.
[0043] Assume now that the invert signal is high. Then in the one state (I=1), the first gate ( 260 ) has a logic 0 output; in the other (I=0) it has a logic 1 output. The second gate operates in the same way. Hence the circuitry ( 262 ) for inverting causes the outputs to be the inverse of the inputs while the “invert” input is high.
[0044] Many other circuits for output inversion may be provided, as is clear to one of skill.
[0045] The filter ( 135 ) and threshold ( 140 ) operation may be achieved using an accumulator with overflow detection (with the overflow indicator forming the output signal). A “leaky” accumulator may also be used to ignore infrequently occurring errors.
[0046] It is possible that the clock to the high-speed samplers could be inadvertently skewed. However, this does not lead to an error, since the skew would be stable with time. That is, difference between the sampling instants between the two samplers would be the same between subsequent enable periods of the dividers, and would therefore not cause a change in the phase relationship between the divider outputs over time. Note that this might cause the divider outputs to be anti-phase rather than in-phase, but this phase relationship would be stable with time and therefore is unimportant. Clock jitter in the sampling clock, as long as it is shared between both samplers, also does not lead to an error. Clock jitter that effects only one sampler leads to erroneous instantaneous comparisons, but these are filtered using the low pass filter ( 135 ) and therefore do not lead to an error in the final phase relationship between the LO signals.
[0047] Referring to FIG. 4 , an example is shown in which both outputs of the divide-by-twos are compared with one another. This circuit is similar to that of FIG. 2 , but with a duplicate set of D-type flip-flops ( 215 , 216 ), a second XOR gate ( 230 ) and a further gate ( 250 ) combining the outputs of the two XOR gates ( 130 , 230 ) in either AND or OR fashion.
[0048] It is assumed that the output of the comparison may occasionally be in error, due to noise or power supply noise or other factors. The purpose of the second set of flip-flops ( 215 , 216 ) with the gates ( 230 , 250 ), acting as samplers and comparator is to make use of the additional information that is available to help average-out the effects of any such errors. An additional benefit is that the loads on each of I and Q are better balanced, since identical circuits are attached to each. With gate 250 as an AND gate it can be ensured that both samplers agree before making a decision to change phase.
[0049] Referring now to FIG. 5 , a further modification allowing both outputs of both divide-by-twos ( 110 , 120 ) is shown. In this case the I and Q outputs ( 111 , 112 ; 121 , 122 ) of each divide-by-two ( 110 , 120 ) are summed in respective adders ( 171 , 172 ). It is the output of the adders ( 171 , 172 ) that provides the inputs to the d-type flip-flops ( 115 , 116 ).
[0050] In this case, the loading on I and Q are identical, since they are each loaded by identical ports of the shared adder. None of the information used for comparison is lost by the addition, and depending on the implementation of the dividers and of the adder, the adder can be used to condition the signal for more robust comparison.
[0051] Referring to FIG. 6 , an example of a control or inhibit circuit ( 300 ) is shown incorporated into the example of FIG. 2 . It will be understood that this circuit could be incorporated into any of the described examples, and that different arrangements having similar functionality will be apparent to the person of skill.
[0052] The circuit ( 300 ) allows an inhibit signal ( 307 ) to freeze the state of the “INVERT” signal ( 141 ) so that no change in phase relationship is possible while the inhibit signal is enabled. In the case of a transceiver it may be enabled during transmission or reception. This is an improvement if a change in phase relationship between LO signals is detrimental but not catastrophic, but a step change in LO phase during transmission or reception is catastrophic. Such an inhibit signal prevents the LO phases from changing to achieve the desired phase relationship, at the cost of a catastrophic step change in LO phase during transmission or reception.
[0053] The circuit ( 300 ) has a further D-type flip flop ( 304 ) with its D input receiving the invert signal ( 141 ). Its Q output connects to the invert input of the second flip-flip ( 120 ). Its clock input is controlled by the output of a two input gate ( 303 ). The first input ( 306 ) of the gate ( 303 ) receives the low frequency sample clock signal ( 180 ); the second input ( 307 ) receives the inverse of the inhibit signal (gate shown as having an inverting input).
[0054] In use when the inhibit signal ( 307 ) logic 0, the gate ( 303 ) passes the clock to the further D-type flip flop ( 304 ), which clocks the value of the INVERT signal ( 141 ) from D input to Q output.
[0055] When the inhibit signal ( 307 ) is taken to logic 1, the further D-type flip flop ( 304 ) is no longer clocked so it holds the last value of INVERT that was clocked to output Q. In this way it freezes the phase relationship of the first and second flip-flops ( 110 , 120 ) and hence the phase relationship of their output signals
[0056] Although the described examples refer to a situation in which phase parity is desirable, it is also applicable to situations where phase opposition is desired. It is also applicable to situations where more than two dividers are provided and where the dividers are divide by n (n>2).
[0057] The examples allow the dividers, and possibly the blocks which generate the input signal to the dividers, to be powered down without a change in the phase relationship of the outputs of the dividers when those blocks are re-enabled. It achieves this without requiring a shared divider, thereby avoiding the disadvantages of a shared divider as described above. Additionally, the cost of the apparatus is presumed to be low. It requires a means of inverting the output of one divider, as well as a high-speed sampler for each LO. The additional blocks are all low-speed and low-cost.
[0058] Description has been made with reference to several examples. The scope is not restricted to described features but extends instead to the full scope of the appended claims and their equivalents.
[0059] While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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An arrangement is described in which phase parity or phase opposition between two signals can be determined, and if necessary remedial action may be taken.
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FIELD OF INVENTION
This invention relates to a method of obtaining a position fix in a GPS receiver and a GPS receiver for the same.
BACKGROUND TO INVENTION
The classic GPS position fix algorithm involves solving the following four equations:
{square root over (( x−s x 1 ) 2 +( y−s y 1 ) 2 +( z−s z 1 ) 2 )}=ρ 1 −ct
{square root over (( x−s x 2 ) 2 +( y−s y 2 ) 2 +( z−s z 2 ) 2 )}=ρ 2 −ct
{square root over (( x−s x 3 ) 2 +( y−s y 3 ) 2 +( z−s z 3 ) 2 )}=ρ 3 −ct
{square root over (( x−s x 4 ) 2 +( y−s y 4 ) 2 +( z−s z 4 ) 2 )}=ρ 4 −ct
where ρ i is the measured pseudorange from a GPS receiver to the i th satellite having a known position vector s i =(s x i , s y i , s z i ), x, y and z are the co-ordinates of the GPS receiver, t is the clock offset of the GPS receiver compared to the GPS time base and c is the speed of light. In the event that pseudoranges can be measured from more than 4 satellites, an overdetermined set of equations may be derived and solved, for example, by using a best fit type, iterative technique. Unfortunately, however, the amount of computation involved in employing such an technique to solve for 4 unknowns, i.e. x, y, z and clock offset, is significant. For example, consider the following conventional method:
Step 1. Calculate the following direction cosines matrix H: H = ( x - s x 1 r 1 y - s y 1 r 1 z - s z 1 r 1 1 x - s x 2 r 2 y - s y 2 r 2 z - s z 2 r 2 1 ⋮ ⋮ ⋮ ⋮ x - s x n r n y - s y n r n z - s z n r n 1 )
where n is the number of satellites (4 or more) and R i is the distance from an estimate of the position of the GPS receiver to the i th satellite, calculated in the following manner:
r i ={square root over (( x−s x i ) 2 +( y−s y i ) 2 +( z−s z i ) 2 )}
Step 2. Calculate the following pseudorange error vector Q: Q = ( ρ 1 - ( r 1 + ct ) ρ 2 - ( r 2 + ct ) ⋮ ρ n - ( r n + ct ) )
Step 3. Calculate a correction vector P whereby P=(H T H) −1 H T Q (or in a simplified form if n=4, P=H −1 Q).
Step 4. Correct the estimate S of the position of the GPS receiver and clock offset whereby S′=S+P, where: S = ( x y z ct )
and S′ is the corrected version. These steps are repeated until the solution has converged to a required degree of accuracy, normally determined when |P| is less than some threshold.
By far the largest contribution to the total computation requirement in steps 1 to 4 above is the 4×4 matrix inversion (H T H) −1 done in step 3.
OBJECT OF INVENTION
It is an object of the present invention to provide a method of obtaining a position fix in a GPS receiver with a reduced computational requirement, and a GPS receiver configured for the same.
SUMMARY OF INVENTION
According to the present invention, such a method and GPS receiver are provided, the method comprising the steps of (i) providing an estimate of clock offset between the GPS receiver and the GPS satellites; (ii) measuring a set of pseudoranges from the GPS receiver to GPS satellites; and (iii) either (a) resolving the set of pseudoranges obtained in step (ii) to obtain a position fix, or (b) providing an estimate of the position of the GPS receiver, resolving the set of pseudoranges obtained in step (ii) to obtain a position fix correction, and obtaining a position fix using the estimate of the position of the GPS receiver and the position fix correction, wherein resolving the pseudoranges in either step (iii)(a) or step (iii)(b) does not involve resolving the pseudoranges for either a new clock offset or clock offset correction.
There is an underlying assumption in the conventional method of obtaining a position fix described of it addressing essentially a four dimensional problem, i.e. solving for x, y, z and clock offset, and also that each unknown is of equal importance. However, the inventor has realized that, at least for some applications, this assumption is not true. Rather, the clock offset is generally stable and can be predicted from previous values. Therefore, it is not necessary to solve for four unknowns each and every time and hence the conventional four dimensional problem, i.e. solving for x, y, z and clock offset, is reduced to a three dimensional problem, i.e. solving for x, y, z, so simplifying the required computation.
In addition, the resultant position fix obtained using a method of the present invention is more stable as the clock offset as source of potential error is removed. Also, a current position fix can be obtained using only three current pseudoranges measurements whereas conventional methods generally rely on the use of old pseudoranges or pseudoranges derived from old position fixes to supplement missing satellite signals.
BRIEF DESCRIPTION OF DRAWING
A method of obtaining a position fix using a GPS receiver in accordance with the present invention will now be described, by way of example only, with reference to the accompanying figures in which:
FIG. 1 shows a GPS receiver according to the present invention, located on a vehicle;
FIG. 2 is a graph showing a plot of the x, y and z co-ordinates and the clock offset of a GPS receiver in a vehicle during a 900 second test drive, wherein the position fix was determined using a conventional method; and
FIG. 3 is a graph showing a plot of the x, y and z co-ordinates and the clock offset of a GPS receiver in a vehicle during the same 900 second test drive, wherein the position fix was determined using a method according to the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a GPS receiver according to the present invention and located on a vehicle for the purpose of providing a position fix. The GPS receiver comprises a GPS antenna, GPS receiver front-end (not shown) and GPS processing unit (not shown) and utilizes conventional methods for GPS signal acquisition and tracking. By way of example, such methods of signal acquisition and tracking are described in GPS Principles and Applications (Editor, Kaplan) ISBN 0-89006-793-7 Artech House. Also, the design and manufacture of such GPS receivers is entirely conventional and, accordingly, those parts which do not directly relate to the present invention will not be elaborated upon here further.
When operative, GPS signals are acquired and tracked for the purpose of deriving pseudorange information from which a position fix is obtained using the following method in accordance with the present invention:
Step 1. Estimates of the position of the GPS receiver (x, y, z) and the user clock offset t are made based on that determined during earlier, conventional computation in which 4 unknowns, i.e. x, y, z and clock error, were resolved. Ideally, the estimate of the position is best provided from the last position fix, however, it is desirable to estimate the clock offset based on many more previous measurements. For example, one might establish the mean clock drift rate t, i.e. the rate at which the local clock is diverging from GPS time, from the previous 50 measurements. Then, an estimate of the clock offset may be provided as a function of the previous clock offset, the clock draft rate and the elapsed time since the last position fix.
Step 2. From new pseudorange measurements, the real range R i from the GPS receiver to respective GPS satellites is determined:
R i =ρ i −ct
Step 3. The following direction cosines matrix H is calculated: H = ( x - s x 1 r 1 y - s y 1 r 1 z - s z 1 r 1 x - s x 2 r 2 y - s y 2 r 2 z - s z 2 r 2 ⋮ ⋮ ⋮ x - s x n r n y - s y n r n z - s z n r n )
where n is the number of satellites (3 or more) and r i is the distance from an estimate of the position of the GPS receiver to the i th satellite, calculated in the following manner:
r i ={square root over (( x−s x i ) 2 +( y−s y i ) 2 +( z−s z i ) 2 )}
Step 4. The following pseudorange error vector Q is calculated: Q = ( R 1 - r 1 R 2 - r 2 ⋮ R n - r n )
Step 5. The following a correction vector, P is calculated whereby. P=(H T H) −1 H T Q (or if n=3, P=H −1 Q). With more than 3 satellites in view, preferably for obtaining an accurate position fix, the above method uses a 3×3 matrix inversion rather than a more computationally expensive, 4×4 matrix inversion, as used by convention methods of the type described above.
Step 6. An estimate of the position of the GPS receiver is corrected: X′=X+P
where: X = ( x y z )
and X′ is the corrected version. These steps are repeated until the solution has converged to a required degree of accuracy.
Step 7. Once the position fix has been calculated, the estimate of the clock error is updated. This can be done, for example, by determining the mean residual timing error δt j from the differences of the actual distance from the position fix X (x, y, z) to each satellite (s x i , s y i , s z i ) and the measured range R i to them, thus: δ t j = 1 n ∑ i = 1 n 1 c ( x - s x i ) 2 + ( y - s y i ) 2 + ( z - s z i ) 2 - R i
The updated estimate of clock error can then be determined from the previous t′ j (i.e. old t) and the means residual timing error δt j :
t=t′−δt
j
Steps (2) to (7) are repeated every half second in order to track the movement of the GPS receiver and thereby the vehicle
In order to illustrate the benefits of the present invention, pseudorange test data was obtained from a GPS receiver located in a vehicle during a 900 second (15 minute) vehicle test drive during which pseudoranges were measured to each available satellite, approximately every half second. Based on the pseudorange test data and obtained using both a conventional method of obtaining a position fix and the aforementioned method according to the present invention respectively, FIGS. 2 and 3 show plots 20 to 23 describing the x, y and z co-ordinates, and the clock offset (multiplied by the speed of light c for the purpose of expressing as a distance measurement) during the test drive. The test involved the vehicle being stationary for roughly 180 seconds (hence the substantial flat section in all plots between 0 and 180 seconds) followed by travel along largely open roads.
As the pseudorange measurements were taken approximately every half second, each corresponding position fix can be considered to be one of a sequence which will bear a strong relationship to the previous one. The dynamics of a typical vehicle mean that the x, y and z co-ordinates will change, however, the change in the clock offset is completely independent of the vehicle dynamics. Rather, it is generally a function of the accuracy of a local, crystal oscillator of the GPS receiver and although the crystal oscillator error can be large, in most practical circumstances, it only varies with temperature. Therefore, over the period of a few minutes, one can expect the clock offset to be highly stable and this is indeed reflected in the plots 23 of both FIGS. 2 and 3.
Referring to FIG. 2 which shows the plots obtained using a conventional method of obtaining a position fix, a first glitch 24 occurs at about 320 seconds as the vehicle travels around a roundabout, under a flyover, and a second glitch 25 at about 550 occurs as the vehicle enters a section of tree-lined roads with progressively worse visibility of the sky and only returned to open skies at around 780 seconds. By utilizing the inherent stability of the clock offset, the method of the present invention mitigates glitches in the plot as illustrated in FIG. 3 . As such, the above analysis shows that not only is the method of the present invention more computationally efficient, it is more robust to the effects of reduced strength signals caused by obscuration of the GPS satellites.
To assess the effectiveness of this clock offset prediction in association, pseudoranges measured from the previously mentioned 15 minute test run were processed. In this case the extreme values of δt j were −8 ns and 11 ns which represents range errors of −2.4 m and 3.3 m respectively with a mean of −1.4 ns representing −0.42 m. It is therefore clear that the clock offset was predicted reasonable accurately.
Note that for the purpose of evaluating the present invention with the pseudorange test data, an initial estimate of the clock error drift rate was provided based on from the velocity fix calculation over the first 100 seconds. Subsequently, this was used in the position calculations for the first 100 seconds worth of pseudoranges which of course could not be accomplished in real-time. As stated above, in real-time, the estimate of the clock drift error would conveniently be based on measurements obtained using conventional methods before the reduced computation method of the present invention was employed.
From reading the present disclosure, other modifications will be apparent to persons skilled in the art. Such modifications may involve other features which are already known in the design and use of GPS receivers and component parts thereof and which may be used instead of or in addition to features already described herein. Although claims have been formulated in this application to particular combinations of features, it should be understood that the scope of the disclosure of the present application also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalization of one or more of those features which would be obvious to persons skilled in the art, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the present invention. The applicants hereby give notice that new claims may be formulated to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.
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A method of obtaining a position fix in a GPS receiver is disclosed together with a GPS receiver for the same. The method comprising the steps of (i) providing an estimate of clock offset between the GPS receiver and the GPS satellites; (ii) measuring a set of pseudoranges from the GPS receiver to GPS satellites; and (iii) either (a) resolving the set of pseudoranges obtained in step (ii) to obtain a position fix, or (b) providing an estimate of the position of the GPS receiver, resolving the set of pseudoranges obtained in step (ii) to obtain a position fix correction, and obtaining a position fix using the estimate of the position of the GPS receiver and the position fix correction, wherein resolving the pseudoranges in step (iii)(a) or step (iii)(b) does not involve resolving the pseudoranges for either a new clock offset or clock offset correction.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The invention relates to compositions, methods, and apparatuses for improving paper surface strength. Paper is sheet material containing interconnected small, discrete fibers. The fibers are usually formed into a sheet on a fine screen from a dilute water suspension or slurry. Paper typically is made from cellulose fibers, although occasionally synthetic fibers are used.
[0004] As described in U.S. Pat. No. 5,585,456, paper products made from untreated cellulose fibers lose their strength rapidly when they become wet, i.e., they have very little wet strength. The wet strength of paper is defined as the resistance of the paper to rupture or disintegration when it is wetted with water. Wet strength of ordinary paper is only about 5% of its dry strength. To overcome this disadvantage, various methods of treating paper products have been employed.
[0005] One method of increasing the strength of paper is by the addition of a starch coating to the surface of paper. As described in U.S. Pat. No. 4,966,652, although originally applied to size (make resistant to water penetration) paper, starch coatings also increase the stiffness of paper. The increase in stiffness is so pronounced that it makes paper suitable for use in such applications as container board, packaging papers, and sheet fed printer papers. The starch is commonly added onto the paper sheet by an Can-machine process (such as a size press device) or an off-machine process.
[0006] As described for example in U.S. patent application Ser. No. 12/323,976, the high cost of paper fiber makes the strength enhancing process even more crucial. Increasingly paper manufacturers are adding significant amounts of less expensive filler materials to defray costs and to enhance other properties required in the paper such as whiteness and brightness. However, papermakers are limited in the amount of fillers in the final product due in great part to a net loss in strength. Tensile strength, z-directional tensile strength and the tendency of the paper to shed filler particles (dusting) during typical handling processes, e.g., printing, are some of the main properties affected. U.S. Pat. No. 7,488,403 describes a method of enhancing the strengthening effect by adding a glyoxylated polyacrylamide polymer to the paper sheet. However there remains a continuing need in the art for methods of imparting appropriate levels of wet strength to paper products.
[0007] The art described in this section 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, unless specifically designated as such. 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 CFR §1.56(a) exists.
BRIEF SUMMARY OF THE INVENTION
[0008] At least one embodiment of the invention is directed towards a method of coating a paper substrate. The method comprises the steps forming a composition by contacting starch and a synthetic polymer during a starch cooking process in a fluid under temperature and conditions sufficient to gelatinize the starch, and applying the composition to a paper substrate, the synthetic polymer not being a starch. The contact may occur after and/or before the starch cooking process has begun. The synthetic polymer may be a copolymer formed from monomer units of both acrylic acid and acrylamide. The starch may be a solid before it is cooked. The composition may have a viscosity greater than a composition in which the polymer only enters the composition after the starch has been cooked. The paper substrate may comprises filler particles and may have a greater surface strength than a paper product similarly made but in which a smaller amount of filler was present and the polymer was added to the composition after cooking. The composition may be applied to a paper substrate by one device selected from the list consisting of a size press device, print roll coater device, air-knife coater device, metering bar coater device, blade coater device, under vacuum coater device, cast coating device, and any combination thereof. A paper product made from the paper substrate may have a greater strength than a paper product made from the same materials but with a smaller amount of starch and in which the polymer was added to the composition after cooking.
[0009] Additional features and advantages are described herein, and will be apparent from, the following Detailed Description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
[0011] FIG. 1 is a graph illustrating how the invention improves the strength of a paper sheet.
[0012] FIG. 2 is a graph illustrating how the invention increases the viscosity of a starch solution.
[0013] For the purposes of this disclosure, like reference numerals in the figures shall refer to like features unless otherwise indicated. The drawings are only an exemplification of the principles of the invention and are not intended to limit the invention to the particular embodiments illustrated.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The following definitions are provided to determine how terms used in this application, and in particular how the claims, are to be construed. The organization of the definitions is for convenience only and is not intended to limit any of the definitions to any particular category.
[0015] “Consisting Essentially of” means that the methods and compositions may include additional steps, components, ingredients or the like, but only if the additional steps, components and/or ingredients do not materially alter the basic and novel characteristics of the claimed methods and compositions.
[0016] “Cooking” means applying thermal energy to a fluid giving it sufficient energy to accelerate the process of gelatinizing starch.
[0017] “Free,” “No,” “Substantially no” or “Substantially free” means a composition, mixture, or ingredient that does not contain a particular compound or to which a particular compound or a particular compound-containing compound has not been added.
[0018] “GCC” means ground calcium carbonate filler particles, which are manufactured by grinding naturally occurring calcium carbonate rock
[0019] “Papermaking Process” means a method of making paper products from a pulp comprising forming an aqueous fibrous papermaking furnish from processed pulp typically comprising cellulose fibers, draining the furnish to form a wet sheet and drying the sheet to form a dry sheet. The steps of forming the papermaking furnish, draining, and drying may be carried out in any conventional manner generally known to those skilled in the art.
[0020] “Paper Substrate” means furnish, wet sheet, and/or dry sheet from a papermaking process.
[0021] “PCC” means precipitated calcium carbonate filler particles, which are synthetically produced.
[0022] “Pre-cooked Starch” means starch which is in such an insoluble form that when within water in the absence of cooking heat or other chemical agents, it is largely insoluble and can only be dispersed into a suspension.
[0023] “Polysaccharide” means a polymeric carbohydrate having a plurality of repeating units comprised of simple sugars, the C—O—C linkage formed between two such joined simple sugar units in a polysaccharide chain is called a glycosidic linkage, and continued condensation of monosaccharide units will result in polysaccharides, common polysaccharides are amylose and cellulose, both made up of glucose monomers, polysaccharides can have a straight chain or branched polymer backbone including one or more sugar monomers, common sugar monomers in polysaccharides include glucose, galactose, arabinose, mannose, fructose, rahmnose, and xylose.
[0024] “STP” means standard temperature and pressure.
[0025] “Surfactant” is a broad term which includes anionic, nonionic, cationic, and zwitterionic surfactants. Enabling descriptions of surfactants are stated in Kirk - Othmer, Encyclopedia of Chemical Technology, Third Edition, volume 8, pages 900-912, and in McCutcheon's Emulsifiers and Detergents, both of which are incorporated herein by reference,
[0026] “Surface Strength” means resistance to loss of material due to abrasive forces applied along the surface of a substrate, one means of measuring surface strength is described in the test protocol in TAPPI 476.
[0027] “Suspension” means a thermodynamically unstable generally homogenous fluid containing an internal phase material dispersed throughout an external phase material, because the internal phase material does not dissolve in the external phase material, over time in the absence of some input of energy (such as mechanical agitation, excipients, or chemical suspending agents) the internal phase material will settle out, the external phase material may be a solid and often has a volume larger than 1 micrometer 3 .
[0028] In the event that the above definitions or a description stated elsewhere in this application is inconsistent with a meaning (explicit or implicit) which is commonly used, in a dictionary, or stated in a source incorporated by reference into this application, the application and the claim terms in particular are understood to be construed according to the definition or description in this application, and not according to the common definition, dictionary definition, or the definition that was incorporated by reference. In light of the above, in the event that a term can only be understood if it is construed by a dictionary, if the term is defined by the Kirk-Othmer Encyclopedia of Chemical Technology, 5th Edition, (2005), (Published by Wiley, John & Sons, Inc.) this definition shall control how the term is to be defined in the claims.
[0029] At least one embodiment of the invention is directed towards a method of increasing the surface strengthening effect that a starch containing coating can impart to a sheet of paper. The method includes the steps of preparing a strengthening composition by cooking starch in the presence of a synthetic polymer in a fluid (such as water), allowing the synthetic polymer and starch to complex with each other in the presence of heat sufficient to increase the gelatinization of the starch in the fluid, and applying the composition to a sheet of paper.
[0030] In at least one embodiment the synthetic polymer contacts the starch before the starch has begun to be cooked. In at least one embodiment the synthetic polymer contacts the starch after the starch has begun to undergo a cooking process.
[0031] In at least one embodiment the pre-cooked starch and the synthetic polymer are kept in a non-cooking state for between 1 minute and 57 years prior to cooking.
[0032] In at least one embodiment the temperature of the non-cooking state is no greater than 30° C.
[0033] In at least one embodiment the temperature of the cooking process is between STP and 200° C.
[0034] In at least one embodiment the fluid the starch is cooked in is at least in part a liquid. In at least one embodiment the fluid the starch is cooked in is at least in part a gas. In at least one embodiment the fluid the starch is cooked in is at least in part water. In at least one embodiment the fluid the starch is cooked in is at least in part steam.
[0035] As described in the textbook Handbook for Pulp & Paper Technologists (7th Printing), by G. A. Smook, TAPPI (1982), (hereinafter “Smook”) (generally and in particular in chapter 18), starch is stored and transported in a pre-cooked format. When pre-cooked, the starch is typically a white granular powder. This powder is largely insoluble in cold water because of its polymeric structure and because of hydrogen bonding between adjacent polymer chains. In order for it to be effective as a paper coating however, water needs to penetrate into the structure and thereby gelatinize the starch into a form suitable for coating. In the absence of an energy input (such as vigorous stirring over a long period of time or added heat) the hydrogen bonding resists and impairs water penetration and gelatinization occurs either extremely slowly or not at all. When an aqueous suspension of pre-cooked starch is heated or cooked, the water is able to penetrate into the structures and swell up and gelatinize the starch. Heating and cooling of the now cooked starch can be performed to obtain a desired viscosity appropriate for applying the starch with a coating device. Typically a starch composition is applied by a coating device when it has a low viscosity achieved by the composition being between 6-15% starch and 85-94% water.
[0036] In at least one embodiment the cooking process excludes applying a temperature or pressure so extreme as to chemically degrade either of the starch and/or the synthetic polymer.
[0037] As elegantly illustrated in Smook's FIGS. 18-5 and 18-6 (page 266), according to the prior art, starch is first cooked and only afterwards is combined with other chemical additives such as strengthening agents to form a composition applied by a coating process. It has however been discovered that by allowing starch to remain in contact with a synthetic polymer during the cooking process, the properties of the resulting cooked starch change. Among those changed properties are greater strengthening effect and a greater viscosity than if the starch and the polymer had come into contact with each other after the cooking process. In addition, because of the intense temperature and pressure effects of the cooking process and because of the specific conditions required to form synthetic polymers, it was not anticipated that synthetic polymers could survive the intense cooking process in a form which preserved their beneficial properties.
[0038] Without being limited by a particular theory or design of the invention or of the scope afforded in construing the claims, it is believed that when the starch and the synthetic polymer contact each other while being cooked together, they form a complex that does not otherwise form and that enhances the properties of the starch. This complex is believed to rely upon interactions too weak to form covalent bonds, but which holds the synthetic polymer and starch together by hydrogen bonds. In addition the altered geometry may change the configuration with which water can gelatinize the starch affecting its viscosity. As a result a starch cooked while in contact with a synthetic polymer is chemically different from cooked starch which has had a synthetic polymer added to it after the starch has been cooked. Objective evidence of these differences can be seen by the differences in viscosity shown in FIG. 2 . These differences are believed to distribute the synthetic polymer relative to the paper sheet in a more beneficial manner.
[0039] In at least one embodiment the starch comprises: natural starch, modified starch, amylose, amylopectin, styrene-starch, butadiene starch, starches containing various amounts of amylose and amylopectin, such as 25% amylose and 75% amylopectin (corn starch) and 20% amylose and 80% amylopectin (potato starch); enzymatically treated starches; hydrolyzed starches; heated starches, also known in the art as “pasted starches”; cationic starches, such as those resulting from the reaction of a starch with a tertiary amine to form a quaternary ammonium salt; anionic starches; ampholytic starches (containing both cationic and anionic functionalities); cellulose and cellulose derived compounds; and any combination thereof and/or a combination thereof which explicitly excludes one or more of these. Some representative examples of starch can be found in U.S. Pat. Nos. 5,800,870, and 5,003,022.
[0040] In at least one embodiment the composition of the starch is such that but for the contact between the starch and the synthetic polymer during the cooking process, the composition would not have proper viscosity and/or proper strengthening properties.
[0041] In at least one embodiment the synthetic polymer is a copolymer, terpolymer, etc. . . . the polymer includes monomeric units of acrylic acid and acrylamide. Additional monomeric units that may be present in the synthetic polymer include one or more of cationic character conferring monomers and other vinyl monomers.
[0042] In at least one embodiment the synthetic polymer and/or the starch is linear, branched, cyclic, and/or hyperbranched.
[0043] In at least one embodiment the synthetic polymer excludes starch.
[0044] Representative cationic character conferring monomers include: diallyl quaternary monomer (generally diallyl dimethyl ammonium chloride, DADMAC), 2-vinylpyridine, 4-vinylpryridine, 2-methyl-5-vinyl pyridine, 2-vinyl-N-methylpyridinium chloride, p-vinylphenyl-trimethyl ammonium chloride, 2-(dimethylamino)ethyl methacrylate, trimethyl(p-vinylbenzyl)ammonium chloride, p-dimethylaminoethylstyrene, dimethylaminopropyl acrylamide, 2-methylacroyloxyethyltrimethyl ammonium methylsulfate, 3-acrylamido-3-methylbutyl trimethyl ammonium chloride, 2-(dimethylamino)ethyl acrylate, and mixtures thereof. In addition to chloride, the counterion for the cationic monomers also can be fluoride, bromide, iodide, sulfate, methylsulfate, phosphate, and the like, and any combination thereof.
[0045] Other vinyl monomers that can be present during preparation of the synthetic polymer include: acrylic esters such as ethyl acrylate, methylmethacrylate and the like, acrylonitrile, vinyl acetate, N-vinyl pyrrolidone, N,N′-dimethyl acrylamide, hydroxy alkyl(meth)acrylates, styrene and the like, allylglycidal ether, glycidyl methacrylate, co-monomers with a 1,2-diol in their structure, such as 3-allyloxy-1,2-propandiol, 3-acryloyloxy-1,2-propandiol and methacryloyloxy-1,2-propandiol, and the like, and any combination thereof.
[0046] In at least one embodiment glyoxal is also present when the starch and the synthetic polymer are cooked together. In at least one embodiment a glyoxyated polyacrylamide polymer is present when the pre-cooked starch and the synthetic polymer are contacted. In at least one embodiment the synthetic polymer or the material that is contacted with the cooking starch is one or more of those compositions described in one or more of U.S. Pat. Nos. 4,966,652, 5,320,711, 5,849,154, 6,013,359, 7,119,148, 7,488,403, 7,589,153, 7,863,395, 7,897,103, 8,025,924, 8,101,046, 8,163,134, and 8,273,215.
[0047] In at least one embodiment the strengthening composition is applied to a paper substrate by one or more of: a size press device, print roll coater device, air-knife coater device, metering bar coater device, blade coater device, under vacuum coater device, cast coating device, and any combination thereof. A representative size press device is described in U.S. Pat. No. 4,325,784. In at least one embodiment the application is performed by an on-machine operation or an off-machine operation. Other examples of coating devices, compositions added to the strengthening composition (after starch cooking), and synthetic polymers (which are present during and/or after starch cooking) are described in US Patent Application 2005/0155731.
[0048] In at least one embodiment the composition is applied to a filler-bearing paper substrate. The filler particles may be PCC, GCC, and any combination thereof.
[0049] In at least one embodiment the resulting paper has superior strength alongside more filler and/or superior optical properties despite having filler or optical property enhancing material in an amount that but for the cooking contact would have produced lessor strength. Optical properties include but are not limited to whiteness, brightness, and opacity all of which are defined as described in the reference Measurement and Control of the Optical Properties of Paper, 2 nd ed., Technidyne Corporation, New Albany, Ind., (1996).
EXAMPLES
[0050] The foregoing may be better understood by reference to the following examples, which are presented for purposes of illustration and are not intended to limit the scope of the invention.
[0051] Several laboratory experiments have been conducted to measure the ability of an AA/AcAm copolymer to increase the surface strength of paper. Except in study 3, base paper containing 16% ash and that has not been passed through a size press was coated using the drawdown method with solutions containing the desired chemistry. The paper was weighted before and after coating to determine specific chemical dose. The paper was dried by passing it once through a drum dryer at about 95° C. and allowed to equilibrate at 23° C. and 50% relative humidity for at least 12 hours.
[0052] Surface strength was measured using TAPPI (Technical Association of Pulp and Paper Industries) method T476 om-01. In this measurement, the surface strength is inversely proportional to the amount of mass lost from the surface of the paper after having been systematically “rubbed” on a turn table by two abrasion wheels. The results are reported in mg of lost material per 1000 revolutions (mg/1000 revs): the lower the number the stronger the surface.
[0000] Below is a summary of the studies conducted in the laboratory.
Study 1. Screening.
[0053] This first study was designed to determine which polymer performed the best among a set of samples varying in acrylic acid mole ratio and/or average molecular weight. Table 1 shows the conditions and the results.
[0000]
TABLE 1
Acrylic
Abrasion
acid/
loss,
Polymer,
acrylamide
Average
mg/1000
Condition
Starch, lb/t
lb/t
ratio
MW
revs
1
14.8
0.00
—
—
1104.4
2
27.0
0.00
—
—
779.4
3
21.2
0.92
7.5/92.5
Low
856.7
4
20.5
0.89
7.5/92.5
High
804.4
5
19.6
0.85
15/85
—
765.6
6
19.1
0.83
30/70
—
798.3
[0054] The first two conditions span a range of starch dose within which the conditions containing the polymers will be dosed. The abrasion loss results demonstrate that the strongest surface is obtained with the copolymer containing 15% acrylic acid. The results of the two polymers containing 7.5% acrylic acid suggest that the higher average molecular weight polymer performs better.
Study 2. Monomer Ratio.
[0055] This study was designed to determine which polymer performed the best among a set of samples varying only in acrylic acid mole ratio. Table 2 shows the conditions and the results.
[0000]
TABLE 2
Abrasion
Acrylic
Polyacrylic
loss,
acid/acrylamide
Starch,
acid/acrylamide,
mg/1000
Condition
ratio
lb/t
lb/t
revs
1
—
15.0
0.00
441.7
2
—
25.9
0.00
262.5
3
7.5/92.5
19.2
0.83
321.7
4
15/85
19.8
0.86
207.5
5
30/70
18.9
0.82
285.8
[0056] The first two conditions are meant to span a range of starch dose within which the conditions containing the polymers will be dosed. The abrasion loss results demonstrate that the strongest surface is obtained with the copolymer containing 15% acrylic acid.
Study 3. Ash Replacement.
[0057] This study was designed to compare surface strength performance as a function of ash content. Controlling only for ash content, base sheets were prepare in the lab using a Noble and Wood mold, pressed in a static lab press and dried in a drum dryer at approximately 100° C. All wet end chemistries were maintained constant. Table 3 shows the conditions and the results.
[0000]
TABLE 3
Abrasion
Acrylic acid,
Acrylic acid/
loss,
%-Average
Starch,
acrylamide,
mg/
Condition
MW, kDa
lb/t
lb actives /t
Ash, %
1000 revs
1
—
63.7
0.00
15.9
346
2
—
66.2
0.00
23.9
483
3
7.5-200
61.8
1.03
15.5
303
4
7.5-200
66.2
1.10
23.8
449
5
15-400
62.6
1.04
15.5
262
6
15-400
58.9
0.98
23.2
346
[0058] The first two conditions only contained starch, while the others contained about 1 lb/t of an AA/AcAm copolymer. The increase in surface strength is maximized with the higher average molecular weight copolymer containing 15% acrylic acid,
Study 4. Cooking a Blend of Starch and AA/AcAm.
[0059] Table 4 illustrates a study designed to test the effect of cooking the starch in the presence of the AA/AcAm copolymer.
[0000]
TABLE 4
Starch and
Abrasion
polymer cooked
Starch,
AA/AcAm,
loss,
Condition
together?
lb/t
lb/t
mg/1000 revs
1
No
21.3
0.00
1156
2
No
31.2
0.00
1034
3
No
37.2
0.00
880
4
No
16.4
1.09
1064
5
No
24.4
1.06
924
6
No
31.8
1.06
794
7
Yes
15.9
1.06
944
8
Yes
22.5
0.98
759
9
Yes
30.1
1.00
588
[0060] The results of these tests demonstrate that the formulation where the starch was cooked in the presence of a synthetic polymer such as AA/AcAm copolymer performs better than the formulation where the blending was done after cooking the starch.
[0061] While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. All patents, patent applications, scientific papers, and any other referenced materials mentioned herein are incorporated by reference in their entirety. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments described herein and/or incorporated herein. In addition the invention encompasses any possible combination that also specifically excludes any one or some of the various embodiments described herein and/or incorporated herein.
[0062] The above disclosure is intended to be illustrative and not exhaustive. This description 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 claims where the term “comprising” means “including, but not limited to”. 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.
[0063] All ranges and parameters disclosed herein are understood to encompass any and all subranges subsumed therein, and every number between the endpoints. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, (e.g. 1 to 6,1), and ending with a maximum value of 10 or less, (e.g. 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range. All percentages, ratios and proportions herein are by weight unless otherwise specified.
[0064] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
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The invention provides methods and compositions for increasing the strengthening effect of a starch coating on paper. The method involves contacting the starch with a synthetic polymer before the starch is cooked. This changes how the starch gelatinizes and how the polymer gets distributed on the paper resulting in greater paper surface strength.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Nos. 60/521,643 filed Jun. 9, 2004, and 60/522,287 filed Sep. 13, 2004.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to coating processes, and more particularly to coating apparatuses and processes suitable for use in the manufacture of heat exchangers and the components.
[0003] The manufacture of heat exchangers requires the joining of fluid passages (typically metal tubes) to heat transfer surfaces such as fins. For example, one type of heat exchanger construction used in the automotive industry comprises a number of parallel tubes that are joined to and between a pair of manifolds, creating a parallel flow arrangement. The ends of the tubes are typically metallurgically joined (brazed, soldered, or welded) to tube ports, generally in the form of holes or slots formed in a wall of each manifold. The tubes thermally communicate with high surface area fins in order to maximize the amount of surface area available for transferring heat between the environment and a fluid flowing through the tubes. The fins are typically in the form of flat panels having apertures through which tubes are inserted, or in the form of sinusoidal centers that are positioned between adjacent pairs of “flat” tubes with oblong cross-sections.
[0004] Tube-to-fin joints formed by brazing techniques are characterized by strong metallurgical bonds that can be formed at temperatures that do not exceed the softening temperatures of the components being joined. One such brazing process is the CUPROBRAZE® process, which involves depositing a braze paste on the tubes or fins, which are then assembled and heated to a suitable brazing temperature. The paste used in the CUPROBRAZE® process contains binders and a metal braze alloy based on the CuSnNiP system, for example, about 75% copper, about 15% tin, about 5% nickel, and about 5% phosphorus. Equipment for the CUPROBRAZE® process is commercially available from various sources, such as Schöler Spezialmaschinenbau GmbH and Bondmet, Ltd., and can be integrated into a tube mill to provide a process that continuously forms and coats tubing suitable for heat exchanger applications.
[0005] Shortcomings of brazing operations that use a braze paste include relatively high material costs, labor requirements, and inconsistent coating thickness. Therefore, alternative processes would be desirable.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention provides a process and apparatus suitable for continuously forming and directly coating a tube with a braze alloy, without the use of a braze paste. The apparatus includes means for continuously delivering tubing material to a forming means that forms a continuous tube from the tubing material downstream of the delivering means, a source containing a metallic material whose bulk composition is essentially the composition of the braze alloy, means for preheating the tube to a temperature of, for example, at least 65° C., means for depositing the braze alloy on a surface of the tube after the tube is heated by the preheating means, and means for cooling the tube and the braze alloy layer as the tube travels downstream from the depositing means and before the surface of the braze alloy layer oxidizes. The depositing means includes an enclosure, at least one thermal spray gun that receives the metallic material from the source, heats the metallic material, and deposits the metallic material to form a layer of the braze alloy on the surface of the tube as the tube continuously travels through the enclosure, and an inert gas through which the metallic material travels from the thermal spray gun to the surface of the tube.
[0007] The process of this invention involves continuously forming a tubing material to form a continuously moving tube, preheating the moving tube to a temperature of at least 65° C., depositing the braze alloy on a surface of the moving tube after the moving tube is preheated, and then cooling the moving tube and the braze alloy layer as the moving tube travels away from the at least one thermal spray gun and before the surface of the braze alloy layer oxidizes. The depositing step involves causing the moving tube to pass through an enclosure and employing at least one thermal spray gun to heat a metallic material whose bulk composition is essentially the composition of the braze alloy, and then deposit the metallic material through an inert gas as the metallic material travels from the thermal spray gun to the surface of the moving tube to form a layer of the braze alloy on the surface of the moving tube as the moving tube passes through the enclosure.
[0008] The thermal spray process produces a braze alloy layer that is strong, clean, and dense without damaging, distorting, or causing metallurgical changes within the tube. Compared to prior deposition processes that deposit a braze paste, the apparatus and process of this invention are capable of directly forming on the tube surface a thin, uniform, and dense braze alloy layer immediately after the tube is formed on a tube mill and at typically tube mill speed so that a continuous tube is coated and sized correctly as it leaves the tube mill. In further contrast to processes employing a braze paste, a secondary operation to dry the braze alloy layer is not required, and material costs are significantly reduced since the metallic material and the directly-deposited braze alloy layer do not require any binders.
[0009] Other objects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1 and 2 schematically represent plan and elevation views of a coating apparatus in accordance with a first embodiment of this invention.
[0011] FIGS. 3 and 4 schematically represent plan and elevation views of a coating apparatus in accordance with a second embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Illustrated in FIGS. 1 and 2 is a coating apparatus 10 in accordance with a first embodiment of the invention. The apparatus 10 performs an in-line spray process that applies a braze alloy coating directly on a continuously moving tube 12 , such as a heat exchanger tube. Such tubes, which typically range in width from about 10 mm to about 100 mm wide, are typically manufactured on tube mills at high linear velocities, such as 150 meters per minute. The apparatus 10 incorporates thermal spray equipment into equipment typically required by a tube mill, such that molten braze alloy is directly deposited onto the tube 12 immediately after the tube 12 is formed from suitable metal stock, such as a strip 14 . Because the forming and coating processes are continuous, the strip 14 is continuously fed from a large spool 16 in accordance with conventional tube mill processes.
[0013] Preferred braze alloys used to form the coating contain copper, tin, nickel, and phosphorus, though it is foreseeable that other coating materials could be used. In practice, it has been determined that the coating must contain at least one weight percent nickel for field corrosion resistance and sufficient phosphorus as a flux during a subsequent brazing operation, for example, in which the tube 12 is brazed to fins to form a heat exchanger. Preferred compositions for the braze alloy depend on the form in which the alloy is provided for deposition, which in turn depends on the thermal spray process used as discussed in greater detail below. In a preferred embodiment, the braze alloy is in wire form and preferably contains, by weight, about 6% to about 7% tin, about 1% to about 2.5% nickel, and about 6% to about 7% phosphorus, with the balance being copper and incidental impurities. If used in powder form, the braze alloy preferably contains, by weight, about 9.0% to about 15.6% tin, about 4.2% to about 5.4% nickel, about 5.3% to about 6.2% phosphorus, about 74.9% to about 79.4% copper, and incidental impurities. In practice, a minimum coating thickness of about 0.0007 inch (about 18 micrometers) is believed necessary to obtain an acceptable tube-to-fin braze. On a coverage basis, braze alloys of this invention must be deposited in excess of 150 grams/m 2 on the tube 12 to obtain a good braze.
[0014] FIGS. 1 and 2 depict the tube 12 as preferably undergoing conventional tube mill operations before deposition of the braze alloy coating. As shown in FIGS. 1 and 2 , the strip 14 passes through a strip guide 18 before passing through a series of rolls 20 that deform the strip 14 into a tubular shape, after which the tubular-shaped strip 14 passes through a welding station 22 where the strip 14 is welded to yield the tube 12 . The enclosure in which the weld operation is performed can be purged with argon or nitrogen to prevent or at least reduce oxidation of the tube 12 . While various cross-sectional shapes are possible, the tube 12 is preferably in the form of a “flat” tube with an oblong cross-section defined by two relatively wide oppositely-disposed flat surfaces. FIGS. 1 and 2 show the tube 12 passing between an opposed pair of abrasive wire brush wheels 24 that roughen the flat surfaces of the tube 12 for the purpose of promoting adhesion of the braze alloy coating, which is deposited on the flat surfaces that are later brazed to the fins. As alternatives to the brush wheels 24 , the tube surfaces can be roughened with a bead blast, or the tube strip 14 could be supplied with a pre-brushed finish. Following welding and surface roughening, the tube 12 must be dry and free of oils and coolant prior to the spray coating operation.
[0015] The thermal spray process is carried out in an enclosure 26 that preferably contains an inert gas such as argon to avoid oxidation of the braze alloy while it is molten during and immediately after deposition. Thermal guns 28 are mounted in the enclosure 26 , which is preferably equipped with a preheater 32 capable of heating the tube 12 to at least 150° F. (about 65° C.), which according to the invention is believed necessary to promote adhesion of the braze alloy coating at the high speed at which the tube 12 is traveling during the coating process. The enclosure 26 , along with any sound abatement and dust collection system, is preferably designed to maintain a neutral to slightly positive pressure environment within the enclosure 26 to maintain the inert atmosphere.
[0016] As known in the art, thermal spray processes involve spraying molten or at least heat-softened material onto a substrate surface to form a coating. Two thermal spray processes are generally encompassed by this invention: plasma spray (also known as plasma arc spray and nontransferred arc spray), and arc spray (also known as wire arc spray). With either coating process, it has been determined that preferred CuSnNiP coatings deposited on the tubel 2 are prone to oxidation to the extent that they will not braze, such that the coatings should be deposited through a shroud of inert or at least nonreactive gas. The brazeability of the deposited coating can be judged based on its color. A coating having a gray color is sufficiently oxide-free to permit subsequent brazing. While exhibiting good adhesion, a gold-colored coating is oxidized to the extent that it will not braze successfully.
[0017] In plasma spray processes, material in powder form (preferably with the powder composition noted above) is injected into a very high temperature plasma generated by a gas (typically argon, nitrogen, hydrogen, or helium) forced through a high voltage discharge between two electrodes, causing the gas to rapidly heat and accelerate to a high velocity that carries the molten powder to the substrate being coated. The hot material impacts the substrate surface and rapidly cools to form the coating. This process is sometimes referred to as a cold process (relative to the substrate material) since the substrate temperature can be kept low during processing, thus avoiding damage, metallurgical changes, and distortion to the substrate material. The powder is fed from a suitable source 30 into the plasma, where it is rapidly heated and accelerated. To prevent oxidation of the braze alloy, the plasma spray process of this invention is preferably conducted in an inert atmosphere (e.g., argon) within the enclosure 26 , and as such can be referred to as vacuum plasma spraying (VPS) or low pressure plasma spraying (LPPS).
[0018] In conventional wire arc spray processes, two wires of the desired coating material are typically used as electrodes across which a high voltage discharge is maintained to melt the wires, and air is forced between the two wires to atomize and propel the molten wire material at the substrate being coated. Contrary to conventional practice, the wire arc spray process of this invention preferably employs an inert or nonoxidizing gas such as nitrogen or argon as the carrier gas to avoid oxidation of the braze alloy, as discussed above. To deposit a braze alloy coating with the preferred wire composition noted above, the bulk composition of the wires should be essentially the same as the desired braze alloy coating. For this purpose, the entire wire may have the composition of the desired coating, or the wire can be formed to have a hollow core formed of copper or tin and filled with a powder whose composition is the balance of the desired coating.
[0019] Thermal spray guns are typically only about 50% to about 80% efficient, necessitating that spray rates must exceed 150 grams/m 2 to deposit enough coating on the tube 12 to obtain the desired 150 grams/m 2 coverage. If the coating is deposited by wire arc spraying, the desired coating coverage is also believed to require the use of wires with a minimum diameter of 0.080 inch (about 2 mm) in view of typical wire arc spray rates being about 35 to 80 pounds (about 16 to 36 kg) per hour, depending on the wire diameter, amperage of the power supply, and capability of the wire feeder. Furthermore, multiple arc spray guns 28 will typically be needed in view of the typical high line speeds of production tube mills. The guns 28 can be arranged in a straight line, W, or V-shaped pattern along the horizontal direction of travel of the tube 12 through the enclosure 26 . The interior walls of the enclosure 26 are preferably coated with a non-stick surface treatment or are otherwise formed of a material that inhibits adhesion of the over-spray from the spray guns 28 .
[0020] The wire arc spray process is believed to be preferred for use with the invention. For example, plasma spray processes use nitrogen as the plasma gas but argon is required to start the actual arc, necessitating a controlled argon purge to start the plasma gun then switching to nitrogen. Also, the wire arc spray process can immediately start spraying the braze alloy, whereas plasma spray processes require a minute or two to warm up before spraying can commence. Finally, the desired coverage for the tube 12 can be difficult to achieve with plasma spray powders, necessitating the use of relatively large particles in order to enable accurate metering and control of the powder feed rate.
[0021] Finally, FIGS. 1 and 2 represent the apparatus 10 as preferably including a quenching station 34 and sizing station 36 downstream from the thermal spray enclosure 26 , where the tube 12 is cooled and then undergoes a final sizing operation, as known in the art. The cooling step is preferably carried out in a manner that cools the braze alloy coating on the tube 12 before the surface of the coating oxidizes. For this purpose, the quenching station 34 may be located immediately adjacent the enclosure 26 or the tube 12 can be continuously enclosed and enveloped by an inert gas up to and through the quenching station 34 .
[0022] FIGS. 3 and 4 depict a second embodiment of the invention that differs from the embodiment of FIGS. 1 and 2 primarily by the order of operations, the use of a single thermal spray gun 28 , and the omission of the preheater 32 and sizing station 36 . As evidenced by FIGS. 3 and 4 , it is possible to perform the thermal spraying operation on the strip 14 before forming and welding the tube 12 , though such an approach is not believed to be preferred for most applications. Notably, by moving the brush wheel 24 and spray gun 28 to face the opposite side of the strip 14 , the apparatus 110 of FIGS. 3 and 4 can be adapted to deposit a braze alloy layer on the surface of the strip 14 that after forming defines the interior surface of the tube 12 , such that internal fins used in charge air coolers and intercoolers can be later brazed within the tube 12 . For such an application, spray guns 28 could be positioned on opposite sides of the strip 14 so that a layer of the braze alloy is provided on both the interior and exterior surfaces of the tube 12 .
[0023] While the invention has been described in terms of particular embodiments, it is apparent that other forms could be adopted by one skilled in the art. Therefore, the scope of the invention is to be limited only by the following claims.
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A process and apparatus for continuously forming and coating a tube with a braze alloy. The apparatus includes a device for continuously delivering tubing material to a device that forms a continuous tube from the tubing material, a device for preheating the tube, a device for depositing the braze alloy on the tube, a device for cooling the tube and the braze alloy layer before the surface of the braze alloy layer oxidizes, and optionally a device for sizing the tube. The deposition device includes an enclosure and at least one thermal spray gun that receives a metallic material from the source, heats the metallic material, and deposits the metallic material through an inert gas to form a layer of the braze alloy on the surface of the tube as the tube continuously travels through the enclosure.
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RELATED APPLICATIONS
This application is a continuation-in-part and claims the benefit under 35 U.S.C. §120 of U.S. patent application Ser. No. 13/739,054 titled Luminaire with Prismatic Optic filed Jan. 11, 2013, which in turn is related to and claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 61/642,205 titled Luminaire with Prismatic Optic filed May 3, 2012, the contents of which are incorporated in their entirety herein.
FIELD OF THE INVENTION
The present invention relates to systems and methods for generating light, and more particularly, a system for effectively distributing light substantially about a light bulb.
BACKGROUND OF THE INVENTION
Achieving nearly uniform light distribution about a light bulb has long been a goal in the lighting industry. Success in this goal has largely depended upon the method of providing light employed by the bulb. Specifically, different methods of light generation produce light with different distributions, which must be compensated for in the construction of the bulb.
Most of the earliest light bulbs were incandescent, which generate light by heating a filament wire until it glows. Due to the relatively sparse nature of the supporting structures necessary for the filament, and due to the 360-degree dispersion of light by the filament, achieving nearly uniform distribution about an incandescent light bulb was not difficult to achieve. However, due to inefficiencies in the method of light production employed in incandescent light bulbs, other methods are desirable.
Fluorescent lamps, specifically compact fluorescent lamps (CFLs), have been steadily replacing incandescent light bulbs in many lighting applications. Similar to incandescent, CFLs produce light in approximately 360 degrees by exciting mercury vapor to cause a gas discharge of light. CFLs are more energy efficient than incandescent light bulbs, but suffer a number of undesirable traits. Many CFLs have poor color temperature, resulting in a less aesthetically pleasing light. Some CFLs have prolonged warm-up times, requiring up to three minutes before maximum light output is achieved. All CFLs contain mercury, a toxic substance that must be handled carefully and disposed of in a particular manner. Furthermore, CFLs suffer from a reduced life span when turned on and off for short period. Therefore, there are a number of disadvantages to using CFLs in a lighting system.
Light emitting diodes (LEDs) are increasingly being used as the light source in light bulbs. LEDs offer greater efficiencies than CFLs, have an increased life span, and are increasingly being designed to have desirable color temperatures. Moreover, LEDs do not contain mercury or any other toxic substance. However, by the very nature of their design and operation, LEDs have a directional output. Accordingly, the light emitted by an LED may not have the nearly omni-directional and uniform light distribution of incandescents and CFLs. Although multiple LEDs can and frequently are used in a single light bulb, solutions presented so far do not have light distribution properties approximating or equaling the dispersion properties of incandescents or CFLs. Accordingly, there is a long felt need for a light bulb that can utilize LEDs as a light source while maintaining uniform and nearly omni-directional light distribution properties.
One issue facing the use of LEDs to replace traditional light bulbs is heat. LEDs suffer damage and decreased performance when operating in high-heat environments. Moreover, when operating in a confined environment, the heat generated by the LED and its attending circuitry itself can cause damage to the LED. Heat sinks are well known in the art and have been effectively used to provide cooling capacity, maintaining an LED-based light bulb within a desirable operating temperature. However, heat sinks can sometimes negatively impact the light distribution properties of the light bulb, resulting in non-uniform distribution of light about the bulb. Accordingly, there is a long felt need for an LED-based light bulb capable of providing uniform light distribution that maintains a desirable operating temperature.
This background information is provided to reveal information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.
SUMMARY OF THE INVENTION
With the foregoing in mind, embodiments of the present invention are related to a luminaire that utilizes a prismatic optic to distribute light from a light emitting element within the luminaire approximately uniformly about the luminaire. The luminaire, according to embodiments of the present invention, can also advantageously combine this prismatic optic with one or more light emitting diodes (LEDs) as a light source, overcoming previous deficiencies in LED-based luminaire designs.
These and other objects, features, and advantages according to the presenting invention are provided by a luminaire including a light source and a prismatic optic. The light source may include one or more LEDs that emit light that is incident upon the prismatic optic. The prismatic optic, in turn, may refract the light substantially about the luminaire, resulting in approximately omni-directional and uniform light distribution. The luminaire may further include a base for connection to a light socket and a heat sink for cooling the light source. The base may be attached to the heat sink, which is, in turn, attached to the light source and the prismatic optic. A surface of the heat sink may have reflective properties configured to reflect light generally towards the prismatic optic. The luminaire may further include a circuit board including circuitry configured to power the light source. The circuit board may be positioned so as to be optimally cooled by the heat sink.
The prismatic optic, according to embodiments of the present invention, may be configured to have specific light refracting properties. Specifically, the prismatic optic may refract light within certain regions with certain uniformities. The light may be refracted within regions of 0 degrees to 135 degrees, 135 degrees to 150 degrees, and 150 degrees to 180 degrees. Furthermore, the light may be of uniform intensity to within a certain percentage of an average intensity, such as within 20%, within 10%, within 5%, or within 1%.
The light source may include a platform upon which one or more LEDs may be attached. The LEDs may be attached to an upper surface and/or a lower surface of the platform, increasing light distribution. Furthermore, the platform may include a section within which the LEDs may be attached that facilitates electric coupling between the LEDs and the circuit board.
A method aspect of the present invention is for using the luminaire. The method may include the steps of generating light and refracting light according to a desired light distribution.
In some embodiments, the optic may have a first and second surfaces. The first surface may comprise a plurality of generally vertical and horizontal segments. Furthermore, the second surface may comprise a curvature. In some embodiments, the curvature may be generally concave.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a luminaire according to an embodiment of the present invention.
FIG. 2 is a perspective view of a lower structure of the luminaire presented in FIG. 1 .
FIG. 3 is a perspective view of a prismatic optic of the luminaire presented in FIG. 1 .
FIG. 4 a is a partial top view of the luminaire presented in FIG. 1 .
FIG. 4 b is a partial bottom view of the luminaire presented in FIG. 1 .
FIG. 5 is a partial side sectional view of the prismatic optic of the luminaire presented in FIG. 1 .
FIG. 6 is a perspective view of an upper structure of the luminaire presented in FIG. 1 .
FIG. 7 is a partial side sectional view of the upper section presented in FIG. 6 .
FIG. 8 is a perspective view of a light source used in connection with the luminaire presented in FIG. 1 .
FIG. 9 a is a perspective view of a housing used in connection with the luminaire presented in FIG. 1
FIG. 9 b is a side sectional view of the luminaire presented in FIG. 1 taken through line 9 b - 9 b.
FIG. 10 is a perspective view of a cap used in connection with the luminaire presented in FIG. 1 .
FIG. 11 is a perspective view of the cross section view of the luminaire as presented in FIG. 9 b.
FIG. 12 is a polar graphical illustration representing a light distribution of the luminaire presented in FIG. 1 .
FIG. 13 is a side elevation of a luminaire according to an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Those of ordinary skill in the art realize that the following descriptions of the embodiments of the present invention are illustrative and are not intended to be limiting in any way. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. Like numbers refer to like elements throughout.
Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.
In this detailed description of the present invention, a person skilled in the art should note that directional terms, such as “above,” “below,” “upper,” “lower,” and other like terms are used for the convenience of the reader in reference to the drawings. Also, a person skilled in the art should notice this description may contain other terminology to convey position, orientation, and direction without departing from the principles of the present invention.
An embodiment of the invention, as shown and described by the various figures and accompanying text, provides a luminaire 100 . Referring initially to FIG. 1 , a luminaire 100 according to an embodiment of the present invention is depicted, the luminaire 100 including a base 110 , a lower structure 200 , a prismatic optic 300 , and an upper structure 600 .
The base 110 of the present embodiment of the luminaire 100 is configured to conform to an Edison screw fitting that is well known in the art. However, the base 110 may be configured to conform with any fitting for light bulbs known in the art, including, but not limited to, bayonet, bi-post, bi-pin, and wedge fittings. Additionally, the base 110 may be configured to conform to the various sizes and configurations of the aforementioned fittings.
In the present embodiment, the base 110 of the luminaire 100 may include an electrical contact 111 formed of an electrically conductive material, an insulator 112 , and a sidewall 113 comprising a plurality of threads 114 . The plurality of threads 114 may form a threaded fitting on inside and outside surfaces of the sidewall 113 . The electrical contact 111 may be configured to conduct electricity from a light socket.
Turning to FIG. 2 , the lower structure 200 may have a lower section 201 defining a first end 202 and an upper section 203 defining a second end 204 . The interface between the lower section 201 and the upper section 202 may define a shelf 206 disposed about a perimeter the lower section 201 . The shelf 206 may include one or more attachment sections 207 at which the prismatic optic 300 may attach to the lower structure 200 . The first end 202 may be attached to the base 110 at the sidewall 113 by any means known in the art, including, not by limitation, use of adhesives or glues, welding, and fasteners.
Each of the first section 201 and the second section 203 may include a void that cooperates with each other to define a longitudinal cavity 208 . The shape and dimensions of the longitudinal cavity 208 will be discussed in greater detail hereinbelow. The upper section 203 may include a body member 209 having an outside surface 210 . The outer surface 210 may be positioned along a longitudinal axis of the luminaire 100 . The outer surface 210 may be configured to reflect light incident thereupon. The outer surface 210 may have a reflection coefficient of at least about 0.1, or about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9, or about 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, or 0.99, or about 1. In one embodiment, the outer surface 210 may act as a substrate and have a layer of reflective paint applied thereto. The reflective paint may advantageously enhance illumination provided by the light source by causing enhanced reflection of the light prior to reaching the prismatic enclosure 300 , which will be discussed in greater detail below. In another embodiment, the outer surface 210 may have a reflective liner applied thereto. Similarly, the reflective liner may be readily provided by any type of reflective liner which may be known in the art.
The upper section 203 may further include one or more channels 212 formed in the outer surface 210 . The channels 212 may be configured to align with the attachment sections 207 and run parallel to the longitudinal cavity 208 , facilitating the attachment of the prismatic optic 300 to the lower structure 200 .
In the present embodiment, the lower structure 200 may be configured to act as a heat sink. Accordingly, portions of the lower structure 200 may be formed of thermally conductive material. Moreover, portions of the lower structure 200 may include fins 214 . In this embodiment, the fins 214 are configured to run the length of the lower section 201 and extend radially outward therefrom. The fins 214 increase the surface area of the lower structure 200 and permit fluid flow between each fin 214 , enhancing the cooling capability of the lower structure 200 . The fins 214 may have a curved vertical profile to emulate the shape of traditional incandescent light bulbs. Optionally, the fins 214 may be configured to conform to the A19 light bulb standard size. Additional information directed to the use of heat sinks for dissipating heat in an illumination apparatus is found in U.S. Pat. No. 7,922,356 titled Illumination Apparatus for Conducting and Dissipating Heat from a Light Source, and U.S. Pat. No. 7,824,075 titled Method and Apparatus for Cooling a Light Bulb , the entire contents of each of which are incorporated herein by reference.
Furthermore, the lower structure 200 may include interior channels formed in the body member 209 . The interior channels may extend from a first opening 216 in an upper surface 222 of the body member 209 to a second opening 218 in an interior surface 224 of the upper section 203 forming the longitudinal cavity 208 . Air may be permitted to flow through the interior channels, providing additional cooling capability. Alternatively, the lower structure 200 may be formed as a substantially solid structure, not including the various structural aspects intended to increase the cooling capacity as described above. The lower structure 200 may further include a recessed region 220 formed in the upper surface 222 of the body member 209 . The recessed region may extend from the void of the upper section 203 to the outside surface 210 .
Referring now to FIG. 3 , a prismatic optic 300 according to an embodiment of the present invention is depicted. In the present embodiment, the prismatic optic 300 may include an upper optic 310 and a lower optic 350 . The upper optic 310 may be attached to the lower optic 350 by any method known in the art, including, but not limited to, threaded coupling, interference fit, adhesives, glues, fasteners, and welding, or combinations thereof. Moreover, in an alternative embodiment, the upper optic 310 and the lower optic 350 may be integrally formed as a single optic. The prismatic optic 300 is configured to define an optical chamber 301 , wherein the optical chamber 301 is configured to permit a light source to be disposed therein.
The prismatic optic 300 may be formed of any transparent, translucent, or substantially translucent material including, but not limited to, glass, fluorite, and polymers, such as polycarbonate. Types of glass include, without limitation, fused quartz, soda-lime glass, lead glass, flint glass, fluoride glass, aluminosilicates, phosphate glass, borate glass, and chalcogenide glass.
Each of the upper optic 310 and the lower optic 350 may include a sidewall 312 , 352 comprising an inner surface 314 , 354 and an outer surface 316 , 356 . Each of the outer surfaces 316 , 356 may comprise a plurality of grooves 318 , 358 formed thereon. Turning to FIGS. 4 a - b , the grooves 318 , 358 are configured to have substantially straight sides 320 , 360 , the sides forming alternating peaks 322 , 362 and valleys 324 , 364 . The angles formed at the peaks 322 , 362 and valleys 324 , 364 , as well as the length of the sides 320 , 360 may be selectively chosen to alter the refraction of light thereby.
Returning now back to FIG. 3 , each of the outside surfaces 316 , 356 may be configured to have a curvature. The degree of the curvature may be selected according to design standards, such as, a curvature that conforms to an A19 light bulb standard, having a diameter of about 2.375 inches. The curvature may also conform to any other industry standard, including, but not limited to, A15 (about 1.875 inches), A21 (about 2.625 inches), G10 (about 1.25 inches), G20 (about 2.5 inches), G25 (about 3.125 inches), G30 (about 3.75 inches), and G40 (about 5 inches). The preceding are provided for exemplary purposes and are not limiting in any way.
The lower optic 350 may include one or more protruding members 366 extending radially inward from a first end the inner surface 354 . The protruding members 366 may be configured to pass through the one or more channels 212 to interface with the attachment sections 207 , which are depicted in FIG. 2 . Each protruding member 366 may be associated with one channel 212 and one attachment section 207 . Each of the protruding members 366 may be attached to an attachment section 207 , thereby attaching the optic 300 to the lower structure 200 . The protruding members 366 may be attached to the attachment sections 207 by any method that can withstand the forces experienced by the luminaire 100 , such as those experienced during installation and removal. Methods of attachment include, but are not limited to, adhesives, glues, welding, and fasteners. Similarly, the upper optic 310 may include protruding members 326 extending radially inward from a first end of the inner surface 314 . The protruding members 326 may be configured to attach to the upper structure 600 described in detail hereinbelow.
Referring now to FIG. 5 , each of the inner surfaces 314 , 354 may include a plurality of generally vertical segments 328 , 368 and a plurality of generally horizontal segments 330 , 370 . Each of the generally vertical segment 328 , 368 may have two ends and may be attached at each end to a generally horizontal segment 330 , 370 , thereby forming a plurality of prismatic surfaces 332 , 372 . It is not a requirement of the invention that the generally vertical segments 328 , 368 be perfectly vertical, nor is it a requirement that the generally horizontal segments 330 , 370 be perfectly horizontal. Similarly, it is not a requirement of the invention that the generally vertical segments 328 , 368 be perpendicular to the generally horizontal segments 330 , 370 . Each of the prismatic surfaces 332 , 372 may be smooth, having a generally low surface tolerance. Moreover, each of the prismatic surfaces 332 , 372 may be curved, forming a diameter of the inner surfaces 314 , 354 .
The variance of the generally vertical segments 328 , 368 from vertical may be controlled and configured to desirously refract light. Similarly, the variance of the generally horizontal segments 330 , 370 from horizontal may be controlled and configured to produce prismatic surfaces 330 , 370 that desirously refract light. Accordingly, the prismatic surfaces 332 , 372 may cooperate with the grooves 318 , 358 , as depicted in FIGS. 3 and 4 a - b , to desirously refract light about the luminaire 100 (shown in FIG. 1 ).
Referring now to FIG. 6 , the upper structure 600 of an embodiment of the present invention is depicted. The upper structure 600 may include a body member 602 having an outer surface 604 . The outer surface 604 may be configured to reflect light incident thereupon. The outer surface 604 may have a reflection coefficient of at least about 0.1, or about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9, or about 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, or 0.99, or about 1. In one embodiment, the outer surface 604 may act as a substrate and may have a layer of reflective paint applied thereto. In another embodiment, the outer surface 604 may have a reflective liner applied thereto.
The upper structure 600 may further include a ridge 606 . The ridge 606 may interface with the prismatic optic 300 , thereby constraining the prismatic optic 300 between the upper structure 600 and the lower structure 200 . Furthermore, the ridge 606 may include one or more attachment surfaces 608 configured to facilitate attachment of the upper structure 600 to the prismatic optic 300 , as shown in FIG. 3 . The protruding members 326 of the upper optic 310 may be attached to the attachment sections 608 by any method that can withstand the forces experienced by the luminaire 100 , such as those experienced during installation and removal. Methods of attachment include, but are not limited to, adhesives, glues, welding, and fasteners.
The upper structure 600 may further include one or more channels 610 formed in the outer surface 604 . The channels 610 may be configured to align with the attachment sections 608 , permitting the passage of protruding members 326 therethrough and facilitating the attachment of the prismatic optic 300 to the upper structure 600 .
In the present embodiment, the upper structure 600 may be configured to act as a heat sink. Accordingly, portions of the upper structure 600 may be formed of thermally conductive material. Moreover, portions of the upper structure 600 may include fins 612 . In the illustrated embodiment, the fins 612 are configured to extend from the ridge 606 generally upwards and towards a longitudinal axis of the upper structure 600 . The fins 612 advantageously increase the surface area of the upper structure 600 and permit fluid flow between each fin 612 , enhancing the cooling capability of the lower structure 600 . The fins 612 may have a curved vertical profile to emulate the shape of traditional incandescent light bulbs. Optionally, the fins 612 may be configured to conform to the A19 light bulb standard size. Those skilled in the art will appreciate that the present invention contemplates the use of various configurations of fins to enhance heat dissipation.
Referring now additionally to FIG. 7 , the body member 604 may further include an inner surface 614 defining an internal cavity 616 . The internal cavity 616 may be configured to cooperate with the longitudinal cavity 208 of the lower structure 200 , defining a continuous cavity. Furthermore, the body member 602 may include a shelf 617 extending radially inward from the inner surface 614 into the internal cavity 616 .
As also illustrated in FIGS. 6-7 , the upper structure 600 may further include a recessed section 618 on the top of the upper structure 600 . The recessed section 618 may include an upper attachment section 620 . The upper attachment section 620 may be configured to attach a housing 900 (described below and illustrated in FIG. 9 ) thereto. The circuit board will be described in greater detail hereinbelow. The attachment section 620 may be configured to permit attachment by any method known in the art, including, but not limited to, fasteners, such as screw and threads, adhesives, glues, and welding. The upper structure 600 may further include a recessed region 622 formed in a lower surface of the body member 604 . The recessed region 622 may be positioned so as to approximately align with the recessed region 220 of the lower structure 200 . Alternatively, the upper structure 600 may be formed as a substantially solid structure, not including the various structural aspects intended to increase the cooling capacity as described above.
Referring now to FIG. 8 , according to an embodiment of the invention, a luminaire including a light source 800 is provided. The present embodiment of the light source 800 employs one or more light emitting elements 802 . The light emitting elements 802 may be disposed within the optical chamber 301 of the prismatic optic 300 , as depicted in FIG. 3 .
The light emitting elements 802 may be oriented to emit light that is incident upon the prismatic surfaces 332 of the upper optic 310 as well as the prismatic surfaces 372 of the lower optic 350 , as depicted, for example, in FIG. 5 . Accordingly, the light emitting elements 802 may be configured to emit light generally radially outward as well as upwards and downwards from the luminaire 100 , as shown in FIG. 1 .
According to the present embodiment of the invention, the light source 800 may include a platform 804 . The platform 804 may include an upper surface 806 , a lower surface 808 , and a void 809 , wherein each of the upper and lower surfaces 806 , 808 are generally flat and configured to permit attachment of the light emitting elements 802 thereto. For example, the light source 800 may include a channel 810 formed into one of the upper surface 806 and the lower surface 808 , or both. The channel 810 may be configured to form a region in the upper surface 806 into which the light emitting elements 802 may be there attached.
The location of the channel 810 on the upper surface 806 may be selectively chosen. In the present embodiment, the channel 810 is formed generally about the periphery of the upper surface 806 , although the channel 810 may be formed in any part of the upper surface 806 . In some embodiments, a plurality of light emitting elements 802 may be distributed within the channel 810 . Each of the plurality of light emitting elements 802 may be selectively distributed, for example, they may be spaced at regular intervals. In an alternative example, the light emitting elements 802 may be clustered in groups. The configuration of the disposition of the light emitting elements 802 may be selected to achieve a desired lighting profile or outcome.
The channel 810 may further include an attachment material disposed within the channel 810 . The attachment material may facilitate the attachment of the light emitting elements 802 within the channel 810 . Furthermore, the attachment material may facilitate the operation of the light emitting elements 802 . For example, where the light emitting elements 802 are LEDs, the attachment material may be formed of an electrically conductive material. Furthermore, the attachment material may be configured to include two or more electrical conduits that are isolated from each other, facilitating the operation of the light emitting elements 802 .
The light source 800 may further comprise a communication section 812 formed adjacent the channel 810 . Accordingly, the communication section 812 may be formed in either of the upper surface 806 and the lower surface 808 , or both. The communication section 812 may contact the channel 810 . Furthermore, the communication section 812 may be formed of an electrically conductive material. Accordingly, the communication section 812 may be in electrically coupled to the channel 810 .
The communication section 812 may include a first terminal 814 and a second terminal 816 . Each of the first and second terminals 814 , 816 may be formed of an electrically conductive material, may contact the channel 810 , and further may be electrically coupled to the channel 810 . Furthermore, where the channel 810 may include an attachment section including two or more isolated electrical conduits, the first terminal 814 may be in communication with a first electrical conduit of the attachment section, and the second terminal 816 may be in communication with a second electrical conduit of the attachment section. For example, and not by limitation, the first terminal 814 may be in communication with a power source conduit, and the second terminal may be in communication with a ground conduit.
Still referring to FIG. 8 , the first and second terminals 814 , 816 may each include a pad 818 , 820 respectively. The pads 818 , 820 may be configured to facilitate attachment of an electrical communication medium thereto. For example, and not by limitation, the dimensions of the pads may be selectively chosen to permit a wire to be soldered thereto. The pads 818 , 820 may be disposed approximately adjacent to the void 809 . Moreover, the pads 818 , 820 may be positioned so as to approximately align with the recessed region 220 of the lower structure 200 and the recessed region 622 of the upper structure 600 . The void 809 may be disposed about approximately the center of the platform 804 . The void 809 may be positioned and dimensioned to approximately align with the longitudinal cavity 208 as shown in FIG. 1 and the internal cavity 616 as shown in FIG. 7 , defining a continuous cavity.
Referring now to FIG. 9 a , a housing 900 according to an embodiment of the invention is presented. The housing 900 may be configured to be disposed substantially about a power source. The housing 900 may include a base section 910 and a monolithic section 950 . The base section 910 may be configured to attach the housing 900 to the base 110 as shown in FIG. 1 . Specifically, the base section 910 may include a body member 911 including plurality of threads 912 configured to cooperate with the threads 114 of the base 110 , wherein the threads 114 are functional on both an inside surface and an outside surface of the base 110 . Alternatively, the base section 910 may be attached to the base 110 by other methods, including, but not limited to, adhesives, glues, fasteners, and welding.
The base section 910 may include an opening (not shown) at a first end 914 . The opening may be configured to have the shape and sufficient dimensions to permit a power source to pass therethrough. The base section 910 may further include a flange 916 extending radially outward from the body member 911 . The base section 910 may still further include a sidewall 918 extending approximately orthogonally from the flange 916 . In one embodiment, the sidewall 918 may be configured to interfere with the fins 214 of the lower structure 200 . In such an embodiment, the housing 900 may be disposed within the longitudinal cavity 208 of the lower structure 200 , and the interference between the sidewall 918 and the fins 214 restricts the translation of the housing 900 beyond the point of that interference. Further, the base section 910 may include one or more ribs 920 that may be attached to the sidewall 918 , the flange 916 , and the monolithic section 950 .
The monolithic section 950 may be configured as a hollow, generally straight, substantially elongated structure. It may include a first end 952 and a second end 954 , with the first end 952 being adjacent the base section 910 and the second end 954 being substantially apart from the base section 910 . The monolithic section 950 may include one or more sidewalls 956 intermediate the first end 952 and the second end 954 , extending generally upward from the base section 910 . The sidewalls 956 may be attached and continuous, so as to define an internal cavity there between. The dimensions of the internal cavity may be sufficient to permit a power source to be at least partially disposed therein, as depicted in FIG. 9 b.
At least one of the sidewalls 956 may include an opening 957 towards the second end 954 . The opening 957 may be configured to facilitate the electrical coupling between a power source and the light source, illustrated in FIG. 8 , and described in greater detail hereinbelow.
At least one of the sidewalls 956 may include one or more vents 958 . The vents 958 may be positioned anywhere along the sidewall 956 . In the present embodiment, the vents 958 are positioned substantially toward the first end 952 . The positioning of the vents 958 , as well as their shape and dimensions, may be selected so as to facilitate the flow of air between the internal cavity defined by the sidewalls 956 and the area surrounding the housing 900 . In one embodiment of the invention, the flow of air may increase the cooling capability of the housing 900 , thereby reducing the operating temperature of a power source disposed within the internal cavity defined by the sidewalls 956 . For example, the vents 958 may be positioned adjacent those parts of a power source that generate the most heat, permitting the rapid transportation of air heated by the power source out of the housing 900 and to heat sinks, such as certain embodiments of the upper structure 200 and the lower structure 600 .
The monolithic section 950 may further include an attachment section 960 located substantially towards the second end 954 . Referring now to FIG. 7 , the attachment section 960 may be configured to attach to the upper attachment section 620 of the upper structure 600 . The attachment section includes a receiving lumen 962 through which a fastener may be disposed and attached thereto. In the present embodiment, a fastener 624 is disposed through the upper receiving section 620 and into the receiving lumen 962 , attaching to the receiving lumen, thereby fixedly attaching the housing 900 to the upper structure 600 . However, alternative embodiments permit the attachment section 960 to attach to the upper attachment section 920 by any method known in the art, including, but not limited to, adhesives, glues, and welding.
Referring now to FIG. 10 , according to an embodiment of the invention, a luminaire including a cap 700 is provided. The cap 700 is configured to cover the recessed section 618 of the upper structure 600 , as depicted in FIG. 7 . The cap 700 includes a domed section 702 and a plurality of tabs 704 extending generally downward and approximately perpendicular to the domed section 702 . One or more of the plurality of tabs 704 may include a catch 706 disposed on one end of the tab 704 . As shown in FIG. 7 , the catch 706 may engage with the shelf 617 of the upper structure 600 , thereby removably coupling the cap 700 to the upper structure 600 .
Referring now to FIG. 11 , a power source according to an embodiment of the present invention is presented. In the present embodiment, the power source may include a circuit board 1000 . The circuit board 1000 may be configured to condition power to be used by the light emitting elements 802 of the light source 800 . Furthermore, the circuit board 1000 may have a first end 1002 and a second end 1004 , wherein the first end 1002 is positioned generally downward and toward the base 110 , and the second end 1004 is positioned generally upward and toward the upper structure 600 . The circuit board 1000 may be dimensioned to permit at least a portion of the circuit board 1000 to be disposed within the internal void of the housing 900 .
The circuit board 1000 may include a first electrical contact 1010 . The first electrical contact may be positioned toward the first end 1002 of the circuit board 1000 . The first electrical contact 1010 may be configured to electrically couple with the electrical contact 111 of the base 110 , thereby enabling the first electrical contact 1010 to supply power to the circuit board 1000 . The circuit board 1000 may further include a second electrical contact 1020 . The second electrical contact 1020 may be positioned toward the second end 1004 of the circuit board 1000 . The second electrical contact 1020 may be configured to electrically couple with the pads 818 , 820 ( 820 not shown) of the light source 800 . The electrical coupling between the second electrical contact 1020 and the pads 818 , 820 enables the circuit board 1000 to deliver power to the light emitting elements 802 .
In one embodiment, the electrical contact 111 conducts power from a light fixture that provides 120-volt alternating current (AC) power. Furthermore, in the embodiment, the light emitting elements 802 comprise LEDs requiring direct current (DC) power at, for instance, five volts. Accordingly, the circuit board 1000 may include circuitry for conditioning the 120-volt AC power to 5-volt DC power.
In a further embodiment, the circuit board 1000 may include a microcontroller. The microcontroller may be programmed to control the delivery of electricity to the light source. The microcontroller may be programmed to, for instance, dim the light emitting elements 802 according to characteristics of the electricity supplied through the electrical contact 111 .
Referring now to FIG. 11 , the light emitted from the light emitting elements 802 may cooperate with the prismatic surfaces 332 , 372 and the grooves 318 , 358 to refract the emitted light substantially about the luminaire 100 . The prismatic surfaces, 332 , 372 and the grooves 318 , 358 may be configured to selectively refract light within desired ranges about the luminaire 100 . Furthermore, the light may be refracted to maintain a uniform intensity within desired ranges about the luminaire 100 .
It is understood that the angles referred to herein are measured according to a polar coordinate system, wherein the angles are measured from the positive Z-axis directed vertically. Moreover, the intensities referred to are in reference to an intensity of the light emitted by the luminaire 100 within a certain angle range. In the present embodiment of the invention, the reference intensity is an average intensity of light emitted within the range of angles between 0 degrees and 135 degrees.
Turning now to FIG. 12 , a graph of ranges of light refraction is presented. Light may be refracted within a first range 1210 about the luminaire. The first range 1210 may include angles within a range between about 0 degrees to about 135 degrees. Furthermore, the light emitted within the first range 1210 may be within about 20%, 10%, 5%, or 1% of the average intensity.
Light may also be refracted within a second range 1220 about the luminaire 100 . The second range 1220 may include angles within a range between about 135 to about 150 degrees. Furthermore, the light emitted within the second range 1220 may be within about 20%, 10%, 5%, or 1% of the average intensity. Light may also be refracted within a third range 1230 about the luminaire 100 . The third range 1230 may include angles within a range between about 150 degrees to about 180 degrees. Furthermore, the light emitted within the third range 1230 may be within about 20%, 10%, 5%, or 1% of the average intensity.
Referring now to FIG. 13 , an alternative embodiment of the invention is presented. In FIG. 13 , a luminaire 1300 is presented having similar elements to that of the embodiments described hereinabove. Specifically, the luminaire 1300 may include a body member 1310 , an optic 1320 carried by the body member 1310 and defining an optical chamber (not shown), and a light source (not shown) carried by the body member 1310 and positioned within the optical chamber. In some embodiments, the optic 1320 may have a first surface (not shown) and a second surface 1322 . Similar to the embodiments described herein above, the first surface may be an inner surface of the optic 1320 . Additionally, the first surface may include a plurality of generally vertical segments and a plurality of generally horizontal segments. Furthermore, the second surface 1322 may be generally smooth, and have a curvature. In some embodiments the curvature may be generally concave. The degree of curvature may be configured to distribute light about the optic 1320 in a desired distribution. Yet further, the optic 1320 may have an upper end, a lower end, and a center. The vertical segments may be generally longer towards each of the upper end and the lower end than toward the center. Additionally, the horizontal segments may be generally longer towards the center than towards the upper and lower ends. The vertical segments and the horizontal segments may similarly be configured to distribute light in a desired distribution.
In some embodiments, the optic 1320 may include an upper optic 1324 and a lower optic 1326 . In such embodiments, each of the upper optic 1324 and the lower optic 1326 may include a first surface and a second surface, similar to the first surface and the second surface 1322 described herein above. Similarly, the first surface of each of the upper optic 1324 in the lower optic 1326 may include a plurality of generally vertical segments and a plurality of generally horizontal segments. Furthermore the second surface of each of the upper optic 1324 and the lower optic 1326 may be generally smooth and comprise a curvature. The curvature of the second surface of each of the upper optic 1324 and the lower optic 1326 may be generally concave. More specifically, the curvature of each of the upper optic 1324 in the lower optic 1326 maybe concave in the direction of a center of the optic 1320 , where the upper optic 1324 and the lower optic 1326 are adjacent each other. Additionally, the curvature may be within the range from about X degrees to about Y degrees.
The remaining elements of the luminaire 1300 , including the body number 1310 and the light source, may be substantially as described in the previous embodiments hereinabove.
Some of the illustrative aspects of the present invention may be advantageous in solving the problems herein described and other problems not discussed which are discoverable by a skilled artisan.
While the above description contains much specificity, these should not be construed as limitations on the scope of any embodiment, but as exemplifications of the presented embodiments thereof. Many other ramifications and variations are possible within the teachings of the various embodiments. While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best or only mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
Thus the scope of the invention should be determined by the appended claims and their legal equivalents, and not by the examples given.
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A luminaire with a prismatic optic permits the nearly uniform distribution of light about the luminaire. The prismatic optic permits the use of directional light sources, such as light emitting diodes, while maintaining the uniform light distribution. Furthermore, a concave shape of the optic further enables uniform light distribution. When light emitting diodes are used, the luminaire further includes a heat sink to maintain a desirable operational temperature without negatively affecting the light distribution properties of the luminaire.
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BACKGROUND
[0001] The preferred embodiment concerns a method for production of a letterpress printing form, in particular a flexographic printing form, advantageously with at least one processing unit for material milling (in particular with a laser). The letterpress printing form exhibits printing elements elevated above a floor, and advantageously exhibits raster points arranged according to a raster.
[0002] Furthermore, the preferred embodiment concerns a letterpress printing form that is advantageously produced according to the aforementioned method.
[0003] The most common method of letterpress printing today is what is known as flexographic printing. In contrast to classical book letterpress printing, for flexographic printing relatively elastic, soft, rubber-like printing forms are provided in which the printing elements have been raised. The printing forms are for the most part produced from rubber or a photopolymer. For example, a printing form made from rubber with a casting mold can be produced with its printing elements. By now it has become typical to use photopolymers that can be locally cross-linked via exposure. The cross-linked regions are insoluble and remain elevated when the non-cross-linked regions are subsequently washed off. However, today more and more rubber-like printing forms are also directly engraved with a laser that ablates material, and the printing elements are thereby left raised.
[0004] A device that is suitable for laser engraving of flexographic printing forms is known from DE 101 16 672 A1, for example.
[0005] The printing forms are normally provided as printing plates or in sleeve form (sleeves) and in both cases are ultimately applied on a printing form cylinder and driven in rotation in the printing machine.
[0006] In flexographic printing the printing elements are additionally normally provided as raster points, which is different than in classical book printing. Given light tone values (and thus lesser print density) this means that relatively elevated raster points spaced relatively far from one another protrude from a floor relatively in a lighter or even in a medium tone value region. Moreover, in flexographic printing a relatively low-viscosity, thin fluid ink is used, whereby the properties of the ink are also for the most part matched to the respective printing substrate (which can come from a relatively large spectrum in flexographic printing, in particular can comprise absorbent and non-absorbent printing substrates).
[0007] Problems can arise in the printout in the printing machine due to this configuration, in particular in specific print density regions. For example, a problem can exist in that ink accumulates into larger drops on the floor and flows together and concentrates, which drops then “spray” uncontrolled onto the printing substrate due to the centrifugal force of the printing form rotating in the printing machine and lead to spotted ink delivery on the printing substrate.
SUMMARY
[0008] It is an object to better control the ink on a letterpress printing form.
[0009] More generally it is an object to provide a letterpress printing form that overall behaves in a more controlled and/or predictable manner in terms of its printing properties upon printing.
[0010] In a letterpress printing form, at least one region at a floor of the printing form is formed between printing elements to reduce a likelihood that printing ink drops which may form at the floor between the printing elements could detach from the floor and result in an undesired ink deposit on a surface being printed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a section through a flexographic printing form with two printing elements in a side view as a first preferred embodiment;
[0012] FIG. 2 shows a section through a flexographic printing form with two printing elements in a side view as a second embodiment;
[0013] FIG. 3 illustrates a section through a flexographic printing form with two printing elements in a side view as a third embodiment;
[0014] FIG. 4 shows a section through a flexographic printing form with two printing elements in a side view as a fourth embodiment;
[0015] FIG. 5 shows a section through a flexographic printing form with two printing elements in a side view as a fifth embodiment;
[0016] FIG. 6 shows a section through a flexographic printing form with two printing elements in a side view as a sixth embodiment of the invention,
[0017] FIG. 7 illustrates a plan view of a section from a flexographic printing form as a seventh embodiment; and
[0018] FIG. 8 shows a printing element in a perspective view similar to as in the exemplary embodiment according to FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the preferred embodiment/best mode illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, and such alterations and further modifications in the illustrated device and such further applications of the principles of the invention as illustrated as would normally occur to one skilled in the art to which the invention relates are included.
[0020] A first preferred embodiment provides that an essentially uniform, uninterrupted floor level does not exist everywhere in the interstices between the elevated printing elements. For example, excessive ink that does not adhere or did not remain adhered to the higher-situated surfaces of the printing elements can collect at such a uniform floor level. This excess ink is theoretically freely mobile on this floor. However, due to adhesion forces at the floor of the printing form thin ink films will remain adhered so strongly that the ink will not yield to the centrifugal force upon the rotation of the printing form. However, there is also effectively a competition between adhesion forces and cohesion forces. Due to the cohesion forces, larger ink accumulations therefore tend to join into drops, contrary to the adhesion forces. However, such a large centrifugal force can then also act on such drops that such a drop can no longer be held on the floor of the printing form by the adhesion force acting on it. This can lead to unwanted ink sprays on the printing substrate.
[0021] The technique of the preferred embodiment advantageously initially breaks up the uniform floor level in that regions between printing elements also protrude above the floor. These can provide further adhesion surfaces for the ink and also act as “breakwaters”, in any case as “ink surface breaks”. The described spray risk can thereby already be remedied or reduced.
[0022] The elevated regions can exist as a structure of the printing form floor. For example, the floor can have fluctuations that are wavy, pebbled, hilly or in any other form. However, it can also be provided that the region protruding above the floor is designed as a more or less precisely localizable and definable, more or less a pronounced elevation.
[0023] It is advantageously provided that the elevated region is designed to be less elevated than a printing element or the printing elements so that these additional elevated regions do not also print. However, it has been shown that it is also not necessarily harmful when these elevated regions project as high as the printing elements because, depending on the ink, adhesion, cohesion and shape of the elevated regions no harmful ink transfer to the printing substrate occurs in spite of a greater height.
[0024] The elevated region can, for example, be designed as a free-standing element; however, it can also be formed connected with a base of a printing element, for example. It can thereby be connected at the base or be formed fused with a base of a printing element or be integrated into a base region of a printing element. The base of the printing element can be designed with a protuberance or the like to form an elevated region. However, further different embodiments are also conceivable.
[0025] A face slope of the base could also be designed differently for the formation of the elevated region, and a base of a printing element could, for example, also receive at least two elevated regions in its peripheral region.
[0026] A preferred embodiment could provide that the base is designed cross- or star-shaped in plan view with a plurality of elevated regions in its peripheral region. The printing region surface could in particular be freely designed in practice and this shape could continue downward into the base region or the like. The printing surface region and cross-sections of the base can, however, also be designed entirely independently of one another.
[0027] According to a development of the method it is provided that the elevated region is formed extending between two printing elements. It thereby advantageously becomes a real ink separator, such that ink surfaces are forcibly separated into ink surface segments and a free cohesion of the ink of larger surfaces is necessarily arrested. For example, the elevated region can thereby be designed essentially in a bank or web shape or, for example, may also be designed essentially in a wall shape.
[0028] A further development of the method is characterized in that a plurality of elevated regions are designed to enclose or form a basin for printing ink.
[0029] Via the preferred basin formations the surface that provides excessive ink on the floor of the printing form is bounded and segmented in advance so that an ink quantity can be kept below a threshold at which the danger exists that ink could collect (due to its cohesion) into drops so large that these could be flung off under the effect of centrifugal force.
[0030] Such a basin could be designed essentially round in plan view, for example, and thereby be three-dimensionally formed approximately dome-shaped or approximately like a hollow cylinder or approximately in a funnel shape, for example. Manifold further embodiment possibilities are also provided for this. For example, the basin could alternatively also be formed approximately in a honeycomb shape in plan view.
[0031] Overall, elevated regions can be formed collectively into a relief structure, for example.
[0032] Another development of the invention provides that basins could be collectively formed into a cell structure corresponding or adapted to a respective printing raster.
[0033] In the method it could also conceivably proceed that, given formation of a structure from elevated regions, the respective printing elements are designed as elevated regions (thus initially a structure of the floor of the printing form is developed that is optimized for the solution of the object posed further above) and then the printing elements are also provided in this structure (advantageously as raster points) in that these printing regions are advantageously worked out to be somewhat more elevated or protruding.
[0034] The method could thus be characterized in that elevated regions formed together with a relief structure are provided or distinguished from the individual regions as printing elements. Whereby, given formation of the structure from elevated regions the respective printing elements are preferably designed as elevated regions.
[0035] The method could also be characterized in that a plurality of elevated regions are formed to enclose or form a basin for printing ink; in that basins are formed together into a cell structure corresponding or adapted to a respective printing raster; and in that regions of the elevated regions are provided or distinguished as printing elements, whereby the respective printing elements are preferably formed upon their formation from elevated regions.
[0036] A next development is characterized in that the techniques are executed dependent on the tone value or dependent on the print density; in particular, techniques could thus be provided or not be provided to a different extent or in a different manner, in particular in a different printing form region, and thus dependent on the size and distribution of the printing elements, for example.
[0037] The method could also be characterized in that the free volume remaining between printing elements is formed in reduced fashion dependent on the raster and/or dependent on the tone value and/or dependent on the printing density. This can occur, for example, in that the floor of the printing form is designed raised.
[0038] A development can also in particular provide that bases of printing elements are designed dependent on raster and/or tone value and/or print density. As already presented further above in a somewhat different context (however likewise in a preferred achievement of the posed object), it could be provided, for example, that a side slope of the respective base is variably designed (at least locally); and/or that at least one elevated region is formed connected with a base of a printing element; and/or that the elevated region is joined to the base; and/or that at least one elevated region is molded fused with a base of a printing element; and/or that the base of the printing element is designed with a protuberance or the like to form an elevated region; and/or that a base of a printing element receives at least two elevated regions in its peripheral region, wherein additionally or alternatively the base could be designed cross-shaped or star-shaped in plan view with a plurality of elevated regions in its peripheral region, for example.
[0039] As already likewise explained in principle further above, it could also be provided that the elevated region is formed extending between two bases of printing elements; and/or that the elevated region is formed essentially in a bank or web shape; and/or that the elevated region is formed essentially in a wall shape; and/or that a plurality of elevated regions are designed to enclose or form a basin for printing ink.
[0040] The basin could be designed essentially round in its plan view and thereby be three-dimensionally designed approximately dome-shaped, for example; or be formed approximately like a hollow cylinder or approximately like a funnel; or the basin could be formed approximately in a honeycomb shape in plan view, for example.
[0041] Elevated regions can advantageously be formed collectively into a relief structure.
[0042] A development of the method provides that the techniques are preferably implemented only for print densities from approximately 10% up to approximately 50%. It has been shown that, surprisingly, ink sprays can occur even from printing form regions with rather average print density, for example. This can possibly be explained in that in deep tone regions the printing elements themselves are already so voluminous that only a little space remains for excess ink while in very light regions the printing elements are only isolated and there in turn so much space remains for the excess ink that no excessively high cohesion tendency exists, but rather the adhesion on the free floor surface predominates.
[0043] Another independent solution of the method is characterized in that the letterpress printing form is designed as a type of rotogravure form with an inverse raster-dependent cup structure, such that webs or web regions between the cups are arranged according to a raster and are provided or distinguished as printing. An optimized floor of the printing form with elevated printing regions also results in the achievement of the posed object, whereby the respective printing elements could preferably be designed as elevated regions given their formation from webs or web regions.
[0044] Another independent solution of the method is that the letterpress printing form is inversely formed with an inverse raster such that regions that are typically formed elevated are designed in negative form as depressions and trench structures typically remaining between these regions that are typically formed elevated are negatively formed as elevated webs, and the elevated webs are arranged according to a raster and are provided or distinguished as printing elements.
[0045] An optimized floor of the printing form with elevated printing regions also results in the achievement of the posed object, whereby the respective printing elements could preferably be designed as elevated regions given their formation from webs or web regions.
[0046] Another independent solution of the method is characterized in that the printing elements are designed capped depending on the point size.
[0047] Printing elements behave differently upon printing due to their differing point size and primarily in flexographic printing due to the relative elasticity of the material of the printing form.
[0048] A good and uniform printing behavior at all point sizes can in particular be achieved according to a development of the method in that the printing elements are capped such that relatively thin columns rise over relatively thick bases, the height extent of which columns is greater at smaller point sizes than at larger point sizes. The columns are advantageously designed set back from the bases, possibly forming terraces or ledges. The bases can preferably be essentially designed such that they widen conically as they descend.
[0049] The ink control of excessive ink on the floor of the printing form is also advantageously benefited via these techniques, for example, since overall less space remains for the excess ink due to the relatively shorter columns in regions of greater print density.
[0050] Protection is also independently claimed for a letterpress printing form (in particular a flexographic printing form) that comprises printing elements elevated above a floor, advantageously comprises raster points arranged according to a raster, advantageously a letterpress printing form designed according to the inventive method that, in an independent solution of the posed object, is characterized in that at least one region protruding above the floor is formed between printing elements.
[0051] This likewise applies for a letterpress printing form (in particular a flexographic printing form) that comprises printing elements elevated above a floor, advantageously comprises raster points arranged according to a raster, which letterpress printing form, in an independent solution of the posed object, is characterized in that elevated regions collectively form a relief structure from the individual regions provided or distinguished as printing elements.
[0052] This likewise applies for a letterpress printing form (in particular a flexographic printing form) that comprises printing elements elevated above a floor, advantageously comprises raster points arranged according to a raster, which letterpress printing form, in an independent solution of the posed object, is characterized in that a plurality of elevated regions are designed to enclose or form a basin for printing ink; in that basins collectively form a cell structure corresponding or adapted to a respective print raster; and in that regions of the elevated regions are provided or distinguished as printing elements.
[0053] This likewise applies for a letterpress printing form (in particular a flexographic printing form) that comprises printing elements elevated above a floor, advantageously comprises raster points arranged according to a raster, which letterpress printing form, in an independent solution of the posed object, is characterized in that the free volumes remaining between printing elements are formed reduced dependent on raster and/or tone value and/or print density.
[0054] This likewise applies for a letterpress printing form (in particular a flexographic printing form) that comprises printing elements elevated above a floor, which letterpress printing form, in an independent solution of the posed object, is characterized in that the letterpress printing form is designed as a type of rotogravure form with an inversely raster-dependent cup structure, such that webs or web regions are arranged according to a raster between the cups and are provided or distinguished as printing elements.
[0055] This likewise applies for a letterpress printing form (in particular a flexographic printing form) that comprises printing elements elevated above a floor, which letterpress printing form, in an independent solution of the posed object, is characterized in that the letterpress printing form is designed inversely with an inverse raster, such that typically elevated regions are designed in negative form as recesses, and trench structures typically remaining between these regions typically formed as elevations are negatively formed as elevated webs, and the elevated webs are arranged according to a raster and are provided or distinguished as printing elements.
[0056] FIG. 1 shows an exemplary embodiment of a segment of a flexographic printing form in section, whereby two printing elements 1 that project from a floor 2 of the printing form are recognizable in a side view. The hatchings in this Figure and in subsequent Figures serve primarily for the clear association of cut surfaces from different regions. The entire presented region of the printing form can, however in principle be formed in one part from the same material, such that the hatchings could also all be of the same type. The forming of such a printing form can preferably occur with a direct engraving using a fiber laser. The fiber laser can sustain a processing focal diameter of less than or equal to 20 μm, advantageously even smaller than or equal to 10 μm, with a clean focusing and a good depth of focus with advantageously a nearly only diffraction-limited laser beam, such that even the finest structures of the printing form and its elements can be prepared.
[0057] The printing elements 1 exhibit bases 3 that preferably expand more or less conically as they descend. A column 5 whose top side 6 forms the actual printing surface of the printing element sits set back on the respective base 3 , possibly leaving a ledge 4 of the base 3 . The bases 3 exhibit sides 7 that in this example have the same slope angles.
[0058] Printing elements in a medium tone or print density region should advantageously be represented in FIG. 1 . In this region the free space 8 between the printing elements 1 can in particular be critical insofar as excess free printing ink can accumulate to form drops there, which can lead to unwanted sprays onto the printing substrate upon printing.
[0059] In the first exemplary embodiment according to FIG. 1 it is therefore provided in a solution to insert elevated regions or structures comprising banks or walls 9 between the bases 3 of the printing elements 1 or to leave the banks or walls 9 upon removal of the material, which banks or walls 9 form basins or bowls 10 between printing elements 1 adjacent to one another, the basins or bowls 10 respectively offering only a limited volume to the printing ink for its cohesion and simultaneously offering the printing ink further surfaces for adhesion, such that a critical drop formation can be avoided. In this exemplary embodiment all printing elements 1 and banks 9 can form a type of cell structure or a relief developed otherwise extending across the printing form.
[0060] For example, another embodiment could also appear such that each base 3 receives wall projections 9 , however the wall projections 9 do not connect with the wall projections 9 of an adjacent base 3 . The critical space 8 between the printing elements 1 would thus also be reduced in its volume and structured in order to avoid an all too free flow and accumulation of printing ink in any case.
[0061] Identical elements are designated with the same reference numbers in the following Figures as in FIG. 1 .
[0062] FIG. 2 shows a second exemplary embodiment in a presentation similar to FIG. 1 . However, here additional elevated elements 11 have been placed or left in the space 8 between the printing elements 1 as an alternative solution. The element 11 has only an exemplary shape and extent could also be designed differently with the same function.
[0063] FIG. 3 shows a further exemplary embodiment in which outgrowths 12 are molded on the bases 3 so that the space 8 between them is reduced. Only two exemplary outgrowths or extensions 12 are shown. These could, for example, be arranged in a star shape around each base 3 . The slope angle of the sides 7 can also be altered, for example be set flatter. Outgrowths 12 or the like arise in turn when this is implemented locally.
[0064] FIG. 4 shows an exemplary embodiment in which an essentially dome-shaped basin 13 is formed for printing ink in the space 8 . Such a basin could also be shaped within the floor surface 2 itself because the floor surface could also be advantageously structured. Such an embodiment is indicated in FIG. 5 with a basin or a trough.
[0065] FIG. 6 shows a tone value-dependent base in an exemplary embodiment. Segments of a printing form are shown in section in FIG. 6 . A printing element 1 that should in turn be in a medium tone or print density region is shown in side view on the left side of the Figure while a printing element 1 of a lighter tone is shown in side view to the right in FIG. 6 . The left printing element essentially corresponds in terms of its shape to the printing element 1 from the preceding Figures. However, here it is indicated with a dashed line 7 ′ that the side slope of the base 3 can also simply be designed flatter (on all sides) in order to reduce the space 8 in this medium tone region. Contrary to this, given lighter tones as in the right region of FIG. 6 the side 7 ′ of the base could even be placed steeper (on all sides) because problematic cohesions of the printing ink normally do not occur in this region given these larger spaces 8 ; rather, the entire space 8 between the printing elements 1 is perhaps so large and essentially isotropic that the ink behaves indifferently here and a strong adhesion occurs on the relatively large floor surface 2 , which prevents a local cohesion into drops. In regions of increasing lightness it is therefore more advantageous to achieve this larger expansion of the space 8 earlier instead of reducing it as in the medium region. The sides 7 are therefore better steeper instead of flatter.
[0066] Moreover, it is indicated that the column 5 of the lighter tone can additionally begin already quite lower than given the medium tone to the left, such that the space 8 is also likewise already increased at higher levels. Moreover, the printout behavior of the relatively small surface 6 , which otherwise could advantageously lie at a somewhat lower level than the surface 6 given a medium or deep tone in order to avoid a too-large print point enlargement of this small surface 6 upon printing, advantageously improves since this relatively thin column 5 is relatively flexible. The column length could be set in steps dependent on tone value.
[0067] FIG. 7 shows a further preferred exemplary embodiment according to type.
[0068] Shown is a plan view of a section from a flexographic printing form. Recognizable here in plan view is a regular structure or a relief that extends across the printing form or at least printing form regions or takes up these.
[0069] For example, a cell or comb structure with basins 14 (or also 10 or 13 ) is specified. The edges of these basins can, for example, be base sides 7 or even ground surfaces 2 . The cells are enclosed by banks 9 or base outgrowths or extensions 12 or the like that in total are networked into a type of grid structure. Columns 5 with elevated, protruding surfaces 6 can be arranged as printing element regions at the intersection points. These surfaces can moreover have nearly arbitrary shapes in plan view and also have offshoots, whereby the surface shapes 6 and the base shapes 7 do not necessary have to be correlated with one another. A type of star or flower shape was assumed here for the surfaces 6 by way of example. Preceding Figures appear to adopt more circular round surfaces 6 which, as said, is however not absolutely mandatory The printing elements can be relatively freely executed in three dimensions, which in particular can also be implemented well and precisely and quickly with a fiber laser.
[0070] In this context it should above all be made clear that given the preferred embodiment, a relief structure as a solution can conceivably be assumed in that the printing elements are then advantageously provided as raster points for which the relief structure could be designed dependent on the raster, for example with regard to desired line intervals, raster angles and so on. In reverse, however, printing elements can also be conceivably assumed that are more or less structure-forming, more or less “grow together” in the base region or are expanded by additional elevated intermediate elements 11 .
[0071] Finally, FIG. 8 shows a printing element 1 in perspective view, similar to as it could be cut from the exemplary embodiment according to FIG. 7 .
[0072] The base 3 ascends like a tree stump with star-shaped roots running out in banks 9 that surround a basin 14 in the floor 2 . Such a base could moreover also be freestanding on the floor 2 with its star-shaped outgrowths without its outgrowths connected with outgrowths of adjacent base 3 to form banks.
[0073] Moreover, it is reminded again at this point that the printing form could in particular be provided as a plate, tube or sleeve, and that the printing form could be arbitrarily engraved or exposed and washed off, thus for example also with material cross-linking under UV. Direct laser engraving with a fiber laser on a round form is only at the moment viewed as a best mode, but not as limiting a scope of the invention.
[0074] While a preferred embodiment has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention both now or in the future are desired to be protected.
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In a letterpress printing form, at least one region at a floor of the printing form is formed between printing elements to reduce a likelihood that printing ink drops which may form at a floor between the printing elements could detach from the floor and result in an undesired ink deposit on a surface being printed.
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