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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority on U.S. provisional patent application Ser. No. 61/684,102, filed on Aug. 31, 2012 and entitled “Traction Plowing System.” The '102 application is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to tillage systems for farming. More specifically, the present invention pertains to a traction tillage system for farming.
[0003] Tillage systems for farming are known in the art. These systems typically include a tractor pulling implements, such as plows, planters, disks, harrows, cultivators, and irrigation spray heads, hack and forth across a field. Conventional tillage systems, however, have several disadvantages. Tractors are heavy and compact soil as they move back and forth across a field. Compacted soil can reduce crop yield by 10-20 percent depending on the extent of the compaction. Conventional tillage systems also use large amounts of fuel because the tractor has to go back and forth across the field repeatedly in order to till the entire field. Finally, conventional tillage systems can create large amounts of dust as the tractor moves back and forth across the field. Accordingly, there is a need for a tillage system that does not suffer from these disadvantages.
SUMMARY OF THE INVENTION
[0004] The present invention addresses this need by providing a traction tillage system that reduces soil compaction, fuel consumption, and dust pollution. In one embodiment, the traction tillage system includes a pair of booms, a pair of wheeled support assemblies connected to, and providing support for, the booms, a pair of carriages connected to the booms so the carriages can move back and forth along the booms, a set of implements connected to the carriages for tilling a field as the carriages move back and forth along the booms, and a carriage drive system connected to the carriages and booms for simultaneously moving the carriages in opposite directions along the booms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGS. 1A and 1B are top views showing one embodiment of the present invention, including exemplary embodiments of the booms, main wheels, carriages, and implements.
[0006] FIG. 2 is a side view of the embodiment shown in FIGS. 1A and 1B in the tilling configuration.
[0007] FIG. 3 is a side view of the embodiment shown in FIGS. 1A and 1B with the implements in the raised position and the main wheels configured so the embodiment can be moved laterally across a field to begin a new pass across the field.
[0008] FIG. 4 is a side view showing the soil compaction created by the embodiment shown in FIGS. 1A and 1B .
[0009] FIG. 5 is a drawing showing the soil compaction created by a conventional tillage system.
[0010] FIG. 6 is a perspective view showing one embodiment of a motor equipped wheeled support assembly included with the present invention.
[0011] FIG. 7 is a side view showing exemplary embodiments of the turn and lift sections of the booms, carriages, implements, and turn wheel mechanisms for turning the implements.
[0012] FIG. 8 is a side view showing exemplary embodiments of a wheeled boom support, a permanent boom section with trailer wheels, the turn and lift sections of the booms, the turn wheel mechanism for turning the implements, and an end plate that houses return pulleys.
[0013] FIG. 9 is an end view showing the wheeled boom support and exemplary embodiments of an end support beam, rolling boom supports, and suspended booms.
[0014] FIG. 10 is a top view showing bow the booms can be adjusted according to the number of implements being used.
[0015] FIG. 11 is an enlarged side view showing the trailer wheels in the stowed and travel Positions.
[0016] FIG. 12 is a cut-away, enlarged view showing the end support beam and rolling boom support brackets.
[0017] FIG. 13 is an enlarged view of one of the rolling boom support brackets shown in FIG. 12 .
[0018] FIG. 14 is a view of the rolling boons support bracket shown in FIG. 13 rotated 180 degrees horizontally.
[0019] FIG. 15 is a side view showing the rolling boom support connected to the end support beam and a boom.
[0020] FIG. 16 is a side view showing one embodiment of a F-shaped support frame included with the turn wheel mechanism.
[0021] FIG. 17 is a top view of FIG. 16 showing one embodiment of a turn wheel connected to the F-shaped support frame.
[0022] FIG. 18 is an enlarged end view showing exemplary embodiments of the boom, carriage, carnage wheel track, carriage wheels, insert tubes included in the boom for receiving the F-shaped support frame, and turn wheel lift track.
[0023] FIG. 19 is a side view showing a second F-shaped support frame included with the turn wheel mechanism.
[0024] FIG. 20 is a top view of FIG. 19 .
[0025] FIG. 21 is a cut-away end view showing the F-shaped support frames of the turn wheel mechanism connected to the turn section of the boom using the insert tubes.
[0026] FIG. 22 is a top view showing one of the turn wheels and a turn wheel bracket used to connect the turn wheel to the F-shaped support frame.
[0027] FIG. 23 is a front view of FIG. 22 showing one embodiment of a swivel arm included with the turn wheel mechanism.
[0028] FIG. 24 is a side view of FIG. 23 .
[0029] FIG. 25 a shows the carriage at a position just before it contacts the turn wheel and the swivel arm.
[0030] FIG. 25 b shows the swivel arm being lifted by the carriage.
[0031] FIG. 25 c shows the carriage right before it disengages with the swivel arm and turn wheel.
[0032] FIG. 25 d shows the swivel arm in a locked position.
[0033] FIG. 26 shows a bottom view of one embodiment of a turntable included with the carriage.
[0034] FIG. 27 is a top view showing one embodiment of the four track wheels included with the carriage.
[0035] FIG. 28 is a side view of the carriage and the turntable shown in FIGS. 26 and 27 .
[0036] FIG. 29 is a front view of the carriage and turntable shown in FIG. 28 .
[0037] FIGS. 30 a - 30 m show how the turn wheel mechanism rotates the turntable included with the carriage.
[0038] FIG. 31 is an enlarged side view of the end plate shown in FIG. 8 .
[0039] FIG. 32 is an end view of the end plate shown in FIG. 31 .
[0040] FIG. 33 is an end view of the end plate shown in FIG. 32 with increased spacing between the booms.
[0041] FIGS. 34-35 illustrate how power and hydraulics may be supplied by a conventional tractor in one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Referring to FIGS. 1A , 1 B, and 2 - 3 , one embodiment of the present invention of a traction tillage system 10 includes a pair of booms, 12 and 14 , a pair of wheeled support assemblies, 16 and 18 , connected to and providing support for the booms, a pair of carriages, 20 and 22 , connected to the booms so that the carriages can move back and forth along the booms, implements, 24 and 26 , connected to the carriages for tilling a field 30 , and a carriage drive system (or pulley drive system) connected to the carriages and the booms for simultaneously moving the carriages in opposite directions along the booms and causing the implements to work against themselves creating their own traction in the process of tiding a field. Implements 24 and 20 may be plows or any other type of equipment used to till a field. Carriage drive system may include a pair of cable spools, 32 and 34 , cables, 36 , 38 , and 40 , a series of pulleys, 42 and 44 ( FIG. 6 ), 46 ( FIG. 7) and 48 (not shown), 50 , 52 , 56 , and 58 ( FIG. 32 ), and a motor or engine 60 . The motor/engine and cable spools may be mounted on wheeled support assembly 16 using a motor/engine support frame 35 , cable 36 may be connected to cable spool 32 , pulleys 44 and 48 , and one end of carriage 20 , cable 38 may be connected to an opposite end of carriage 20 , pulleys 50 , 52 , 56 , and 58 , and one end of carriage 22 . Cable 40 may be connected to an opposite end of carriage 22 , pulleys 46 and 42 , and cable spool 34 .
[0043] Motor/engine 60 may be a QSF2.8 (Tier 4 Final/Stage IV) motor manufactured by Cummins, Inc. or any other motor or engine capable of moving the carriages back and forth along the booms. Detailed information regarding the QSF2.8 engine may be found at cummingsengines.com.
[0044] Wheeled support assembly 16 may include a first support frame 62 connected to the booms and wheeled support assembly 18 may include a second support frame 64 connected to the booms. Wheeled support assembly 16 may include a first set of main wheels, 66 and 68 , and wheeled support assembly 18 may include a second set of main wheels, 70 and 72 . The main wheels may be positioned in a tilling position, as shown in FIGS. 1 and 2 , or rotated 90 degrees and positioned in a moving position as shown in FIG. 3 .
[0045] When the equipment is operating, the main wheels allow the system 10 to be moved from one position to the next position which is parallel to the last position tilled. The system 10 docs not move to a new position while the implements are in the ground or moving back and forth across the field. When the system is moved into place, the implements are pulled by the cables in opposite directions until they reach the ends of the booms where they travel up the lift sections and are pulled out of the ground. When the implements are out of the ground, system 10 can move in a parallel manner to the next position.
[0046] When system 10 completes on pass and reaches the cud of the field, the main wheels, 66 , 68 , 70 , and 72 turn 90 degrees and system 10 moves laterally across the field to the next tilling position. The system 10 may be moved so that the main wheels, 66 and 68 , line up with the tracks made by the second set of main wheels, 70 and 72 , when the system 10 is moved to the next position to reduce wheel tracks made by the system.
[0047] The system 10 may include an end plate 74 connected to booms 12 and 14 and boom support cables, 76 and 78 , connected between the end plate 74 and wheeled support assembly 18 to provide additional support for booms 12 and 14 .
[0048] Booms 12 and 14 may include main boom sections 80 and 82 , lift sections 84 , 86 , 88 , and 90 , and turn sections 92 , 94 , 96 , and 98 . The lift and turn sections may be approximately equal in length and substantially shorter in length than the main boom sections. The main boom and turn sections may be substantially level and the lift sections may be sloped upward or inclined so that the implements move upward out of the ground as they travel up the lift sections. Booms 12 and 14 may also include wheeled boom support sections, 100 and 102 ( FIG. 9 ), which may be included as part of wheeled support assembly 18 .
[0049] The booms may be constructed from pipes, steels beams, or other similar materials used to make conventional booms used in the construction industry. The distance between the booms may be increased or decreased in order to accommodate different sized implements and the booms may be raised and lowered with respect to the wheeled support assemblies.
[0050] FIGS. 4 and 5 illustrate how the present invention can reduce soil compaction when compared to conventional field tillage systems. As shown in FIG. 4 , the system of the present invention only creates two instances of soil compaction, 104 and 106 , as it moves across a field. A conventional tractor 108 having four rear wheels would create a significantly higher number of instances of soil compaction when tilling the same field because it would have to move back and forth across the field multiple times in order to completely till the field.
[0051] As shown in FIG. 6 , wheeled support assembly 16 may include a rectangular main frame 110 having two vertical support members, 112 and 114 , and a rectangular hit frame 116 connected to the main frame 110 . Wheeled support assembly 16 may include conventional hydraulic pistons or electric motors (not shown) inside the two vertical support members to move the hit frame up and down with respect to the main frame. Vertical support members 112 and 114 may include John Bean Auto Life, Symmetric Two Post Mfr. Model 421500S16. Wheeled support assembly 16 may include four support arms, 118 , 120 , 122 , and 124 , extending out from two slots, 126 and 128 , defined on the vertical support members under the lift frame.
[0052] Main wheels, 66 and 68 , may be connected to the main frame 110 using hinges, 130 and 132 , that allow the main wheels to be positioned in the working position, where the wheels are parallel with the main frame 110 , and rotated 90 degrees to the moving position, where the wheels are perpendicular to the main frame 110 . Hydraulic motors, hydraulic pistons, or electric motors (not shown) may also be included in, or connected to, the main frame 110 for rotating the main wheels hack and forth between the tilling and moving positions.
[0053] Lift frame 116 may include an upper lip 134 , which can be used to connect the booms 12 and 14 to the lift frame 116 , and a series of holes 136 defined in a lower portion 138 of the lift frame 116 , which can be used to connect pulleys, 42 and 44 , to the lift frame 116 at various different locations depending on the positions of the booms 12 and 14 .
[0054] Wheeled support assembly 16 may include a pair of brackets, 140 and 142 , which can be used to connect the first support frame 62 to the main frame 110 , and a pair of coulter wheels, 144 and 146 , connected to the main frame 110 adjacent to the main wheels 66 and 68 . Hydraulic jacks, 148 ( FIG. 7) and 150 (not shown) may be connected to the main frame 110 for driving the coulter wheels down into the ground in order to prevent the system 10 from moving when the implements 24 and 26 encounter soil having different consistencies.
[0055] First support frame 62 may include a first pair of support struts, 152 ( FIG. 1A) and 154 ( FIG. 7 ) connected on one end to the main frame 110 using the brackets, 140 and 142 , and on the opposite end to first support beam 156 . First support beam 156 , in turn, is connected to the booms 12 and 14 and, more specifically, to turn sections, 92 and 94 . Turn sections 92 and 94 may be connected to lift frame 116 using locking tabs, 158 and 160 . Wheeled support assembly 16 may include pulley support arms 162 ( FIGS. 6 and 7 ) and 164 (not shown) connected to lift frame 116 . Pulley support arms 162 and 164 may be connected to lift frame 116 so that they can be slid back and forth along the lift frame 116 and aligned with pulleys 42 and 44 when they are positioned in different locations along the lift frame 116 .
[0056] As shown in FIGS. 7-8 , the system 10 may include carriage turning mechanisms 166 (not shown), 168 , 170 (not shown), and 172 , for turning the carriages around after completing a pass across a field. Second support frame 64 ( FIG. 1B ) may include a second pair of support struts, 174 and 176 ( FIG. 10 ), a third pair of support struts, 178 and 180 , and a pair of second support beams, 182 and 184 . Support beam 182 may be connected to wheeled boom support sections, 100 and 102 , using hollow tubes 181 and 183 , and support beam 184 may be connected to an opposite end of wheeled boom support sections 100 and 102 using hollow tubes 185 and 187 .
[0057] Wheeled support assembly 18 ( FIGS. 9-10 ) may include an I-shaped main frame 186 , a pair of rolling brackets, 188 and 190 , connected to the main frame 186 and the wheeled boom support sections, 100 and 102 , of the first and second booms. Main wheel 70 is connected to the main frame 186 using a first set of four hinged spacer arms, 192 , 194 , 196 , and 198 (not shown) and a first hinge 200 so that main wheel 70 can be rotated 90 degrees from a tilling position to a moving position. Main wheel 72 is connected to an opposite end of main frame 186 in a similar manner using a second set of four hinged spacer arms, 202 , 204 , 206 , and 208 (not shown) and a second hinge 210 so main wheel 72 can be rotated 90 degrees from a oiling position to a moving position.
[0058] I-shaped main frame 186 may include two T-shaped members, 212 and 214 , connected together using a main support beam 216 , which is inserted inside the T-shaped members and secured using conventional nuts and bolts, 218 , 220 , 222 , and 224 . Main frame 186 may include a series of holes 226 that can be used to secure the rolling brackets, 188 and 190 , in place along the main frame 186 .
[0059] Wheeled support assembly 18 may include hydraulic pistons, 228 and 230 , for raising and lowering the I-shaped main frame 186 . Piston 228 is connected between hinge 200 and t-shaped member 212 and piston 230 may be connected between hinge 210 and t-shaped member 214 . Wheeled support assembly 18 may also include hydraulic jacks, 232 and 234 , for driving coulter wheels, 236 and 238 , into the ground in order to prevent the system 10 from moving.
[0060] Rolling brackets 188 and 190 may be moved back and forth along main name 186 using rollers 240 and 242 .
[0061] Wheeled support assembly 18 may include highway wheels, 244 and 246 ( FIG. 11 ), connected to wheeled boom support section 100 using wheel support arms, 248 and 250 , and binges, 252 and 254 . These wheels can be rotated down into place when needed to move the wheeled support assembly 18 on a highway and then rotated back up so that they lay flat on top of wheeled boom support section 100 when not in use.
[0062] Referring to FIGS. 12-15 , rolling bracket 188 may include two bracket pieces, 256 and 258 , which are connected to main frame 186 using two u-clips 260 , and conventional nuts and bolts, 262 and 264 . Rolling bracket 188 may be connected to the main frame 186 and wheeled boom support section 100 by placing the bracket pieces on opposite sides of the support beam 216 and support section 100 , holding the two bracket pieces together using the two u-clips 260 , and then securing the two bracket pieces to the support section 216 and support section 100 using conventional nuts and bolts, 262 and 264 .
[0063] Carriage turning mechanism 168 ( FIGS. 16-24 ) may include turning frame pieces, 266 and 268 , return wheel 270 pivotally connected to frame piece 266 using a pivot arm 272 , a large turn wheel 274 rotatably connected directly to frame piece 268 , and small turn wheel 276 rotatably connected to frame piece 268 using L-shaped bracket 278 and support arm 280 . Pivot arm 272 may include stops, 282 and 284 , that prevent the pivot arm 272 from rotating in one direction, and a lift wheel 286 rotatably connected to the pivot arm 272 using bracket 288 . Carriage turning mechanisms 166 , 170 and 172 are constructed in a similar manner.
[0064] Frame pieces, 266 and 268 , may be connected to turn section 94 using hollow tubes, 290 and 292 , included as part of turn section 94 . Frame pieces (not shown) for carriage turning mechanisms 166 , 170 , and 172 are connected to turn sections 92 , 96 , and 98 in a similar manner.
[0065] Carriage 20 may include a main body 294 , a turntable 296 , having a main turn arm 298 and secondary turn arm 299 , rotatably connected to the main body 294 , and brackets 300 , which can be used to connect implement 24 to carriage 20 . Carriage 20 may include four (4) rollers 304 (two of which are shown in FIG. 18 ) connected to the main body 294 using roller brackets 306 . Booms 12 and 14 , including turn section 94 , may include roller tracks 308 that allow carriages 29 and 22 to rod back and forth along booms 12 and 14 . Carriage 20 is identical to carriage 22 .
[0066] FIGS. 25 a - d illustrates the operation of the return wheel 270 as carriage 22 moves past the carriage turning mechanism 168 . As shown in these figures, return wheel 270 pivots up out of the way as the carriage 22 moves through the carriage turning mechanism 168 and then fails back down into place after the carriage 22 has moved past the mechanism 168 .
[0067] Carriage 22 ( FIGS. 26-29 ) may include push wheels, 310 and 312 , and lift wheel tracks, 314 and 316 , connected on opposite sides of the main body 294 . When carriage 22 moves through the carriage turning mechanism 168 as shown in FIGS. 25 a - d , lift wheel 286 rolls up and over push wheel 310 and along lift wheel track 314 . A cable spool 318 may be roiatably connected to the main body 294 and used to adjust the length of cable 38 when the distance between booms 12 and 14 is increased or decreased.
[0068] FIGS. 30 a - m illustrate how carriage turning mechanism 168 rotates turntable 296 180 degrees as the carriage 22 is pulled past the turning mechanism 168 in one direction and then pulled past the turning mechanism 168 in the opposite direction. As shown in the figures, large turn wheel 274 pushes on turn arm 298 and initiates the rotation of the turntable 296 ( FIGS. 30 a - d ). Small turn wheel 276 then engages with secondary turn arm 299 and continues rotating the turntable 296 until the turntable 296 has been rotated 90 degrees with respect to its initial position ( FIGS. 30 e - g ). This completes the movement of carriage 22 past the turning mechanism 168 in the first direction. When the carriage 22 is then pulled back in the opposite direction, return wheel 270 , which cannot pivot in this direction, engages with the turntable as shown in FIG. 30 g and rotates the turntable 296 90 more degrees ( FIGS. 30 b - m ).
[0069] As shown in FIGS. 31-33 , end plate 74 may include a first ladder-like structure 320 connected to a second ladder-like structure 334 using a main elongated support beam 348 . First ladder-like structure may include a first pair of vertical support beams, 322 and 324 , a first set of horizontal cross beams, 326 , 328 , and 330 , connected at a top, middle, and lower portion of the first pair of vertical support beams, and a first hollow cross beam 332 connected to a bottom portion of the first pair of vertical support beams. Second ladder-like structure 334 may include a second pair of vertical support beams, 336 and 338 , a second set of horizontal cross beams, 340 , 342 , and 344 , connected at a top, middle, and lower portion of the second pair of vertical support beams, and a second hollow cross beam 346 connected to a bottom portion of the second pair of vertical support beams.
[0070] As shown in FIGS. 34-35 , power and hydraulics may be supplied to the system 10 using a conventional tractor 350 and a lift platform 352 . The lift platform 352 may be raised and lowered using a hydraulic lift 354 . Tractor 350 Includes a motor (not shown), a clutch system (not shown), a power take-off (not shown) for driving the cable drums, 32 and 34 , and hydraulics (not shown) for raising and lowering the wheeled support assemblies and turning the wheels connected to the wheeled support assemblies. The lift platform 352 may be connected to lift frame 116 ( FIG. 6 ) and move up and down with the booms 12 and 14 . Cable spools, 32 and 34 , may be connected to a 3-point hitch (not shown) and the power take off included with the tractor 350 . Hydraulic hoses (not shown) included with the system 10 may be connected to hydraulic connectors (not shown) included with the tractor 350 . Electrical connectors (not shown) included with system 10 may be connected to electrical connectors (not shown) included with the tractor 350 .
[0071] The above-described embodiments are merely possible examples of implementations set forth for a clear understanding of the principles of this disclosure. Many variations and modifications may be made to the above-described embodiments without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the accompanying claims.
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A field tillage system that reduces soil compaction, fuel consumption, and dust pollution includes a pair of wheeled support assemblies, a pair of booms connected to the wheeled support assemblies so that the booms can be moved up and down with respect to the wheeled support assemblies and in and out with respect to one another, a pair of carriages connected to the booms so that the carriages can be moved hack and forth along the booms, a set of implements connected to the carriages for tilling a field as the carriages move back and forth along the booms, and a drive system connected to the carriages for simultaneously moving the carriages and implements in opposite directions creating opposing forces thereby producing their own traction as they move along the booms.
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FIELD OF THE INVENTION
[0001] The invention relates to chromogenic media suitable for the selective growth and detection of one or more selected yeast species.
[0002] Preferably, the invention relates to methods suitable for the detection of yeast species of Brettanomyces/Dekkera and Zygosaccharomyces and for the determination of the cell count of said yeasts. The invention further relates to the use of said method in oenological and/or food industry processes and the media and kits necessary for performing the examination.
BACKGROUND OF THE INVENTION
[0003] The invention is suitable for the detection of the yeast species described herein from theoretically any kind of sample, preferably from a foodstuff, a food processing intermediate or a food raw material.
[0004] The selective detection and separation of yeast species having a role in beer and wine production that are in many cases detrimental, from wild yeast species is of particular significance.
[0005] Loureiro V and Malfeito-Ferreira M. [Spoilage yeasts in the wine industry. Int J Food Microbiol. 2003; 86(1-2):23-50.] give a detailed summary about microbiological problems caused by yeasts that are present in wine. The authors of the publication talk about methods that are presently known for detecting yeasts that cause deterioration in food, and analyze factors that help the colonization of yeasts on grapes and in wine.
[0006] Depreciation of wine that are originated in microbiological reasons cause a serious loss worldwide, affecting wine in premium categories, that are being matured in a wood barrel, even harder.
[0007] As this problem has a huge economic significance, procedures that recognize the presence and multiplication of harmful microorganisms on time are extremely important. With the help of these, the infestation can be prevented, or the intervention to lower the extent of deterioration can be done targetedly.
[0008] The majority of microorganisms that have a role in the creation of wine get into the process from the grapes or the wine-making equipment.
[0009] The species composition and the number of cells of the microflora change depending on the circumstances, the number of bacteria is infinitesimal, yeasts dominate. Among the yeasts, apart from the cultured (noble) strain of Saccharomyces there are many wild yeasts present, that dominate the fermenting medium for a long time. Among the wild yeasts, the genera of Brettanomyces/Dekkera and the Zygosaccharomyces tolerate high level of alcohol concentration relatively well and are resistant of the usual wine making procedures, therefore if they proliferate during the maturation of the wine it can cause the deterioration of it.
[0010] The genera of Zygosaccharomyces , especially the Zygosaccharomyces bailii can generate undesirable secondary fermentation and the formation of an adverse aroma in wines with residual sugar content, but at the same time they have a very important role in commencing the fermentation of high sugar content must and in fermenting must with inappropriate glucose: fructose proportion.
[0011] There is an adverse phenol-like character (the so called “brettyness”) that is caused by the metaboism byproduct of the species of Brettanomyces (mainly the B. bruxellensis ) particularly during the production of red wine and as a consequence there is a significant decrease in quality and price. These non desirable components of flavor were described by sensory evaluations as “disinfectant”, “bretty”, “leather”, “wet dog”, “rancid”, “sweaty horse”, “ordure”, “stall” and “animal character”. The compounds arisen by the influence of Brettanomyces , in small quantities can contribute to the complexity of the wine (mild animality), however, above a certain number of cells the presence of the Brettanomyce is non-desirable. Their proliferation at an early stage of maturation can be prevented with carbon monoxide treatment, to which these yeasts are relatively sensitive. Although the sulphurization itself can influence the smell of the wine in a disadvantageous way and suppress the development, therefore the treatment has to be targeted. The condition of targeted intervention is the early identification of the presence of Brettanomyces in the maturing wine, when the number of these microorganisms and the concentration of their metabolism products are still low.
[0012] For this, we can use a number of analytical methods (ELISA, molecular biology methods, flow cytometry, culturing, chromatography methods), but most of them require special equipment and knowledge, furthermore they are very time consuming and sumptous, because in the medium there are a large number of other microorganisms that makes demonstrability very difficult.
[0013] For example, Cocolin and his co-workers [Molecular Detection and Identification of Br ettanomyces/Dekkera bruxellensis and Brettanomyces/Dekkera anomalus in Spoiled Wines. Appl Environ Microbiol. 2004; 70(3): 1347-1355.] created a PRC-RFLP test for the identification of Brettanomyces bruxellensis and Brettanomyces anomalus . The key of their method is that different patterns for the two species are obtained, when a DNA fragment that was propagated during the PCR reaction is digested with restriction enzyme. The method is highly sensitive, and is suitable for detecting and separating two Brettanomyce species, however, it requires special lab equipment and it is relatively costly.
[0014] Phister and Mills Meal-Time PCR Assay for Detection and Enumeration of Dekkera bruxellensis in Wine. Applied and Environmental Microbiology. 2003; 69(147430-74341 used the RT-PCR method for identifying the Dekkera ( Brettanomyces ) bruxellensis in wine. The method is very sensitive (it is able to make a detection in a concentration of 1 cell/ml) and selective, but it is even more expensive than the traditional PCR, the equipment costs are also high and its use requires appropriately qualified personnel.
[0015] Stender and his colleagues [Identification of Dekkera bruxellensis ( Brerranomyces ) from wine by fluorescence in situ hybridization using peptide nucleic acid probes. Appl. Environ. Microbiol. 67:938-941 (2001)] detected Dekkera ( Brettanomyces ) bruxellensis from wine, Connell and his colleagues [Rapid Detection and Identification of Brettanomyces from Winery Air Samples Based on Peptide Nucleic Acid Analysis. Am. J . Enol. Vitic. 2002; 53(4): 322-24] detected Brettanomyces strains from the air of cellars with chemiluminescence in situ hybridization method (with the application of peptide nucleic acid probe). The method is highly sensitive, but is based on culturing, therefore it is time consuming and requires qualified workers, additionally, the cost of the tests are significant.
[0016] Mitrakul and his colleagues [Discrimination of Brettanomyces/Dekkera yeast isolates from wine by using various DNA fingerprinting methods. Food Microbiol. 1999 16 3-14.] used the RAPD-PCR method for the identification of Brettanomyces/Dekkera strains. This method is suitable for species and strain identification, but its condition is having a special instrument (PCR). The authors used it in combination with other identification methods, which were based on culturing and physiological tests, therefore the assay also became time consuming.
[0017] Ibeas and his colleagues [Detection of Dekkera - Brettanomyces Strains in Sherry by a Nested PCR Method. Appl. Environ. Microbiol. 1996 , 62(3) 998-1003] identified Brettanomyces/Dekkera strains in sherry, with “nested” PCR. This method is highly sensitive, it does not require growing the strains, therefore it gives a quick, reliable result in 10 hours. Although it requires special equipment, and remains of sherry in the sample block the reaction, thus we can get a false result.
[0018] The Oeno Yeast Kit (Partec) identification is a fluorescent detection method, based on flow cytometry, that detects metabolically active yeast cells. Similarly to other cytometric procedures, this method is not specific to Brettanomyces/Dekkera species , therefore it can only be used in wine samples that are in the phase of maturing, when the presence of other yeasts are not probable. The test is expensive and needs special instruments.
[0019] To sum up, the advantage of molecular methods are selectivity and quickness, the advantage of instrumental methods are accuracy and quickness. Their disadvantage is that they require special and expensive instruments, the reaction is quite costly and the implementation and evaluation require qualified personnel. The common disadvantage of procedures of molecular biology is that if they identify one or two species, other species that can trigger deterioration of wine and food stay hidden.
[0020] The solution to this problem is using a medium, that is selective to the species of Brettanomyces/Dekkera and/or Zygosaccharomyces . The significant benefit of this medium is that using it does not require special equipment, neither microbiologist, nor analytical qualifications, and the examination can be carried out and evaluated in a wine cellar by an oenologist. A disadvantage of this technique that the selectivity of the medium is limited, therefore other microorganisms, e.g. colonies of wild yeast might appear (false positive result).
[0021] Renouf V. and Lonvaud-Funel A. [Development of an enrichment medium to detect Dekkera/Brettanomyces bruxellensis, a spoilage wine yeast, on the surface of grape berries. Microbiol Res. 2007; 162(2):154-67.] created a selective medium and with that, the species of Dekkera/Brettanomyces can be enriched, thus the procedure of indentification can be made sensitive.
[0022] Barata A. and his colleagues [Ascomycetous yeast species recovered from grapes damaged by honeydew and sour rot. Journal of Applied Microbiology, 2008 104(4) 1182-1191.] rose the alcohol content and used cycloheximide only as a source of carbon, thus assuring that their medium is selective for species of Dekkera/Brettanomyces.
[0023] Schuller D. and his colleagues C. [A differential medium for the enumeration of the spoilage yeast Zygosaccharomyces bailii in wine. J Food Prot. 2000 63(11):1570-5.] created a medium that serves the selective culturing of Zygosaccharomyces bailii . With the proper adjustment of the concentration of formic acid and glucose they made the medium so selective, that only the Z. bailii caused a pH drift to alkaline direction, which resulted in a change of colour of the medium.
[0024] The aim of Hocking A D. [Media for preservative resistant yeasts: a collaborative study. Int J Food Microbiol. 1996 29(2-3):167-75] was creating a medium that is most suitable for identifying yeast that is resistant to preservatives in food. According to the publication, they authors examined 5 media, from which 3 were selective. Two out of 3 were made selective by adding acetic acid, while the third medium was a ZBM ( Zygosaccharomyces bailii ) medium, which contained tripan blue paint. When comparing the efficacy of the media, the ZBM medium appeared to be adequetly selective for Z. bailii , however, it was less suitable for counting because its growing inhibition effect.
[0025] By applying the above mentioned methods, media can be made selective for growing yeasts. An additional task is to identify the given yeast species, which in case of wild yeast is often done by scent sample, by adding a compound to the medium, e.g. p-coumaric acid, which transforms the yeast to a distinctive smelling compound.
[0026] Couto J. A. and his colleagues [A simple cultural method for the presumptive detection of the yeasts Brettanomyces/Dekkera in wines. Left Appl Microbiol. 2005 41(6):505-10.] presents an easy and reliable method in their publication for identifying the Brettanomyces/Dekkera yeasts. The base of their method is utilizing selective medium, which contains glucose, cycloheximide, chloramphenicol and p-coumaric acid. The presence of yeasts are evaluated by turbidity and scent.
[0027] Rodrigues N, and his colleagues [Development and use of a new medium to detect yeasts of the genera Dekkera/Brettanomyces . J Appl Microbiol. 2001 90(4):588-99.] developed a selective medium as well, for identifying species of Dekkera/Brettanomyces in an environment connected to wine making. They ensured the selectiveness of the medium by adding ethanol and cycloheximide. They proved the identification of acid producing strains by adding bromocresol green. Adding p-coumaric acid ensured the identification of Dekkera/Brettanomyces strains based on scent samples.
[0028] During the method applied by Lebrun Labs (Easy Blue Brettanomyces Test Kit), the selective medium that blocks the growth of most yeasts discolours from the effect of acids produced by microbes (pH change). Furthermore, the Dekkera/Brettanomyces colonies produce a distinctive smelling, volatile compound from the p-coumaric acid in the medium, whose perception happens by smelling it, so it requires experience and/or a comparative scent sample. Although this method does not require qualification or special instruments, it has its disadvantages: the medium is not absolute selective, which can lead to false positive results.
[0029] During the supplementary usage of p-coumaric acid, the metabolite it formulates [4-ethylfenol (4-EP), 4-ethylguaiacol (4-EG), isovaleric acid] has a smell that is typical of Brettanomyces/Dekkera yeasts, whose identification requires experience and/or scent sample. Taking a scent sample means opening the Petri dish again and again, which become a potential source of infection themselves.
[0030] Therefore, according to the technical knowledge, there were proposals for solutions, where the mentioned species of wild yeast were identified in a chromogenic medium, based on a reaction that was accompanied by discolouration.
[0031] Loureiro V, Malfeito-Ferreira M. [“Spoilage yeasts in the wine industry.” Int J Food Microbiol. 2003 86(1-2):23-50.] have a detailed, in-depth summary where they discuss the colony of yeasts on grapes and in wines, as well as mentioning the industrial identification techniques. They present the components that must be found in general media that are for identifying yeasts, and in relation to these they mention indicators that are used in these media: bromocresol green and bromphenol blue.
[0032] In the international publication no. WO0073494 (A1) Leao Cecilia and her colleagues describe media that are eligible for identifying species of Zygosaccharomyces , such as Zygosaccharomyces bailii and Zygosaccharomyces bisporus , from wine and other food. The medium is made of a general mineral medium, that is supplemented with vitamins and trace elements, glucose and formic acid as sources of carbon, acid base indicator and optionally with antibiotics. Here, the indicator is mostly bromocresol green.
[0033] On the blue selective medium, distributed by Millipore, we experience the discolouration around the Brettanomyces colonies, due to the acid they produce.
[0034] The solution (inventors: Loureiro Virgilio Borges and colleagues. “Culture medium for detection of Dekkera and Brettanomyces ”) that was disclosed in the patent application, published under the number of EP1185686(A1) (it corresponds to the international publication no. WO2000073495A1), relates to a method and use of a general medium for identifying Dekkera and Brettanomyces yeasts, and determining their cell counts. According to the method, the following are added to the medium: nutrients; nonfermentable energy source, mainly ethanol; p-coumaric acid; acid base indicator, mainly bromocresol green; cycloheximide for blocking the growth of yeasts and antibiotics for blocking the growth of bacteria, chloramphenicol or oxytetracycline. The medium shows a distinctive discolouration as an effect of cultured (noble) colonies of Dekkera and Brettanomyces strains. The degree of discolouration changes depending on the growth pattern as an effect of decreasing pH. Furthermore, during culturing a distinctive, phenollike aroma develops after a few days of incubation, which is easy to identify. The invention can be applied well in food industry.
[0035] In publication No. ES2268970(A1) Velazquez P. E. et al (“Yeasts detection culture medium comprises glucose mixed with buffer microorganism and bacterial growth inhibitors and e.g. a nitrogen source”) a medium suitable for the detection of yeasts has been taught, where the medium comprises glucose as carbon source, a calcium carbonate buffer, active agents capable of inhibiting the growth of different microorganisms and bacteria, nitrogen sources and a pH indicator which is actually neutral red. The medium is capable of detecting the Brettanomyces/Dekkera bruxellensis in foods and drinks. The identification is based on the acetic acid odour of the medium and on the appearance of transparent lines around the Dekkera/Brettanomyces yeast colonies present in the medium.
[0036] The Japanese patent application JP56106588 discloses a method for the production of a biological culture medium which contains methoxylated pectin and which is formed by admixing lactose (5 g), eosine Y (0.5 g), methylene blue (0.065 g), low methoxylated pectin (25 g) and deionized water (1 l) in the presence of agar-agar. The resulted mixture is sterilized, its pH is adjusted to 7.1 with sodium phosphate, and in a Petri dish a gel is poured from the resulted mixture. The culture medium is used for culturing yeasts, bacteria, microorganisms and fungi. The inventors do not have any knowledge about whether the medium is suitable for detecting yeast species, particularly Dekkera/Brettanomyces yeast colonies on the basis of colour change.
[0037] The above mentioned methods, that are based on culturing, can be conducted with minimal previous experience and they are cheap. In the case of the present methods, the identification is based mostly on the colour change of the indicator, for example, the organic acids produced by the Brettanomyces cause the acidification of the pH of the medium and thus the change of colour of the indicator. The selectivity of the methods were usually limited, therefore they were unable to distinguish certain wild yeasts from one another. The object of the invention is aimed to develop a medium and a selective culturing method which is more reliable and more easily estimable than previous ones and by the application of which, specific yeast colonies can be visually identified and unambiguously distinguished and separated from other microorganisms able to grow on the medium and which are relatively less problematic in the aspect of oenology.
SHORT DESCRIPTION OF THE INVENTION
[0038] The invention is based on the finding that the different metabolites of yeasts cause differentiated changes of colour of certain staines, i. e. different groups of yeasts cause different colour reactions in the medium of the invention and are thereby selectively detectable.
[0000] The invention relates to a chromogenic and preferably selective medium suitable for the detection and growth of one or more yeast(s), optionally of harmful (detrimental) yeast, comprising
a nutrient suitable for the feeding and/or growing of yeast, including at least or preferably the one or more yeast species to be detected, an agent capable of inhibiting the growth of other microorganisms, preferably of other yeasts, more preferably of Saccharomyces species, preferably in a concentration capable of inhibiting said growth, and a chromogenic stain, wherein the chromogenic stain is the combination of the following dyes, said combination being chromatic in visible light:
one or more types of substituted and/or unsubstituted bis-3,7 diaminophenothiazines, and one or more types of substituted fluoresceins.
[0044] Preferably, the bis-3,7 diaminophenothiazine dye of formula I in the medium of the invention has the chemical structure
[0000]
[0045] wherein
[0046] R1, R2, R3 and R4 are independently H, methyl or ethyl, preferably H or methyl,
[0047] Q1, Q2, Q3 and Q4 are independently H, C1-4 alkyl, halogen, pseudohalogen, —NO or —NO 2 , preferably H, methyl or ethyl, most preferably H,
[0048] or the soluble salt thereof, and
[0049] the chemical structure of the substituted fluorescein dye of formula II is
[0000]
[0050] wherein
[0051] R1, R2, R3 and R4 are independently halogen, pseudohalogen, —NO or —NO 2 ,
[0052] Q1 and Q2 are H, C1-4 alkyl, C1-4 alkoxy, halogen, pseudohalogen, —NO vagy —NO 2 , 5- or 6-member heterocycle or Q1 and Q2 together form a 5- or 6-member heterocycle, in which case Q1 and Q2 are situated on adjacent C atoms,
[0053] or the soluble salt thereof.
[0054] Preferably, the substituted or unsubstituted bis-3,7 diaminophenothiazine is selected from the group consisting of: methylene blue, methylene violet, azure stains, such as Azure A, Azure B and any mixtures thereof. Preferably, the medium of the invention contains at least two substituted or unsubstituted bis-3,7 diaminophenothiazine compounds selected from the group consisting of: methylene blue, methylene violet, Azure A, Azure B, most preferably selected from methylene blue, Azure B, Azure A, Azure C, thionine.
[0055] Preferably, the substituted fluorescein is selected from the group consisting of: Eosin Y, Eosin B and any mixtures thereof. Preferably, the substituted fluorescein is Eosin Y.
[0056] Preferably, the chromogenic stain comprises at least two types of bis-3,7 diaminophenothiazines having different degrees of methylation, preferably the mixture of methylene blue and Azure B. In a preferred embodiment the bis-3,7 diaminophenothiazines of two different degrees of methylation (e.g. two of methylene blue, Azure B, Azure A, Azure C, thionine defined herebelow, particularly methylene blue and Azure B) have molar amounts that are at most 50% or 30%, preferably at most 20% or 10% different relative to the component that is present in smaller amount. Most preferably, the chromogenic stain is a mixture of methylene blue and Azure B in a ratio of essentially 1:1 and of Eosin Y (Azure II eosinate).
[0057] Most preferably, the chromogenic stain is a mixture of the substituted or unsubstituted bis-3,7 diaminophenothiazine and the substituted fluorescein, preferably in a ratio of from 1.5:1 to 1:1. Most preferably, the substituted or unsubstituted bis-3,7 diaminophenothiazine is a mixture of methylene blue and Azure B, preferably in a ratio of essentially 1:1. More preferably, the chromogenic stain in the selective and chromogenic medium is Azure II eosinate.
[0058] In a preferred embodiment, the molar amounts of the at least one type of substituted or unsubstituted bis-3,7 diaminophenothiazine dye and the at least one type of substituted fluorescein dye are at most 50% or 30%, preferably 20% or 10% different relative to the amount of the component that is present in smaller amount.
[0059] Most preferably, the culture medium of the invention comprises multiple types of substituted or unsubstituted bis-3,7 diaminophenothiazine dyes, wherein R1, R2, R3 and R4 in general formula I are H, methyl or ethyl, preferably H or methyl so that the substituents R1, R2, R3 és R4 are different in the different dyes. Most preferably, the 3,7 diaminophenothiazine dye of the invention is a mixture of compounds with different degrees of methylation. Most preferably, R1, R2, R3 and R4 are H or methyl, and the bis-3,7 diaminophenothiazine component dyes are different in the degree of methylation.
[0000] Accordingly and preferably, methylene blue and the demethylated intermediers thereof or the mixture thereof may also be used in the stain, selected from:
a 3,7-bis(dimethylamino)-phenothiazin-5-ium salt, preferably acetate or chloride (methylene blue),
a N-methyl,N′,N′-dimethylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure B),
a N′,N′-dimethylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure A: CAS 531 533),
a N-methylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure C),
a Phenotiazin-5-ium-3,7-diamine salt, preferably chloride or acetate (thionine).
[0060] Most preferably, the stain comprises a mixture of Azure B and methylene blue.
Preferably, the invention relates to a chromogenic and preferably selective medium suitable for the selective growth and detection of one or more yeast(s) selected from:
a yeast species of the Brettanomyces and/or Dekkera genera, a yeast species of the Zygosaccharomyces genus, a yeast species of the Lachancea genus, preferably at least a yeast species of the Brettanomyces and/or Dekkera genera, and comprising a nutrient suitable for the nutrition and/or growth of yeasts including at least or preferably the one or more yeast species to be detected, an agent capable of inhibiting the growth of other microorganisms, preferably of other yeasts, more preferably of Saccharomyces species, preferably in a concentration capable of inhibiting said growth, and a chromogenic stain, wherein the chromogenic stain is the combination of the following dyes, said combination being chromatic in visible light: one or more types, preferably at least two types, preferably two types of substituted and/or unsubstituted bis-3,7 diaminophenothiazines selected from:
a 3,7-bis(dimethylamino)-phenothiazin-5-ium salt, preferably acetate or chloride (methylene blue), a N-methyl,N′,N′-dimethylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure B), a N′,N′-dimethylphenothiazin-5-ium-3,7-diamin salt, preferably acetate or chloride (Azure A), a N-methylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure C), a Phenotiazin-5-ium-3,7-diamine salt, preferably chloride or acetate (thionine), and
one or more types of substituted fluoresceins selected from: eosin dyes, prefereably Eosin B and Eosin Y.
[0076] In a preferred embodiment the selective and chromogenic medium comprises a gelling agent and is formulated as:
[0077] solid powder, gelled culture medium and preferably the medium is in a pre-prepared, ready to use form, preferably in solid and/or gel form, most preferably being pre-poured on plates.
[0078] Most preferably, the agent inhibiting the growth of Saccharomyces species is a chemotherapeutic agent or an antibiotic, preferably cycloheximide
[0079] According to a further aspect, the invention relates to the use of the chromogenic medium of the invention for the detection or qualitative or quantitative determination of one or more yeast(s) from a foodstuff, a food processing intermediate, and/or a food raw material, preferably an agricultural product, the yeast selected from: a yeast of the Brettanomyces and/or Dekkera genera, a yeast of the Zygosaccharomyces genus and/or a yeast of the Lachancea genus.
[0080] In a preferred embodiment a yeast of the Brettanomyces and/or Dekkera genera is detected, said yeast is preferably selected from the group consisting of Brettanomyces bruxellensis, Brettanomyces anomalus, Brettanomyces custersianus, Brettanomyces naardenensis , and Brettanomyces maims.
[0081] In a preferred embodiment a yeast species of the Zygosaccharomyces genus is detected, wherein said yeast is preferably Zygosaccharomyces bailii.
[0082] In a preferred embodiment a yeast species of the Lachancea genus is detected, wherein said yeast is preferably Lachancea fermentatii.
[0083] Preferably, the invention relates to the use of the following chromogenic and selective medium for the detection or qualitative or quantitative determination of one or more yeast(s) from a foodstuff, a food processing intermediate, and/or a food raw material, wherein the foodstuff is preferably a foodstuff prepared by fermentation, particularly wine, said yeast being selected from a yeast of the Brettanomyces and/or Dekkera genera, a yeast of the Zygosaccharomyces genus and/or a yeast of the Lachancea genus, preferably at least a yeast of the Brettanomyces and/or Dekkera genera,
[0084] wherein the medium that is chromogenic and selective is suitable for the selective growth and detection of said one or more yeast(s),
[0085] and said medium contains
a nutrient suitable for the nutrition and/or growth of yeasts including at least or preferably the one or more yeast species to be detected, an agent capable of inhibiting the growth of other microorganisms, preferably of other yeasts, more preferably of Saccharomyces species, preferably in a concentration capable of inhibiting said growth, and a chromogenic stain, wherein the chromogenic stain is the combination of the following dyes said combination being chromatic in visible light: one or more type(s), preferably at least two types, preferably two types of substituted and/or unsubstituted bis-3,7 diaminophenothiazines selected from:
a 3,7-bis(dimethylamino)-phenothiazin-5-ium salt, preferably acetate or chloride (methylene blue), a N-methyl,N′,N′-dimethylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure B), a N′,N′-dimethylphenothiazin-5-ium-3,7-diamin salt, preferably acetate or chloride (Azure A), a N-methylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure C), a Phenotiazin-5-ium-3,7-diamine salt, preferably chloride or acetate (thionine), and
one or more type(s) of substituted fluoresceins selected from: eosine dyes, prefereably Eosin B and Eosin Y.
[0096] In the use according to the invention
preferably, when the colony is pink and/or strongly fuorescent under UV light, it is considered to be the detection of a yeast species or multiple yeast species of the Brettanomyces and/or Dekkera genera, preferably, when the colony is blue and optionally faintly fuorescent under UV light, it is considered to be the detection of a yeast species of the Zygosaccharomyces genus, preferably Zygosaccharomyces bailii, preferably, when the colony is greenish blue with a pink edge and/or is faintly fluorescent under UV light with the edge strongly fluorescent under UV light, it is considered to be the detection of a yeast species of the Lachancea genus, preferably Lachancea fermentatii.
[0100] Preferably, the foodstuff prepared by fermentation according to the invention is preferably wine or beer, particularly preferably red wine.
[0101] According to a further aspect, the invention relates to a method for the detection or qualitative or quantitative determination of one or more yeast(s) selected from the group below, from a foodstuff, a food processing intermediate, and/or a food raw material, the method comprising the following steps:
providing the medium of the invention, in particular a medium selected from the media defined supra, obtaining a sample from a foodstuff, a food processing intermediate and/or a raw food material, wherein the foodstuff is preferably a foodstuff prepared by fermentation, particularly wine, preparing the sample to add to the medium, optionally filtering and/or concentrating and/or enriching the sample in microorganisms, plating the sample or suitable part thereof on the medium, incubating the medium under conditions suitable for the culturing of the yeast species, until colonies are obtained, detecting the yeast species by the discolouration of said colonies.
[0108] Preferably, said yeast is a yeast of the Brettanomyces and/or Dekkera genera.
[0109] Preferably, said yeast is a yeast or yeast species of the Zygosaccharomyces genus.
[0110] Preferably, said yeast is a yeast or yeast species of the Lachancea genus.
[0111] Preferably, when the colony is pink and strongly fluorescent under UV light, it is considered to be the detection of a yeast or multiple yeast species of the Brettanomyces and/or Dekkera genera.
[0112] Preferably, when the colony is blue and optionally faintly fluorescent under UV light, it is considered to be the detection of a yeast species of the Zygosaccharomyces genus, preferably Zygosaccharomyces bailii.
[0113] Preferably, when the colony is greenish blue with a pink edge and/or is faintly fluorescent under UV light with the edge strongly fluorescent under UV light, it is considered to be the detection of a yeast species of the Lachancea genus, preferably Lachancea fermentatii.
[0114] According to a preferred embodiment, the number of the colonies is provided relative to the amount of the original sample, preferably the volume or weight thereof, and therefore the method is quantitative.
[0115] Most preferably, the colonies and preferably the number of the colonies are evaluated under UV light, based on fluorescence.
[0116] In a preferred embodiment the foodstuff is a foodstuff prepared by fermentation, preferably
beer or wine, preferably red wine, the food processing intermediate is malt, must, fermenting malt or must, and/or the food raw material is grape.
[0120] According to a preferred embodiment, the culture medium suitable for the culturing of said yeast is provided in a pre-prepared, ready to use form, preferably in solid or gel form, most preferably being pre-poured on plates.
[0121] According to a further aspect, the invention relates to a reagent kit for use in the method of the invention, containing the medium of the invention and means of preparing a gel culture medium thereof.
DEFINITIONS
[0122] In accordance with the taxonomical classification of Brettanomyces/Dekkera genus, first the anamorph (asexually reproducing) forms were identified and such forms were subsequently classified into the Brettanomyces genus. Later, the presences of sexually reproducing forms were also observed in certain species, which were classified into the Dekkera genus. The following species were identified as anamorph species: Brettanomyces bruxellensis, Brettanomyces anomalus, Brettanomyces custersianus, Brettanomyces naardenensis , and Brettanomyces nanus , while telemorph character was established with regard to two species: Dekkera bruxellensis and Dekkera anomala . However, later, it was verified by DNA tests that these two are identical with Brettanomyces bruxellensis and Brettanomyces anomalus , which actually represent their telemorph variations. Accordingly, in the description the professionally accepted “ Brettanomyces/Dekkera ” term is used, which generally includes any yeasts that are identified or taxonomically classified as members of these genus.
[0123] The Brettanomyces/Dekkera genus includes B. anomalus, B. bruxellensis, B. claussenii, B. custersianus, B. lambicus, B. naardenensis and B. nanus species.
[0124] In the description “medium” refers to any nutrient containing media suitable for feeding and growing yeast species and which can be prepared in solid, e.g. gel, form. The term “culture medium” refers to a medium which is solid, e.g. gel-like, and microorganisms are applied on the surface of culture medium.
[0125] “Yeasts” constitute a group of fungi which are eukaryote species having nucleus, generally one-celled, although under certain conditions some of their species are capable of forming pseudo or real mycelium. They reproduce via budding or via fission. Although in a broad sense, these species do not constitute a single phylogenetic category, they can generally be classified into two phyla (divisions), the Ascomycetes and the Basidiomycetes.
[0126] Preferably, one or more yeasts that can be detected according to the invention belong to the yeasts of the Ascomycota phylum, more preferably of the Saccharomycotina subphylum, more preferably of the Saccharomycetes class, highly preferably of the Saccharomycetaceae family.
[0127] The term “yeast” refers to yeast, yeast type or yeast category defined in a specific manner, preferably, to yeast that belongs to a definite taxonomical unit, particularly preferably to a definite genus or species.
[0128] In the description the term “yeast species” means any yeast known to have an expressly beneficial effect on the given fermentation process and which is appropriately characterized. Preferably, noble yeast is an established strain of a given yeast species. The term “harmful yeast species” or “harmful yeast” means any yeast, the presence of which or the presence of which above a given amount or concentration has a detrimental effect on the production of a given product prepared by fermentation.
[0129] “Product prepared by fermentation” means any product, preferably food products, for the preparation of which a yeast effect, preferably the conversion of carbohydrates to alcohol and carbon dioxide by the yeast, is necessary. Preferably, the product prepared by fermentation contains alcohol, i.e. is an alcoholic beverage, preferably beer or wine, highly preferably wine, more preferably red wine.
[0130] The word “contains” is no exclusionary in its meaning and allows for the addition or involvement of other properties or procedural steps to the content of the already listed properties or procedural steps.
[0131] In the context of the description the word “contains” can be limited to the expressions “it basically contains” and/or “in fact, it contains” which should be interpreted as “it contains” prescribed properties or prescribed procedural steps or components which are specified in some list, e.g. within the scope of the patient claim but in addition to these the presence of further properties, procedural steps, or components fundamentally not affecting any other objects described in the invention are also allowed.
[0132] The word “one” used in some of the definitions in the description and where the context so permits article “a” importing the singular can be deemed to carry the meaning of plural unless otherwise required by the context, unless, for example, the usage of “one” unambiguously refers to “one” as a numeral.
DESCRIPTION OF THE FIGURES
[0133] FIG. 1 : Identification of wild yeasts along winemaking (noble) yeasts on selective medium
[0134] The patterns assigned to sequence numbers are the following:
[0000] 1: Dekkera bruxellensis CBS 73; 2: Pichia membranifaciens var. membranifaciens CBS 191; 3: Zygosaccharomyces bailii var. bailii CBS 4688; 4: Zygosaccharomyces bailii var. bailii CBS 4689; 5: Zygosaccharomyces mellis CBS 684; 6: Zygosaccharomyces rouxii CBS 441; 7: Lachancea fermentati CBS 707; 8: Issatchekia orientalis CBS 6799; 9: Brettanomyces custersianus CBS 4805; 10: Saccharomyces cerevisiae T-158C; 11: Saccharomyces cerevisiae S6; 12: Schizosaccharomyces pombe
[0135] FIG. 2 : colonies of Brettanomyces from a vinous media, on a selective, coloured medium
DETAILED DESCRIPTION OF THE INVENTION
[0136] The present inventors unexpectedly found during the creation of the invention that if azure-II-eosinate or other chromogenic paint that contains chemically similarly structured molecules is added to a selective medium—which is suitable for growing yeast, but blocking the growth of Saccharomyces —then in the medium we get, we can identify Brettanomyces species among the appearing colonies, with the help of azure-II-eosinate.
[0137] Quite surprisingly, the present inventors observed the following:
[0000] 1. On this medium, the Brettanomyces colonies are painted pink, which are visible for the eyes
2. The pink colonies are fluorescent in ultraviolet light, which confirms the separation of the species.
[0138] With the help of this method, the Brettanomyces/Dekkera colonies can be easily distinguished from other wild yeasts that are able to grow on a selective medium, by looking at them. The identification that is based on visibility, not only makes the identification process much easier, but it also does not require experience and scent samples, furthermore, it makes scenting samples unnecessary, which bears the possibility of spreading the infection. The reason why it is more specific to Brettanomyces/Dekkera species than other methods, is that it is able to identify other yeast species that are not winemaking (noble) yeasts, which (only) causes a problem in case of sweet wines with a higher residue of sugar.
[0139] We have also run the experiments using different azure and eosin dyes. All of the stains'colours changed with the increase of pH. Yet, these stains did not provide the previously experienced colour reaction and were not appropriate to distinguish the species of Brettanomyces/Dekkera from other, examined yeasts.
[0140] According to the invention, for getting the desired results, we need substituted or unsubstituted bis3,7-diamino-phenothiazines together with the substituted derivatives of fluorescein.
[0141] There was a medium stain that was known before with the same components, eosin and methylene blue, but it was not used for identifying yeast contamination. For example, the United Kingdom publication no. GB1248197 [ABBOTT LAB (US), “Diagnostic method and apparatus for the detection of bacteria”] discloses an eosin methylene blue agar medium that contains lactose, however, identifying the yeasts in the reference are not based on eosin methylene blue medium. For our understanding, previously they used the azure-II-eosin for other purposes, mainly for colouring tissue samples.
[0142] According to the Japanese disclosure document no. JP56106588A they used eosin-Y (0.5 g, 7.23×10 −4 mol) and methylene blue (0.065 g, 2.03×10 −4 mol) in one medium only, however, the document does not provide any information about the different discolouration of the medium and/or the colonies as a result of growing different types of yeasts.
[0143] The chromogenic stain to be used according to the invention is therefore the combination of at least one type of substituted or unsubstituted bis-3,7 diaminophenothiazine stain and at least one type of substituted fluorescein stain. Preferably, the combination of the substituted or unsubstituted bis-3,7 diaminophenothiazine stain of formula I herebelow and the substituted fluorescein stain of formula II herebelow.
[0144] The chemical structure of the bis-3,7 diaminophenothiazine stain of formula I is
[0000]
[0145] wherein
[0146] R1, R2, R3 and R4 are independently H, methyl or ethyl, preferably H or methyl,
[0147] Q1, Q2, Q3 and Q4 are independently H, C1-4 alkyl, halogen, pseudohalogen, —NO or —NO 2 , preferably H, methyl or ethyl, preferably H or methyl, most preferably H.
[0148] Preferably, the bis-3,7 diaminophenothiazine stain of formula I is present in a cationic form, such as a salt formed with an anion. The anion is preferably a halide ion, most preferably chloride ion. According to a variation, the anion is formed by the substituted fluorescent stain of formula II.
[0149] The chemical structure of the substituted fluorescent stain of formula II is
[0000]
[0150] wherein R1, R2, R3 és R4 are independently halogen, pseudohalogen, —NO or —NO 2 ,
[0151] Q1 and Q2 are H, C1-4 alkyl, C1-4 alkoxy, halogen, pseudohalogen, —NO or —NO 2 , 5- or 6-member heterocycle or Q1 and Q2 together form a 5- or 6-member heterocycle, in which case Q1 and Q2 are situated on adjacent C atoms.
[0152] Preferably, R1 and R4 are halogen, more preferably Br or —NO 2 .
[0153] Preferably, R2 and R3 are halogen, more preferably Br.
[0154] Preferably, Q1′ is H, methyl or halogen and Q2 is H.
[0155] Preferably, the substituted fluorescein stain of formula II is used in an anionic form, preferably in the form of a salt formed with a cation. Preferably, the cation is sodium ion, potassium ion or ammonium ion. According to a further preferred variation, the cation is formed by the bis-3,7 diaminophenothiazine stain of formula I.
[0156] Preferably, the chromogenic medium of the invention comprises the at least one type of substituted or unsubstituted bis-3,7 diaminophenothiazine stain and the at least one type of substituted fluorescein stain in essentially identical molar amounts, i. e. the amount of the at least one type of substituted or unsubstituted bis-3,7 diaminophenothiazine stain and the amount of the at least one type of substituted fluorescein stain in the culture medium are at most 50% or 30%, preferably at most 20% or 10% different relative to the component that is present in smaller amount, that is, the ratio of the molar amounts is from 1.5:1 to 1:1 or from 1.3:1 to 1:1, preferably from 1.2:1 to 1:1 or from 1.1:1 to 1:1, most preferably the rate of the molar amounts is 1:1 or vice versa.
[0157] Most preferably, the culture medium of the invention contains multiple types of substituted or unsubstituted bis-3,7 aminophenothiazine stains, in the general formula I of which R1, R2, R3 and R4 are H, methyl or ethyl so as that the substituents R1, R2, R3 and R4 are different in the different stains (R1, R2, R3 and R4 may not be identical). Most preferably, R1, R2, R3 and R4 are H or methyl and the bis-3,7 diaminophenothiazine component stains are different in the degrees of methylation.
[0158] Accordingly and preferably, methylene blue and the demethylated intermediers thereof or the mixture thereof may be used in the stain, selected from
[0000] a 3,7-bis(dimethylamino)-phenothiazin-5-ium salt, preferably acetate or chloride (methylene blue),
a N-methyl,N′,N′-dimethylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure B),
a N′,N′-dimethylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure A: CAS 531 533)
a N-methylphenothiazin-5-ium-3,7-diamine salt, preferably acetate or chloride (Azure C),
a phenotiazin-5-ium-3,7-diamine salt, preferably chloride or acetate (thionine).
[0159] Most preferably the mixture of Azure B and methylene blue is present in the stain.
[0160] Chemical formula of methylene blue:
[0000]
[0161] Similarly, the substituted fluoresceins may be of one or more types. Most preferably, an eosin stain or a mixture of eosin stains is used, which may preferably comprise for example Eosin B or Eosin Y.
[0000]
[0162] The eosin stain is preferably Eosin B or Eosin Y, the formulas of which are, respectively
[0000]
[0163] Most preferably, the stain used according to the invention is Azure II eosinate. Azure II eosinate (CAS 53092-85-6) is a mixture of methylene blue and Azure B in the ratio of 1:1 and of eosin Y. Azure II eosinate is available from various manufacturers (such as Fluka, Sinopharm, CN és Nile Chemicals, Ind.).
[0164] It is apparent for the skilled artisan that further substituted variants or salts of the stains of the inventions may be used, provided they are chromatic and the colour changes in the presence of yeast.
[0165] Considering growth media, any growth medium being suitable for culturing yeasts and containing at least an agent which inhibits the growth of Saccharomyces strains can be used, e.g. growth media disclosed in the background of the invention.
[0166] Based on the above, the invention concerns a method for selective culturing of Brettanomyces/Dekkera yeasts and differential staining of their colonies, where a growth medium suitable for culturing yeast cells is prepared, which is made selective by the addition of an appropriate chemotherapeutic agent or antibiotic inhibiting the growth of Saccharomyces strains and by the addition of chromogenic stain of the invention.
[0167] The culture medium may be of varied composition. Theoretically, any growth medium suitable for culturing yeasts is appropriate and known by a person skilled in the art. The growth medium preferably contains ingredients selected from the following group: sugar, e.g. glucose; aminoacid- or peptid-containing extract or hydrolizate, such as pepton, yeast extract, “yeast nitrogen base” or “yeast carbon base; geling agent, e.g. agar; and optionally salt. Highly preferably, the growth medium comprises glucose, yeast nitrogen base and agar.
[0168] Additionally, the growth medium also contains substances inhibiting the reproduction of microbes having a role in the normal or healthy fermentation of foodstuff. Provided the foodstuff in which the detection method is performed is a foodstuff prepared by fermentation, the growth-inhibiting substance feasibly prevents the growing of microorganisms performing the natural fermentation of the foodstuff, e.g. it blocks the growing of noble yeast. It is obvious for a person skilled in the art that the growth inhibitor should be applied at least in such a concentration which is already sufficient enough to block the growth of such microorganisms. At the same time the inhibitor concentration may have an upper threshold not to inhibit the growth of yeasts, the presence of which is desired to be tested. Preferably, the foodstuff is a foodstuff fermented by Saccharomyces species, such as beer, wine or other yeast containing product or intermediate, and the agent inhibiting the growth of Saccharomyces strains is an appropriate chemotherapeutic agent or antibiotic, e.g. cycloheximide applied in a concentration, e.g. of 0.5-50 μg/ml, preferably 1-20 μg/ml, particularly preferably 2-10 μg/ml, highly preferably something like 5 μg/ml, thereby the selectivity of the growth medium is enhanced or it is made selective.
[0169] The sample may be any sample used in the production of such foodstuff, e.g. a sample taken from devices used in the process or a sample drawn from the liquid used for cleaning the devices.
[0170] The prepared culture medium is brought to a form suitable for sample application. According to a certain variation a gel is prepared and a plate is poured into, e.g., a Petri dish. Alternatively, any other solid (e.g., in a form of gel) culture medium can be applied where the sample can be plated and the progeny (e.g. colonies) of a single cell can be separated.
[0171] In addition to Petri dishes any other culturing container having large surface can be preferably used, where the sample can be spread on the surface of medium formed in it, and it can be closed (e.g., has a lid) and in which the microorganism colonies can be detected and feasibly visualized. It is preferable for the culturing container to be made of glass or plastic, more preferably plastic, and preferably it has a transparent lid.
[0172] Kolle dishes or Roux flaks may also be used, they also have large surfaces but the sample should be introduced into the dish through a small opening and performing uniform plating also presents difficulties. Then the opening should be closed in a way that allows some aeration but the sample does not get uncontaminated.
[0173] Consequently, according to the invention, sterilisable culturing dishes with lid may be used, in which samples to be tested can be plated on a large surface.
[0174] From the samples (e.g., water used for washing barrels or other surfaces) or from their suitable dilutions a predetermined amount is plated on the surface of culture media then they are incubated at 10-37° C., preferably at 20-30° C., particularly preferably at room temperature for about 5-20 days, preferably for 8-16 days, and highly preferably for 10-14 days. It is obvious for a person skilled in the art that the incubation time is necessarily longer at lower temperatures.
[0175] On culture medium prepared according to the invention, Saccharomyces yeasts stop growing, and the colour of Brettanomyces/Dekkera colonies become pink and they can be discriminated from microorganisms which are not harmful or just slightly harmful to the wine. The results are evaluated visually. In the event of sample application, the result can be made quantitative by giving the number of cultivable yeast cells per 1 ml.
[0176] Detection sensitivity of Brettanomyces/Dekkera yeasts may be enhanced by filtering a higher amount of wine through membranes with 0.45 μm or 0.22 μm pore size, then by placing the membrane on the surface of the culture medium. In this case it should be ensured that no air bubbles are present between the membrane and the agar surface.
[0177] Furthermore, the invention relates to culture media for performing the above method where the medium is in a powder or in a ready-to-use form, and also to the kits containing them and other components necessary for performing the examination (e.g. sample application devices) and the user instructions as well. Preferably, the reagent kit of the invention comprises the culture medium necessary for performing the method of the invention in the form and amount pre-weighed for each test and in a form poured into plastic Petri dishes in advance.
[0178] The method developed by us is cheap and it does not require special instrumentation and easy to perform by anyone. The procedure requires no sterile laboratory conditions and only little attention is to be paid to ensure that the right sample is placed on the surface of the culture medium. The culture medium contains components easily available. In addition to components used for growth, the medium contains antibiotics inhibiting the growth of yeasts, e.g.—other culture media similar to selective Brettanomyces —cycloheximide as well. This antibiotic is used for the identification of different species in yeast diagnostics. In the concentration used by the inventors, it prevents the growth of most yeasts playing a role in wine-making (e.g. Saccharomyces ) while this concentration is still tolerated by the species causing the degradation of wine.
[0179] The present invention is further illustrated, but not limited by the following examples.
EXAMPLES
[0180] In the following examples, unless indicated otherwise, the following concentrations and compositions were applied. Composition of medium that was suitable for growing yeast cells was the following: 1% glucose, 0.67% “yeast nitrogen base”, 2% agar, which was made selectively by using 5 μg/ml cycloheximide as an antibiotics for blocking the growth of Saccharomyces strains. Azure-II-eosinate was used in a 30 μg/ml concentration.
Example 1
Identifying Brettanomyces/Dekkera Species From Must
[0181] We make a 10 scale dilution sequence in 5 steps from destilled water that we gained from must. From each dilution we streak 50 μl onto the surface of the selective, chromogen medium in the Petri dishes. We make the grafting in three parallel running measurements. We incubate the Petri dishes between 20-25° C. for 10-14 days. The pink colonies that appear on the surface of the medium after the incubation time is over imply the Brettanomyces/Dekkera infection. We choose the dishes in which we can easily identify the number of colonies. If we multiply the number of colonies by twenty, plus the value of the dilution we get the plate count of the Brettanomyces/Dekkera of the must applied to 1 ml.
[0182] A positive dish can be examined under UV light as well. The fluorescence of the colonies confirms the obtained results.
Example 2
Identifying Brettanomyces/Dekkera Species From Bottled Wine
[0183] We shake up the wine before taking a sample, then we filtrate 500 ml of it through a membrane filter with 0.45 μm pore diameter. We place the membrane filter on the surface of the selective chromogenic medium in the Petri dish, in a way that it fits properly (there should be no air bubble between them). The Petri dishes are incubated on 20-25° C. for 10-14 days.
Example 3
Identifying Brettanomyces/Dekkera Species From Red Wine Stored in Barrels
[0184] We centrifugate 50 ml from the red wine in the barrel (3000 rpm, 10 min, Hereus Multifuge 3S). We suspend the pellet in 1 ml destilled water. From the suspension we streak 100 μm on the surface of the selective chromogenic medium in the Petri dish. The Petri dishes are incubated on 20-25° C. for 10-14 days.
Example 4
Identifying Brettanomyces/Dekkera Species From Barrels
[0185] After washing the barrels, we filtrate 500 ml from the wash water through a membrane filter with 0.45 μm pore diameter. We place the membrane filter on the surface of the selective chromogenic medium in the Petri dish, in a way that it fits properly (there should be no air bubble between them). The Petri dishes are incubated on 20-25° C. for 10-14 days.
Example 5
Identifying Brettanomyces/Dekkera Species From Grapes
[0186] We gently shake the grapes that are soaked in destilled water for an hour on room temperature. Meanwhile the cells from the grapes are being washed in the water. After this, we pour out the water from the grapes and filtrate it through a membrane filter with 0.45 μm pore diameter. We place the membrane filter on the surface of the selective chromogenic medium in the Petri dish, in a way that it fits properly (there should be no air bubble between them). The Petri dishes are incubated on 20-25° C. for 10-14 days.
Example 6
Identifying Zygosaccharomyces bailii From Bottled Sweet Wines
[0187] We filtrate 500 ml from the bottled sweet wine through a membrane filter with 0.45 μm pore diameter. We place the membrane filter on the surface of the selective chromogenic medium in the Petri dish, in a way that it fits properly (there should be no air bubble between them). The Petri dishes are incubated on 30° C. for 10-14 days. The appearing blue colonies show a positive result.
Example 7
Identifying the Level of Infectivity of Collective Strains of Brettanomyces/Dekkera, Zygosaccharomyces bailii and Lachancea fermentatii
[0188] We suspend 1 loop from the culture in 5 ml destilled water. From the suspension we streak it on the surface of the differentiating medium with the loop. The Petri dishes are incubated on 20-25° C. for 10-14 days. The appearing blue Zygosaccharomyces bailii colonies, the pink Brettanomyces/Dekkera , and the greenish blue Lachancea fermentatii with the pink edge indicate infection.
Example 8
Recovering Pure Culture of Brettanomyces/Dekkera Strains in Culture Collection
[0189] We suspend 1 loop of the infected culture in 5 ml destilled water. With the loop we streak on the differentiating medium from the suspension. The Petri dishes are incubated on 20-25° C. for 10-14 days.
[0190] We make a suspension from the appearing pink colonies (1 loop/5 ml sterile destilled water), and from the suspension we streak on the differentiating medium with a loop. The Petri dishes are incubated on 20-25° C. for 10 days. If we do not observe other colonies apart from the pink ones, we can be ascertained about the purity of the culture.
Example 9
Testing Other Azure and Eosin Stains (Reference Example)
[0191] We conducted the experiment according to example X. with the following stains as well:
Stain
[0192] Azure A (Azure A chloride)
Azure B
Azure II
[0193] Eosin B
Eosin Y
[0194] The colour of the applied stains change in each case with the increase of pH. The stains were not suitable for clearly separating the species of Brettanomyces/Dekkera from the other, examined yeasts.
Example 10
Testing Media
[0195] We conducted the experiment according to example X with the following media:
[0196] YPD (1% glucose, 1% pepton, 0.5% yeast extract, 2% agar)
[0197] YNB (1% glucose, 0.67% yeast nitrogen base, 2% agar)
[0198] YCB (0.5% ammonium sulfate, 1.17% yeast carbon base, 2% agar)
[0199] We experienced the most contrasted pink/blue discolouration on YNB medium in case of the azure II-eosin.
INDUSTRIAL APPLICABILITY
[0200] The process and the media specified by the invention can be advantageously applied in the first place to monitor cell counts of Brettanomyces/Dekkera , identify or exclude their proliferation, as well as to detect for a hygienic purpose Brettanomyces/Dekkera yeasts responsible for the deterioration of wines and provisions in case of utensils used for storage with which they can get directly into contact. The usage of the medium makes the early identification of the growth of Brettanomyces/Dekkera yeasts—that can trigger the deterioration of food and wine—possible, as well as verifying the effect of the treatments that are aimed at avoiding deterioration. The method can identify other microorganisms, such as yeast species belonging to the Zygosaccharomyce genus and Lachancea genus.
[0201] An advantage of this method is that it makes it possible to easily identify the colonies of Brettanomyces/Dekkera by looking at them, furthermore, colonies of yeast species belonging to the Zygosaccharomyces and Lachancea genus can be distinguished from the colonies, other species and wild yeasts that are able to grow on a selective medium. The identification that is based on visibility, not only makes the identification process much easier, but it also does not require experience and scent samples, furthermore, it makes scenting samples unnecessary, which bears the possibility of spreading the infection. The reason why it is more specific to Brettanomyces/Dekkera species than other methods, is that it is able to identify other yeast species that are not winemaking (noble) yeasts, which causes a problem in case of sweet wines with a higher residue of sugar.
[0202] The method that we developed is cheap, it does not require special instruments, anyone can carry it out. Circumstances of a sterile laboratory are not necessary, it only requires minimal attention to put the right sample onto the surface of the medium. The medium contains easily accessible components.
REFERENCES:
[0203] Barata A., Seborro F., Belloch C., Malfeito-Ferreira M., Loureiro V.: Ascomycetous yeast species recovered from grapes damaged by honeydew and sour rot. Journal of Applied Microbiology, Volume 104, Issue 4, pages 1182-1191
[0204] Couto J A, Barbosa A, Hogg T.: A simple cultural method for the presumptive detection of the yeasts Brettanomyces/Dekkera in wines. Left Appl Microbiol. 2005;41(6):505-10.
[0205] EP1185686(A1) Loureiro Virgilio Borges; Goncalves Maria Da Graca Alves; Rodrigues Nuno Miguel Sousa Fa. Culture medium for detection of Dekkera and Brettanomyces
[0206] ES 2268970 (A1) Velazquez Perez Encarna; Lopez Rodrigues Da Silva Luis; Trujillo Toledo Martha Estela [Es]; Mateos Gonzalez Pedro Francisc; Martinez Molina Eustoquio. Yeasts detection culture medium comprises glucose mixed with buffer microorganism and bacterial growth inhibitors and e.g. a nitrogen source
[0207] GB1248197—ABBOTT LAB [US], “Diagnostic method and apparatus for the detection of bacteria”
[0208] Hocking A D.: Media for preservative resistant yeasts: a collaborative study. Int J Food Microbiol. 1996;29(2-3): 167-75.
[0209] Jose I. Ibeas, Ignacio Lozano, Francisco Perdigones, and Juan Jimenez: Detection of Dekkera - Brettanomyces Strains in Sherry by a Nested PCR Method. Appl. Environ. Microbiol. Mar. 1996, p. 9981003 Vol. 62, No. 3
[0210] Laurie Connell , Henrik Stender, and Charles G. Edwards: Rapid Detection and Identification of Brettanomyces from Winery Air Samples Based on Peptide Nucleic Acid Analysis. Am. J . Enol. Vitic. 2002; 53(4): 322-24.
[0211] Loureiro V, Malfeito-Ferreira M. Spoilage yeasts in the wine industry. Int J Food Microbiol. 2003;86(1-2):23-50.
[0212] Luca Cocolin, Kalliopi Rantsiou, Lucilla lacumin, Roberto Zironi, and Giuseppe Comi: Molecular Detection and Identification of Brettanomyces/Dekkera bruxellensis and Brettanomyces/Dekkera anomalus in Spoiled Wines. Appl Environ Microbiol. 2004; 70(3): 1347-1355.
[0213] Mitrakul, C. M., T. Henick-Kling, and C. M. Egli: Discrimination of Brettanomyces/Dekkera yeast isolates from wine by using various DNA fingerprinting methods. Food Microbiol. 1999;16:3-14.
[0214] Renouf V, Lonvaud-Funel A.: Development of an enrichment medium to detect Dekkera/Brettanomyces bruxellensis , a spoilage wine yeast, on the surface of grape berries. Microbiol Res. 2007;162(2): 154-67.
[0215] Rodrigues N, Gonçalves G, Pereira-da-Silva S, Malfeito-Ferreira M, Loureiro V. Development and use of a new medium to detect yeasts of the genera Dekkera/Brettanomyces . J Appl Microbiol. 2001;90(4):588-99.
[0216] Schuller D, Côrte-Real M, Leão C.: A differential medium for the enumeration of the spoilage yeast Zygosaccharomyces bailii in wine. J Food Prot. 2000;63(11):1570-5.
[0217] Stender, H., C. Kurtzman, J. J. Hyldig-Nielsen, D. Sorensen, A J. Broomer, K. Oliveira, H. Perry-O'Keefe, A. Sage, B. Young, and J. Coull: Identification of Dekkera bruxellensis ( Brerranomyces ) from wine by fluorescence in situ hybridization using peptide nucleic acid probes. Appl. Environ. Microbiol. 67:938-941 (2001).
[0218] Trevor G. Phister and David A. Mills: Real-Time PCR Assay for Detection and Enumeration of Dekkera bruxellensis in Wine. Applied and Environmental Microbiology. 2003; 69(12):7430-7434.
[0219] WO0073494 (Al) Leao Cecilia; Corte-Real Manuela; Schuller Dorit
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The invention deals with chromogenic media which are suitable for the selective growth and identification of one or more species of yeast.
The subject of the invention is the method that enables us to identify and determine the cell count of Brettanomyces/Dekkera and Zygosaccharomyces yeasts. Besides, the subjects of invention are also the use of the method in wine and/or food industry and the stocks for conducting the experiment.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation in Part of U.S. patent application Ser. No. 09/630,201 filed on Aug. 1, 2000 and claims priority to U.S. Provisional Patent Application No. 60/362,899 filed Mar. 8, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to spectroscopic data processing data technology and its application in calibration and noninvasive measurement of blood analytes, such as glucose. More particularly, this invention relates to a method for attenuating spectroscopic interference resulting from tissue heterogeneity, patient-to-patient variation, instrument related variation, and physiological variation.
[0004] 2. Background Information
[0005] The need for an accurate, noninvasive method for measuring blood analytes, particularly glucose is well understood and documented. Diabetes is a leading cause of death and disability worldwide and afflicts an estimated 16 million Americans. Complications of diabetes include heart and kidney disease, blindness, nerve damage and, high blood pressure with the estimated total cost to United States economy alone exceeding $90 billion per year. Diabetes Statistics, Publication No. 98-3926, National Institutes of Health, Bethesda Md. (November 1997). Long-term clinical studies show that the onset of complications can be significantly reduced through proper control of blood glucose levels. The Diabetes Control and Complications Trial Research Group, The effect of intensive treatment of diabetes on the development and progression of long - term complications in insulin - dependent diabetes mellitus, N Eng J of Med, 329:977-86 (1993). A vital element of diabetes management is the self-monitoring of blood glucose levels by diabetics in the home environment. A significant disadvantage of current monitoring techniques is that they discourage regular use due to the inconvenience and pain involved in drawing blood through the skin prior to analysis. Therefore, new methods for self-monitoring of blood glucose levels are required to improve the prospects for more rigorous control of blood glucose in diabetic patients.
[0006] Numerous approaches have been explored for measuring blood glucose levels, ranging from invasive methods such as microdialysis to noninvasive technologies that rely on spectroscopy. Each method has associated advantages and disadvantages, but only a few have received approval from certifying agencies. To date, no noninvasive techniques for the self-monitoring of blood glucose have been certified.
[0007] One method using near-infrared spectroscopy involves the illumination of a spot on the body with near-infrared electromagnetic radiation which is light in the wavelength range 700 to 2500 nm. The light is partially absorbed and scattered, according to its interaction with the tissue constituents prior to being reflected back to a detector. The detected light contains quantitative information that is based on the known interaction of the incident light with components of the body tissue including water, fat, protein, and glucose.
[0008] Previously reported methods for the noninvasive measurement of glucose through near-infrared spectroscopy rely on the detection of the magnitude of light attenuation caused by the absorption signature of blood glucose as represented in the targeted tissue volume. The tissue volume is the portion of irradiated tissue from which light is reflected or transmitted to the spectrometer detection system. The spectroscopic signal related to glucose is extracted from the spectral measurement through various methods of signal processing and one or more mathematical models. The models are developed through the process of calibration on the basis of an exemplary set of spectral measurements and associated reference blood glucose values (the calibration set) based on an analysis of capillary (fingertip), alternative invasive, or venous blood.
[0009] Near-infrared spectroscopy has been demonstrated in specific studies to represent a feasible and promising approach to the noninvasive prediction of blood glucose levels. One of the studies reports three different instrument configurations for measuring diffuse transmittance through the finger in the 600-1300 nm range. Meal tolerance tests were used to perturb the glucose levels of three subjects and calibration models were constructed specific to each subject on single days and tested through cross-validation. Absolute average prediction errors ranged from 19.8 to 37.8 mg/dL. M. Robinson, R. Eaton, D. Haaland, G. Keep, E. Thomas, B. Stalled, P. Robinson, Noninvasive glucose monitoring in diabetic patients: A preliminary evaluation, Clin Chem, 38:1618-22 (1992).
[0010] Other studies present results through a diffuse reflectance measurement of the oral mucosa in the 1111-1835 nm range with an optimized diffuse reflectance accessory. In vivo experiments were conducted on single diabetics using glucose tolerance tests and on a population of 133 different subjects. The best standard error of prediction reported was 43 mg/dL and was obtained from a two-day single person oral glucose tolerance test that was evaluated through cross-validation. H. Heise, R. Marbach, T. Koschinsky, F. Gries, Noninvasive blood glucose sensors based on near - infrared spectroscopy, Artif Org, 18:439-47 (1994); H. Heise, R. Marbach, Effect of data pretreatment on the noninvasive blood glucose measurement by diffuse reflectance near - IR spectroscopy, SPIE Proc, 2089:114-5 (1994); R. Marbach, T. Koschinsky, F. Gries, H. Heise, Noninvasive glucose assay by near - infrared diffuse reflectance spectroscopy of the human inner lip, Appl Spectrosc, 47:875-81 (1993) and R. Marbach, H. Heise, Optical diffuse reflectance accessory for measurements of skin tissue by near - infrared spectroscopy, Applied Optics 34(4):610-21 (1995).
[0011] Some other studies have recorded spectra in diffuse reflectance over the 800-1350 nm range on the middle finger of the right hand with a fiber-optic probe. Each experiment involved a diabetic subject and was conducted over a single day with perturbation of blood glucose levels through carbohydrate loading. Results, using both partial least squares regression and radial basis function neural networks were evaluated on single subjects over single days through cross-validation. An average root mean square prediction error of 36 mg/dL through cross-validation over 31 glucose profiles has also been reported. K. Jagemann, C. Fischbacker, K. Danzer, U. Muller, B. Mertes, Application of near - infrared spectroscopy for noninvasive determination of blood/tissue glucose using neural network, Z Phys Chem, 191S:179-190 (1995); C. Fischbacker, K. Jagemann, K. Danzer, U. Muller, L. Papenkrodt, J. Schuler, Enhancing calibration models for noninvasive near - infrared spectroscopic blood glucose determinations, Fresenius J Anal Chem 359:78-82 (1997); K. Danzer, C. Fischbacker, K. Jagemann, K. Reichelt, Near - infrared diffuse reflection spectroscopy for noninvasive blood - glucose monitoring, LEOS Newsletter 12(2):9-11 (1998); and U. Muller, B. Mertes, C. Fischbacker, K. Jagemann, K. Danzer, Noninvasive blood glucose monitoring by means of new infrared spectroscopic methods for improving the reliability of the calibration models, Int J Artif Organs, 20:285-290 (1997).
[0012] In a study of five diabetic subjects conducted over a 39-day period with five samples taken per day, absorbance spectra through a transmission measurement of the tongue in the 1429-2000 nm range were collected. Every fifth sample was used for an independent test set and the standard error of prediction for all subjects was greater than 54 mg/dL. J. Burmeister, M. Arnold, G. Small, Human noninvasive measurement of glucose using near infrared spectroscopy (abstract), Pittcon, New Orleans La. (1998).
[0013] In a study involved in noninvasive measurement of blood glucose during modified oral glucose tolerance tests over a short time period, the calibration was customized for the individual and tested over a relatively short time period. T. Blank, T. Ruchti, S. Malin, S. Monfre, The use of near - infrared diffuse reflectance for the noninvasive prediction of blood glucose, IEEE Lasers and Electro-Optics Society Newsletter,13:5 (October 1999).
[0014] In all of these studies, limitations are cited that would affect the acceptance of such a method as a commercial product. These limitations include sensitivity, sampling problems, time lag, calibration bias, long-term reproducibility, and instrument noise. Fundamentally, however, accurate noninvasive estimation of blood glucose is presently limited by the available near-infrared technology, the trace concentration of glucose relative to other constituents, and the complex nature of the skin and living tissue of the patient. O. Khalil, Spectroscopic and clinical aspects of noninvasive glucose measurements, Clin Chem, 45:165-77 (1999).
[0015] As we have discovered, chemical, structural, and physiological variations occur that produce dramatic and nonlinear changes in the optical properties of the tissue sample. S. Malin, T. Ruchti, An Intelligent System for Noninvasive Blood Analyte Prediction, U.S. Pat. No. 6,280,381 (Aug. 28, 2001). Relevant studies may be found in the following references: R. Anderson, J. Parrish, The optics of human skin, Journal of Investigative Dermatology, 7:1, pp.13-19 (1981), W. Cheong, S. Prahl, A. Welch, A review of the optical properties of biological tissues, IEEE Journal of Quantum Electronics, 26:12, pp.2166-2185, (December 1990), D. Benaron, D. Ho, Imaging (NIRI) and quantitation (NIRS) in tissue using time - resolved spectrophotometry: the impact of statically and dynamically variable optical path lengths, SPIE, 1888, pp.10-21 (1993), J. Conway, K. Norris, C. Bodwell, A new approach for the estimation of body composition: infrared interactance, The American Journal of Clinical Nutrition, 40, pp.1123-1140 (December 1984), S. Homma, T. Fukunaga, A. Kagaya, Influence of adipose tissue thickness in near infrared spectroscopic signals in the measurement of human muscle, Journal of Biomedical Optics, 1:4, pp.418-424 (October 1996), A. Profio, Light transport in tissue, Applied Optics, 28:12), pp. 2216-2222, (June 1989), M. Van Gemert, S. Jacques, H. Sterenborg, W. Star, Skin optics, IEEE Transactions on Biomedical Engineering, 36:12, pp.1146-1154 (December 1989), and B. Wilson, S. Jacques, Optical reflectance and transmittance of tissues: principles and applications, IEEE Journal of Quantum Electronics, 26:12, pp. 2186-2199.
[0016] In particular, the characteristics and variation of the tissue sample produce profound interference in the tissue measurement that leads to degradation in the accuracy and precision noninvasive glucose measurements. For example, the near-infrared diffuse reflectance (absorbance) spectrum is a complex combination of the tissue scattering properties that are dominated by the concentration and characteristics of a multiplicity of tissue components including water, fat, protein, and glucose. Physiological variation causes dramatic changes in the tissue measurement over time and lifestyle, health, aging, and environmental exposure lead to spectrally manifested structural variations. Errors in glucose measurements develop when the net analyte signal of glucose is attenuated by interference or when the sample is outside the effective range of the calibration model.
[0017] The measurement is further complicated by the heterogeneity of the sample, the multi-layered structure of the skin, changes in the volume fraction of blood in the tissue, hormonal stimulation, temperature fluctuations, and blood analyte levels. This can be further considered through a discussion of the properties of skin.
[0018] Tissue Scattering Properties
[0019] 1. Skin Structure
[0020] The structure and composition of skin varies widely among individuals, between different sites within an individual, and over time on the same individual. Skin includes a superficial layer known as the stratum corneum, a stratified cellular epidermis, and an underlying dermis of connective tissue. Below the dermis is the subcutaneous fatty layer or adipose tissue. The epidermis, with a thickness of 10-150 μm, together with the stratum corneum provides a barrier to infection and loss of moisture and other body constituents, while the dermis is the thick inner layer that provides mechanical strength and elasticity. F. Ebling, The Normal Skin, Textbook of Dermatology, 2 nd ed.; A. Rook; D. Wilkinson, F. Ebling, Eds.; Blackwell Scientific, Oxford, pp 4-24 (1972). In humans, the thickness of the dermis ranges from 0.5 mm over the eyelid to 4 mm on the back and averages approximately 1.2 mm over most of the body. S. Wilson, V. Spence, Phys. Med. Biol., 33:894-897 (1988).
[0021] In the dermis, water accounts for approximately 70% of the volume. The next most abundant constituent is collagen, a fibrous protein comprising 70-75% of the dry weight of the dermis. Elastin fibers, also a protein, are plentiful though they constitute a smaller proportion of the bulk. In addition, the dermis contains a wide variety of structures (e.g., sweat glands, hair follicles, and blood vessels) and other cellular constituents. F. Ebling, supra. Conversely, the subcutaneous layer (adipose tissue) is by volume approximately 10% water and is composed primarily of cells rich in triglycerides or fat. The concentration of glucose varies in each layer according to a variety of factors which include the water content, the relative sizes of the fluid compartments, the distribution of capillaries, the perfusion of blood, the glucose uptake of cells, the concentration of glucose in blood, and the driving forces (e.g. osmotic pressure) behind diffusion. Due to the high concentration of fat, the average concentration of water soluble glucose in subcutaneous tissue is significantly lower than that of the dermis.
[0022] 2. Skin Properties
[0023] Noninvasive technologies measure the alteration of a probing or excitation signal, such as near-infrared radiation, emitted radiation from the body, and radio wave, by specific properties of tissue, such as absorption, scattering, impedance, optical rotation, and fluorescence. However, other sample constituents of tissue often interfere, and the specific response, (the alternation of the probing or excitation signal due to or related to glucose) is greatly attenuated or completely obscured.
[0024] For example, one may consider the measurement of glucose through near-infrared spectroscopy on the basis of the absorption of glucose. In a near-infrared absorption spectrum, a change in the concentration of glucose is reflected by a change in the absorption of light according to the absorption and scattering properties of glucose and/or the effect of glucose changes upon the anatomy and physiology of the sampled site. However, in addition to the effect of glucose on the near-infrared light probing signal that is delivered to the skin, the probing signal is also reflected, diffusely reflected, transmitted, scattered, and absorbed in a complex manner related to the structure and composition of the tissue. When near-infrared light is delivered to the skin, a percentage of it is reflected, while the remainder penetrates into the skin. The proportion of reflected light, or specular reflectance, is typically between 4-7% of the delivered light over the entire spectrum from 250-3000 nm for a perpendicular angle of incidence. J. Parrish, R. Anderson, F. Urbach, D. Pitts, UV-A: Biologic Effects of Ultraviolet Radiation with Emphasis on Human Responses to Longwave Ultraviolet, New York, Plenum Press (1978). The 93-96% of the incident light that enters the skin is attenuated due to absorption and scattering within many layers of the skin. These two processes, combined with the orientation of the spectrometer sensors, determine the tissue volume irradiated by the source and “sampled” through the collection of diffusely reflected light.
[0025] Diffuse reflectance or remittance is defined as that fraction of incident optical radiation that is returned from a turbid sample as a function of wavelength. Alternately, diffuse transmittance is the fraction of incident optical radiation that is transmitted through a turbid sample. Absorption by the various skin constituents mentioned above accounts for the spectral extinction of the light within each layer. Scattering is the main process by which the beam may be returned to contribute to the diffuse reflectance of the skin. Scattering also has a strong influence on the light that is diffusely transmitted through a portion of the skin.
[0026] The scattering of light in tissues is in part due to discontinuities in the refractive indices on the microscopic level, such as the aqueous-lipid membrane interfaces between each tissue compartment or the collagen fibrils within the extracellular matrix. B. Wilson, S. Jacques, Optical reflectance and transmittance of tissues: principles and applications, IEEE Journal of Quantum Electronics, 26:12 (December 1990). The spatial distribution and intensity of scattered light depends upon the size and shape of the particles relative to the wavelength, and upon the difference in refractive index between the medium and the constituent particles. The scattering of the dermis is dominated by the scattering from collagen fiber bundles in the 2.8 μm diameter range occupying twenty-one percent of the dermal volume, and the refractive index mismatch is 1.38/1.35 S. Jacques, Origins of tissue optical properties in the UVA, Visible and NIR Regions, Optical Society of America, Topical Meeting, Orlando Fla. (Mar. 18-22, 1996). The spectral characteristics of diffuse remittance from tissue result from a complex interplay of the intrinsic absorption and scattering properties of the tissue, the distribution of the heterogeneous scattering components, and the geometry of the point(s) of irradiation relative to the point(s) of light detection.
[0027] The near-infrared absorption of light in tissue is primarily due to overtone and combination absorbances of C—H, N—H, and O—H functional groups. As skin is primarily composed of water, protein, and fat; these functional groups dominate the near-IR absorption in tissue. As the main constituent, water dominates the near-infrared absorbance above 1100 nm and is observed through pronounced absorbance bands at 1450, 1900, and 2600 nm. Protein in its various forms, in particular, collagen is a strong absorber of light that irradiates the dermis. Near-infrared light that penetrates to subcutaneous tissue is absorbed primarily by fat. In the absence of scattering, the absorbance of near-infrared light due to a particular analyte, A, can be approximated by Beer's Law at each wavelength by:
A=εcl (1)
[0028] where a is the analyte specific absorption coefficient, c is the concentration and l is the pathlength. An approximation of the overall absorbance at a particular wavelength is the sum of the individual absorbance of each particular analyte given by Beer's Law. The concentration of a particular analyte, such as glucose, can be determined through a multivariate analysis of the absorbance over a multiplicity of wavelengths because a is unique for each analyte. However, in tissue compartments expected to contain glucose, the concentration of glucose is at least three orders of magnitude less than that of water. Given the known extinction coefficients of water and glucose, the signal targeted for detection by reported approaches to near-infrared measurement of glucose, i.e. the absorbance due to glucose in the tissue, is expected to be, at most, three orders of magnitude less than other interfering tissue constituents. Therefore, the near-infrared measurement of glucose requires a high level of sensitivity over a broad wavelength range. Multivariate analysis is often utilized to enhance sensitivity.
[0029] In addition, the diverse scattering characteristics of the skin, e.g. multiple layers and heterogeneity, cause the light returning from an irradiated sample to vary in a highly nonlinear manner with respect to tissue analytes, in particular, glucose. Simple linear models, such as Beer's Law have been reported to be invalid for the dermis. R. Anderson, J. Parrish, The optics of human skin, Journal of Investigative Dermatology, 77:1, pp. 13-19 (1981). Such nonlinear variation is a recognized problem and several reports have disclosed unique methods for compensating for the nonlinearity of the measurement while providing the necessary sensitivity. S. Malin, et al., supra; E. Thomas, R. Rowe, Methods and apparatus for tailoring spectroscopic calibration Models, U.S. Pat. No. 6,157,041 (Dec. 5, 2000).
[0030] Dynamic Properties of the Skin
[0031] While knowledge and utilization of skin properties, high instrument sensitivity, and compensation for inherent non-linearities are all vital to the application of noninvasive technologies in blood analyte measurement, an understanding of the biological and chemical mechanisms that lead to time dependent changes in the properties of skin tissue is equally important and yet, largely ignored. At a given measurement site, skin tissue is often assumed to remain static, except for changes in the target analyte and other interfering species. However, variations in the physiological state and fluid distribution of tissue profoundly affect the optical properties of tissue layers and compartments over a relatively short period of time. Such variations are often dominated by fluid compartment equalization through water shifts and are related to hydration levels and changes in blood analyte levels. A. Guyton, J. Hall, Textbook of Medical of Physiology, 9 th ed., Philadelphia, W.B. Saunders Co. (1996).
[0032] Problem Statement and Description of Related Technology
[0033] A major difficulty in the noninvasive measurement of biological constituents and analytes in tissue through near-infrared spectroscopy arises from the fact that many constituents, such as glucose, are present in very small concentrations compared to sources of interference. In particular, the complex, heterogeneous and dynamic composition of the skin, together with profound variation over time, between tissue sample sites within a patient and from patient-to-patient interferes with and thereby attenuates the net analyte signal of many target analytes, such as glucose. In addition, the actual tissue volume sampled and the effective or average pathlength of light are varied. Therefore, the optical properties of the tissue sample are modified in a highly nonlinear and profound manner that introduces significant interference into noninvasive tissue measurements. Both calibration and measurement using noninvasive measurement devices would benefit from a method that attenuates the components of spectral interference related to the heterogeneity of the tissue, patient-to-patient differences, and variation through time (e.g., physiological effects).
[0034] Several methods are reported to compensate in some part for the dynamic variation of the tissue and patient-to-patient differences. For example, noninvasive measurement of glucose through calibration models that are specific to an individual over a short period of time are reported. K. H. Hazen, Glucose determination in biological matrices using near - infrared spectroscopy, Doctoral Dissertation, University of Iowa (August 1995); J. J. Burmeister, In vitro model for human noninvasive blood glucose measurements, ” Doctoral Dissertation, University of Iowa (December 1997).
[0035] This approach avoids modeling the differences between patients and therefore cannot be generalized to more individuals. In addition, the calibration models have not been tested over long time periods and do not provide a means for correcting for variation related to sample sites or physiological effects.
[0036] Several other approaches exist that employ diverse preprocessing methods to remove spectral variation related to the sample and instrumental variation including multiplicative signal correction (P. Geladi, D. McDougall and H. Martens, Applied Spectroscopy, vol. 39, pp. 491-500, 1985), standard normal variate transformation (R. J. Barnes, M. S. Dhanoa, and S. Lister, Applied Spectroscopy, 43, pp. 772-777, 1989), piecewise multiplicative scatter correction (T. Isaksson and B. R. Kowalski, Applied Spectroscopy, 47, pp. 702-709, 1993), extended multiplicative signal correction (H. Martens and E. Stark, J. Pharm Biomed Anal, 9, pp. 625-635, 1991), pathlength correction with chemical modeling and optimized scaling (T. Isaksson, Z. Wang, and B. R. Kowalski, J. Near Infrared Spectroscopy, 1, pp. 85-97, 1993), and FIR filtering (S. T. Sum, Spectral Signal Correction for Multivariate Calibration, Doctoral Dissertation, University of Delaware, 1998). In addition, a diversity of signal, data, or pre-processing techniques are commonly reported with the fundamental goal of enhancing accessibility of the net analyte signal. D. L. Massart, B. G. M. Vandeginste, S. N. Deming, Y. Michotte and L. Kaufman, Chemometrics: a textbook, Elsevier Science Publishing Company, Inc., pp. 215-252,1990; A. V. Oppenheim and R. W. Schafer, Digital Signal Processing, Englewood Cliffs, Prentice Hall, 1975, pp. 195-271; M. Otto, Chemometrics, Weinheim: Wiley-VCH, 1999; and K. R. Beebe., R. J. Pell and M. B. Seasholtz, Chemometrics A Practical Guide, John Wiley & Sons, Inc., pp. 26-55, 1998. Notably, Sum describes a solution to variation due to changes in a given physical sample and instrumental effects through the use of signal preprocessing techniques. The reported method reduces the variance in the spectral measurement arising from non-chemical sources while retaining the variance caused by chemical change. The sources of variance include the physical traits of the sample(s), such as, particle size and shape, packing density, heterogeneity, and surface roughness. The method includes preprocessing through a derivative step (see A. Savitzky and M. J. E. Golay. Smoothing and Differentiation of Data by Simplified Least Squares Procedures, Anal. Chem., vol. 36, no. 8, pp. 1627-1639, 1964) followed by a spectral transformation through either multiplicative scatter correction or standard normal variate transformation. In addition, a FIR filter is described which for certain applications is found to be more effective in reducing both the instrumental and sample related variation.
[0037] While methods for preprocessing effectively compensate for variation related to instrument and physical changes in the sample and enhance the net analyte signal in the presence of noise and interference, they are inadequate for compensating for the sources of tissue related variation defined above. For example, the highly nonlinear effects related to sampling different tissue locations cannot be effectively compensated for through a pathlength correction because the sample is multi-layered, heterogeneous, and leads to large nonlinear variation. In addition, fundamental assumptions inherent in these methods, such as the constancy of multiplicative and additive effects across the spectral range and homoscadasticity of noise are violated in the noninvasive tissue application.
[0038] E. V. Thomas and R. K. Rowe have disclosed a method for reducing intra-subject variation through the process of mean-centering both the direct and indirect measurements for calibration and prediction. E. V. Thomas and R. K. Rowe, Methods and Apparatus for Tailoring Spectroscopic Calibration Models, U.S. Pat. No. 6,157,041 (Dec. 5, 2000). However, that patent does not address the key problem related to sample heterogeneity and complexity, physiological and chemical variation related to the dynamic nature of the tissue, and the common problem of optical variation that occurs from sample-to-sample. In addition, the method is applied to the raw spectroscopic measurement and, as a result, it is dominated by variation resulting from surface effects such as surface roughness, hydration, coupling efficiency, and reflectance.
[0039] In view of the problems left unsolved by the prior art, there exists a need for a method and apparatus to reduce interference in tissue measurements related sample heterogeneity, time related variations, patient-to-patient differences, and instrumental effects.
SUMMARY OF THE INVENTION
[0040] This invention is an improvement of the invention described in U.S. Pat. No. 6,115,673 (herein after '673 patent), entitled Method and Apparatus for Generating Basis Sets for Use in Spectroscopic Analysis, issued to S. Malin and K. Hazen on Sep. 5, 2000. In the '673 patent, we disclosed a method for enhancing a net analyte signal related to a particular analyte by transforming the corresponding spectroscopic measurement pursuant to a basis set. The basis set includes a spectral representation of at least one component found in a sample that is typically a source of interference. The spectral measurement is transformed by the removal of the signal related to the basis set from the spectral measurement.
[0041] In this invention, we have modified the approach disclosed in '673 patent and extended it to various sources of interference related to the bulk properties of the tissue. Specifically, we have identified the following components as sources of interference: (1) tissue heterogeneity (i.e. sampling location); (2) structural and compositional differences patient-to-patient; (3) time dependent sources of interference (e.g. physiological variation); and (4) instrument variation (i.e. instrument-to-instrument differences and instrument variation through time)
[0042] The solution according to this invention includes reduction of the identified sources of interference through the measurement of a “tissue” basis set and the subsequent transformation of a spectroscopic measurement. The transformed measurement is used to estimate the concentration of an analyte through the application of a multivariate calibration model.
[0043] The tissue basis set is generated for each patient, sample-site, time period, and instrument and represents the interfering background signal related to the overall optical properties of the tissue. When an apparatus is used to constrain the interference related to tissue heterogeneity, the basis set contains only interference specific to a patient, a physiological state or time period, and an instrument.
[0044] Due to the time dependent properties of the sampled tissue, the basis set is collected within a close proximity in time to the spectral measurement. In addition, the transformation of the spectral measurement via the basis set introduces an offset to the analyte measurement that is corrected through a bias adjustment.
[0045] The invention leads to the attenuation of tissue variability that is manifested in spectral measurements. During the process of calibration, the reduction in spectral interference leads to parsimonious and robust models that can be applied to a broader range of different tissue types, characteristics, and conditions.
[0046] The solution according to this invention has numerous advantages. For examples: First, it is particularly effective for attenuating the common and significant source of sample-to-sample spectral interference related to tissue heterogeneity and errors in the tissue volume that is sampled;
[0047] Second, a method is given that leads to the attenuation of spectral interference related to the dynamic properties of the tissue;
[0048] Third, the method of attenuation is uniquely determined for each tissue location and physiological state through the generation of a basis set, and thus the attenuation of the interference is significantly improved over methods that utilize common preprocessing steps for these diverse situations;
[0049] Fourth, the method of interference attenuation is optimized with respect to patient, instrument, tissue sampling site, and physiological state/condition (all major sources of interference that limit the performance of noninvasive measurement systems);
[0050] Further, the method is applied subsequent to standard preprocessing of the spectra and as a result is not dominated by variation related to surface effects; and
[0051] Finally, the method provides a unique and sensitive method of determining when the tissue location or state is not suitable for measurement of glucose noninvasively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] [0052]FIG. 1 is schematic block diagram illustrating a noninvasive sensor comprising a probing system, a detection system, and a measurement system;
[0053] [0053]FIG. 2 is a plot of typical absorbance spectrum measurement from the forearm of a human subject;
[0054] [0054]FIG. 3 is a flow diagram illustrating the operation steps of the noninvasive measurement system according to this invention;
[0055] [0055]FIG. 4 is a plot of spectral variance of multi-individual, multi-day data set processed using three different basis sets;
[0056] [0056]FIG. 5 is a Clarke-Error grid of glucose predictions using data that was processed using no basis set prior to application of a multivariable model;
[0057] [0057]FIG. 6 is a Clarke-Error grid of glucose predictions using data that was processed using a basis set that was created for each subject; and
[0058] [0058]FIG. 7 is a Clarke-Error grid of glucose predictions using data that was processed using a basis set that was created for each visit or day.
DETAILED DESCRIPTION OF THE INVENTION
[0059] The following discussion describes a solution for improving the accuracy of noninvasive analyte determination through the reduction of major sources of interference. The solution uses a representation of the interference in the form of a tissue basis set to transform tissue measurements such that the signal related to the target analyte is enhanced and more accessible. The transformed measurement is then used as part of a larger set to develop a multivariate calibration model or to estimate the concentration of an analyte in tissue through the application of a previously developed multivariable calibration model.
[0060] The solution comprises the following steps: (1) development of a basis set that includes at least one interfering component, (2) adjustment of noninvasive tissue measurements using the basis set, (3) multivariable analysis for calibration development, and (4) noninvasive analyte measurement. In addition, it is beneficial to both the calibration process and noninvasive analyte measurement to perform a bias adjustment to the reference analyte values and the analyte measurements, respectively. Further, the solution also includes steps of outlier detection and preprocessing.
[0061] Exemplary Noninvasive Sensor 100
[0062] [0062]FIG. 1 is schematic block diagram showing an exemplary noninvasive sensor 100 , which comprises a probing system 101 , a detection system 102 and a measurement system 103 . The probing system 101 utilizes an excitation or probing signal 104 to sample or probe a volume of tissue 106 in the body. A suitable location on the body for measurement may be found on the fingers, palmar region, hand, forearm, upper arm, eye, leg, plantar region, feet, toes, abdomen, earlobe, or torso although other positions are possible. The probing signal is unique to specific technologies and can be, for example, near-infrared light, electromagnetic radiation, visible light, heat, an electrical current, a radio wave, or ultrasound. While FIG. 1 depicts the probing signal 104 originating in the sensor 100 , in an alternate embodiment, the probing signal 104 can originate either from a different source not connected to the sensor 100 or from within the body itself. The probing signal 104 interacts with the tissue and the sensor detects a portion of the modified probing signal (i.e. response signal) 105 . The tissue volume 106 that is “sampled” is the portion of probed tissue from which the modified probing signal 105 is detected by the sensor 100 .
[0063] The detection system 102 detects a portion of the modified probing signal 105 and ultimately converts the detected signal, referred to as the “tissue measurement”, mε 1×N where N corresponds to the dimensionality of the measurement, into a digitized form for analysis in the measurement system 103 . For example, in the case of near-infrared spectroscopy, the tissue measurement, commonly denoted by I, refers to the intensity spectrum of the tissue sample represented by the intensity at N wavelengths (or wavelength ranges or selected wavelengths) selected from the 700-2500 nm wavelength range.
[0064] In the preferred embodiment of the invention, a background or reference, I 0 , may be used to standardize or normalize the tissue measurement mε 1×N . Typically, the reference is collected either simultaneously with the in-vivo measurement, I, or within a close time interval. The reference is a representation of the probing signal 104 applied to the tissue and is used to determine the nature and extent of the modification of the probing signal that occurs due to the interaction of the probing signal 104 and the sampled tissue volume 106 . In addition, I 0 is used to standardize I against instrument related variation. Typically, I and I 0 are either ratio-ed or subtracted. For example, in the case of near-infrared spectroscopy, the absorbance of light by the sampled tissue volume is estimated according to the calculation:
A = - log 10 ( I I 0 ) ( 2 )
[0065] where I 0 is an estimate of light incident on the sample, I is an intensity spectrum of light detected and A represents an absorbance spectrum containing quantitative information that is based on the known interaction of the incident light with components of the body tissue.
[0066] [0066]FIG. 2 is a plot of A versus wavelength, showing a typical absorbance spectrum measurement from the forearm of a human subject. The absorption bands occur primarily due to water, fat, and protein. More particularly, however, the tissue measurement may include a specific set of wavelengths in the near-infrared region that have been optimized for the extraction of features and for the measurement requirements. For example, the noninvasive measurement of glucose has been found to optimally perform in the wavelength range 1100 to 1935 nm, or a selected subset thereof such as 1150 to 1850 nm.
[0067] Alternatively, I can be referenced to a representation of the tissue measurement at some point in time prior to the collection of I and can be determined from a single tissue measurement or from the mean or a robust estimate of the mean (e.g., the trimmed mean) of several tissue measurements. Finally, I may include either a single tissue measurement collected with an instrument or a combination of several optimally selected tissue measurements collected over a defined measurement period and averaged. Methods for selecting the tissue measurement, used to produce the lowest noise measurement, include similarity or distance measures (i.e., select the most similar), or clustering operations.
[0068] As indicated above, a tissue measurement, I is passed from the detection system 102 to a measurement system 103 . The measurement system 103 constitutes a processing device embodying the measurement process depicted in FIG. 3. Note that the processing device of this invention may constitute a computer system or similar electronic computing device that manipulates and transforms data represented as physical/electrical quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers, or other such information storage, transmission or display devices. Furthermore, the processing device may constitute a microprocessor, microcontroller, or other processing device incorporated into an apparatus specifically constructed for the purposes of the invention. Alternately, the invention may include one or more logic devices specifically configured or programmed to perform the steps of the invented method. The process shown in FIG. 3 is embodied as computer-readable code stored in a computer readable storage medium such as, but not limited to: any type of disk medium, both fixed and removable, read-only memories (ROM's) including EPROM and EEPROM, random access memories (RAM's), magnetic or optical cards, or any type of medium suitable for storing electronic instructions and data.
[0069] The designation of the tissue measurement by the variable “m” is used to refer to the signal that is supplied by the system for analysis and may be, for example, either I or A as described previously.
[0070] Measurement System 103
[0071] The noninvasive measurement of blood chemistry such as a blood analyte, as shown in FIG. 3, involves collecting a tissue measurement 301 described in the prior section, preprocessing the tissue measurement for enhancing the analytical signal and attenuating noises 302 , applying a basis set to the preprocessed tissue measurement 304 to transform the preprocessed tissue measurement 303 , performing an outlier detection 305 , making a bias correction term 306 , applying a multivariate calibration model to the transformed tissue measurement 307 , and determining such as displaying the measurement of the analyte digitally or/and graphically 308 .
[0072] The processing may be performed in a field programmable gate array (FPGA) and in a laptop CPU. Other typical devices that may be employed include a complex programmable logic device (CPLD), an embedded processor, a microprocessor, or a specialized signal processing chip. Typically, the FPGA or CPLD is utilized early in the digital train, but may be employed at later stages.
[0073] Basis Set Measurement 304
[0074] A tissue basis set, denoted by Sε P×N , is a set of P vectors that represents components of interference present in a tissue sample. The basis set is formed through the collection of tissue measurements, mε 1×N , at various times and tissue locations under diverse conditions. For example, the basis set is generated with the first n measurements of a day, wherein n≧1. For another example, the basis set may be generated with the last n measurements prior to a current sample, wherein n≧1. Further, the basis set may be generated with a moving series of samples as in a time series analysis. For example, for current spectrum n, the n−10 to n−2 samples may be utilized to generate the basis set if the reference values are availiable.
[0075] The principal sources of interferences identified include:
[0076] 1. Tissue heterogeneity (sampling location);
[0077] 2. Patient-to-patient structural and compositional differences;
[0078] 3. Time dependent sources of interference (e.g., physiological variation); and
[0079] 4. Instrumental variation (instrument-to-instrument differences and instrument variation through time).
[0080] It is important to note that a different tissue basis set is generated for each patient, sample-site, instrument, and time period and represents the interfering background signal related to the overall optical properties of the tissue. When an apparatus is used to constrain the interference related to tissue heterogeneity, the basis set contains only interference specific to a patient, a physiological state or time period, and an instrument.
[0081] More specifically, the basis set is a set of tissue measurements that are processed and combined according to noise requirements and the type of variation represented. Therefore, the basis set is a set of tissue measurements that are collected at various tissue sample sites on a particular patient and associated with a particular time period and instrument. The tissue measurements are used for a finite time period subsequent to their collection and are associated with a particular patient, physiological state, and instrument. When an apparatus is employed to ensure the sample site is repeatable, the basis set is reduced and typically contains only one measurement, termed the “tissue template.” In this latter embodiment, multiple tissue measurements may be averaged to form the tissue template.
[0082] When the noninvasive sensor is applied to measure an analyte, as depicted in FIG. 3, the basis set is normally collected and calculated prior to the collection of additional tissue measurements. In applications involving post-processing, or the collection of multiple tissue measurements prior to producing an analyte measurement, the basis set may be calculated from a multiplicity of tissue measurements spanning the time period of applicability. This time period is generally less than 24 hours. It is beneficial to preprocess the basis set to attenuate random noise, baseline variation associated with the instrument, variation related to surface contact, and low frequency interference related to scattering. Preprocessing steps include filtering, averaging, derivative calculations, multiplicative scatter correction, smoothing, and normalization. As indicated by FIG. 3, the basis set 304 is applied to transform 303 preprocessed tissue measurements, x, to produce the corrected measurement, z. Therefore, it is necessary that the methods and steps used to preprocess the basis set be identical to those applied in the preprocessing step 303 of FIG. 3 to tissue measurements.
[0083] For example, we consider an application in which the guide system is used to constrain the sample-to-sample variability of a near-infrared diffuse reflectance tissue measurement by the attachment of a guide to the sample measurement site. At the time of guide attachment, a tissue measurement is, collected after inserting an optical probe into the guide aperture. Several tissue measurements associated with various probe placements within the aperture are subsequently taken. The set of tissue measurements or near-infrared spectra, each associated with a different probe insertion. One or more of these spectra may be utilized in the formation of a basis set. For example, the spectra may be processed through the following steps: filtering via a 15-point Savitsky-Golay first derivative and wavelength selection (1150-1950 nm). The resulting set of preprocessed tissue measurements forms the basis set associated with the guide attachment to the arm and is used to transform all subsequent preprocessed tissue measurements collected using the same guide attachment. Alternately, the preprocessed set of tissue measurements are averaged using either a mean calculation or a robust estimate of the mean (e.g., trimmed mean) and the resulting averaged processed tissue measurement is the basis set or the tissue template.
[0084] In a second example, a guide system is not employed and six tissue measurements are collected in a localized area of the tissue, each associated with a different sampling location. The set of tissue measurements are processed through the following steps: filtering through a 15-point Savitsky-Golay first derivative and wavelength selection. The resulting set of six preprocessed tissue measurements forms the basis set associated with the current sampling conditions such as those related to patient, instrument, and time period.
[0085] While the application of the basis set to calibration and measurement data is the same, the selection of the basis set is different. In the case of the calibration set, the basis set may be comprised of a subset of the calibration data or a set of processed tissue measurements that is derived from the calibration set. When a calibration set is collected, several basis sets are selected from the individual calibration samples and combined to form a robust estimate of the mean over a short time interval, for a particular subject, instrument, and probe placement. If more than one sampling location is used per subject, a cluster analysis may be performed to determine a basis set capable of representing a continuum of probe placements. For example, a set of calibration data was collected on 17 subjects and two instruments. Each subject participated in one to three different visits (days of experimentation) and on each visit a guide system was employed to constrain the tissue sampling location. A separate basis set was determined for each subject, visit, and instrument by (1) first preprocessing each tissue measurement and (2) calculating the mean of all preprocessed tissue measurements associated with each subject, visit, and instrument.
[0086] Finally, in certain applications it is desirable to optimize the selection of tissue measurements used to create a basis set. The purpose for selecting an optimal subset of samples is to capture the characteristic background that is comprised of the primary energy absorbing and scattering constituents in the tissue. The inclusion of samples with slight spectral variations not related to these tissue constituents results in the computation of an unrepresentative basis set and leads to a less efficient correction of the data. Four methods are disclosed for performing sample selection prior to the determination of a basis set.
[0087] The first method is to compute a robust estimate of the mean (preprocessed) of the data set targeted for the basis set. Specifically, the trimmed mean is calculated by excluding the highest and lowest 25% of values at each wavelength or variable prior to averaging.
[0088] The second method is to perform a Principal Component Analysis (PCA) and to remove samples that contain high leverage with respect to the sample population. Several methods are employed using PCA such as a leave-one-out analysis of the captured covariance from the resulting PCA eigenvalues. Samples which when left out result in a drop in covariance greater than a preset limit are removed. In an alternate embodiment a T-Squared or Q-Test of the Principal Component scores is performed. Samples exceeding a defined confidence interval are excluded from the basis set computation.
[0089] The third method for selecting a subset of samples is to process known spectral features into quantifiable information that is used to determine the state of the tissue encountered. Spectral bands that contain information related to fat, water, protein, surface reflectance, probe-to-surface contact, etc. is compressed into single property values through processing and then used individually or in combinations, either linear or by complex functionality, to determine samples that have information most consistent with the current optical state of the tissue. Samples associated with inconsistent optical states with respect to the calibration set or property values exceeding those predefined through calibration are excluded. The remaining samples are to compute the basis set.
[0090] The final method involves propagating the collected spectral measurements through a rudimentary predictive model and comparing the resulting analyte estimates to spectral features that are related to key optical characteristics of the encountered tissue. Measurements that have a high correlation to extracted features related to sampling anomalies, such as surface reflectance, are excluded from the sample population. The remaining samples are used to compute the basis set.
[0091] The basis set is typically generated prior to data collection. For the case of subtracting off the initial spectrum of the day, the basis set is the first spectrum or a processed version of it. However, in some instances all of the data is required prior to generation of the basis set. For example, if we were to subtract out the mean spectrum of the day, then we would need all of the spectra prior to processing. For a time-series based basis set, we would utilize data up until the point of data collection in the formation of the basis set.
[0092] Transformation 303 by Applying Basis Set 304
[0093] Referring to FIG. 3, the noninvasive system 301 collects a tissue measurement, m, that is subjected to preprocessing 302 corresponding to the preprocessing performed on the basis set tissue measurements. Subsequently, the preprocessed tissue measurement, x, is transformed 303 for the purpose of attenuating interference as described previously. The tissue measurement is applied to the basis set through a transformation and a set of normalization parameters according to
z =ƒ( x,S,P ) (3)
[0094] where z is the transformed spectral measurement, S is the basis set and P is the set of weights or normalization parameters. The transformation, ƒ(?), is a function that is used to attenuate the interference represented by S that is contained in x. The methods used for transformation may include: subtraction or a weighted subtraction, division, deconvolution, multiplicative scatter correction, and rotation.
[0095] In the preferred embodiment, the transformation occurs through
z=x −( c T S+d ) (4)
[0096] where cε 1×P is used to weight each member of the tissue basis set to optimally reduce the interference in x and dε 1×N is an intercept adjustment. The coefficients c and d are either preset or determined through multiple linear regression. An extension of this embodiment occurs when one tissue sample site is used. In this case, the basis set consists of one processed tissue measurement associated with a particular time and guide placement and the basis set is applied to the processed tissue measurement through
z=x−S. (5)
[0097] Noninvasive Analyte Measurement Through Calibration 307
[0098] The measurement of an analyte, as shown in FIG. 3, is accomplished through the application of a calibration model 307 to the processed tissue measurement, x, after correction via the tissue basis set, S and outlier detection 305 . Therefore, prior to the analyte measurement a calibration model or equation is determined. The calibration model is given by
ŷ =ƒ( z )+ b; (6)
[0099] where ŷ is the estimated glucose concentration, zε 1×N is a processed and transformed tissue measurement, ƒ: N → 1 is a model used to measure glucose on the basis of the preprocessed and transformed tissue measurement, and b is an offset adjustment 306 for the glucose measurement.
[0100] The calibration model is determined from a calibration set of exemplary paired data points each including a pre-processed and transformed (via tissue basis set) tissue measurement and an associated reference analyte value (y) determined from an analysis of a blood or interstitial fluid sample. As described previously, in calibration development, a basis set is developed for each patient and time period in order to account for the short-term optical tissue property changes observed in an individual over time and to correct for gross optical tissue property differences between individuals. The resulting set of preprocessed and transformed tissue measurements and corresponding reference analyte values is used to calculate the calibration model, ƒ(.). Designing the structure of ƒ(.) is through the process of system of identification as introduced by L. Ljung, Systems Identification: Theory for the User, 2d.ed, Prentice Hall (1999). The model parameters are calculated using known methods including multivariate regression or weighted multivariate regression (N. Draper and H. Smith, Applied Regression Analysis, 2d.ed., John Wiley & Sons, New York, 1981), principal component regression (H. Martens, T. Naes, Multivariate Calibration, John Wiley & Sons, New York, 1989), partial least squares regression (P. Geladi, B. Kowalski, Partial least - squares regression: a tutorial, Analytica Chimica Acta, 185, pp.1-17, 1986), or artificial neural networks (S. Haykin, Neural Networks: A Comprehensive Foundation, Prentice Hall, Upper Saddle River N.J., 1994).
[0101] In the preferred embodiment the calibration model is linear:
ŷ=zF+b; (7)
[0102] where Fε N×1 and b is an offset adjustment 306 for the glucose measurement. The determination of F is through partial least squares regression with 15 factors. Alternately, an artificial neural network is employed. For example, after re-sampling z every 10 nm, a neural network may utilize one hidden layer with eight nodes. Additionally, it is important to note that more than one model may be used for a given application as previously disclosed.
[0103] After the development of a calibration and the collection of a basis set specific to a patient, time period, and instrument, measurements occur according to the process shown in FIG. 3.
[0104] Optionally, the bias corrected tissue measurements, z, undergo an outlier detection step 305 . The spectra that we collect in a noninvasive glucose measurement are complex as is the data processing that follows. There are many situations in which the physical sampling (collection of spectra) results in anomalies. These may be based in environmental effects such as temperature or in instrumentation related issues such as applied pressure to the sampling site. Small sampling errors may result in spectra that are not representative of the desired sampled region. These unrepresentative spectra often greatly confound subsequent analysis. A simple example is that if you mean center a data set and utilize in the calculation of the mean an extreme outlier, then the mean is not ultimately subtracted. For another example, for analyses that utilize a multivariate model such as PLS or PCR spectral outliers greatly confound multivariate model generation and/or subsequent analysis. Hence, the purpose of outlier detection is to remove samples that confound model generation and/or maintenance. Separately, outlier detection is critical so that unrepresentative sample spectra are not converted into inaccurate predicted glucose concentrations but are rather reported as bad measurements.
[0105] As indicated in FIG. 3, the necessity for outlier detection, and the form of an outlier detection procedure are dependent on the sampling technology employed. However, in the preferred embodiment outlier detection is performed by comparing the preprocessed and transformed tissue measurement z to the members of the basis set through a distance metric or measure of similarity. Preferably one of the following metrics is used to determine a measure of similarity: Euclidean distance, the Mahalanobis distance, or the correlation coefficient. When the tissue measurement is no longer similar to the members of the basis set the interference has changed and a new basis set is collected. For example, when the basis set has one member that has been preprocessed, subsequent tissue members are compared with the basis set through the calculation of the correlation coefficient. If repeated tissue memberships have a correlation coefficient when compared to the basis set less than 0.98 the basis set is re-collected to represent the new tissue state.
[0106] Alternately, the detection of an invalid basis set is achieved by monitoring key optical properties of the sampled tissue that are reflected in select spectral features and determining if the variation in the features exceeds that from the calibration set or other previously established limits. Methods such as Principal Component Analysis (PCA) and Linear Discriminate Analysis (LDA) are used to define sample rejection criteria and set detection limits. Once it is determined that a new template is needed, the user collects N (N being greater than or equal to one) spectral samples and M (being greater than or equal to one) direct measurements of the desired biological constituent(s). Sample selection techniques described subsequently is applied to determine the subset of samples that will be used in computing the new tissue template.
[0107] Bias Adjustment
[0108] The correction of interference through a basis set leads to a bias in the measurement that causes a bias correction to be beneficial to both the calibration reference values and the analyte estimates. The bias adjustment is associated with each tissue basis set and is determined by comparing an analyte measurement with a known value. Specifically, the bias adjustment is set equal to the difference between an analyte measurement and the known property value according to:
b=y−ŷ; (8)
[0109] where ŷ is the noninvasive analyte measurement and y is the reference analyte value. When more than one pair of noninvasive analyte measurements and reference analyte values are available, then b is taken as the mean difference of all pairs. In the preferred embodiment, a reference analyte value is collected at the same time as the basis set and b=y.
[0110] During calibration, the reference property values are adjusted prior to the calculation of the calibration model by subtracting an analyte value associated with the tissue template measurement from each reference property value. In the preferred embodiment, the analyte value is calculated as the average of the reference property values associated with each member of the basis set.
[0111] Exemplary Application of the Invention
[0112] A data set was collected on five individuals with diabetes who participated in a clinical study involving the manipulation of blood glucose levels through carbohydrate ingestion and insulin administration. As part of the clinical protocol each subject participated in approximately three to four visits with each visit lasting approximately 8 hours and occurring at a minimum of four days apart. At the beginning of each visit a probe placement guide was attached to the tissue site in which future samples for that visit were to be collected. Spectral samples were collected by aligning the fiber optic probe from the near-infrared spectrometer with the aperture of the probe placement guide and inserting the fiber probe into the guide aperture by lowering the sample toward the probe. A reference blood glucose concentration was collected with each spectral sample and samples were collected approximately 15 minutes apart.
[0113] The collected spectral measurements were preprocessed using no basis set, a client specific basis set in which a subset of data from each individual was used to process their own respected data, and a visit specific basis set according to the preferred embodiment of the invention in which a subset of data from each visit was used to process their respected visits. The spectral variance associated with the three preprocessed and transformed data sets were computed at each wavelength and are plotted in FIG. 4. The overall variance across all wavelengths was reduced using the client basis set and was further reduced using the visit specific basis set. The client specific basis set successfully reduces the patient-to-patient interference but fails to address the key problem related to sample heterogeneity and complexity and physiological and chemical variation related to the dynamic nature of the tissue that occurs over time. Application of the visit specific basis set localizes the collected measurements with respect to the sampled tissue site and time which attenuates major interferences caused by tissue heterogeneity and physiological variation. A standardized multivariable glucose calibration model that was previously developed using the process disclosed in the invention was applied to preprocessed and transformed data sets to determine the impact of each method on glucose prediction. FIGS. 5 and 6 contain the independent glucose predictions on a Clarke-Error grid obtained from the data corrected using no basis set and a client specific basis set, respectively. FIG. 7 contains the independent predictions from the data processed using the visit specific basis set that was computed using the method described in the preferred embodiment. The predictions obtained by applying no basis set and a client basis set exposed the existence of different clusters in the predictions representing the variability of the optically sampled tissue between individuals and within individuals on different visits. The distances between clusters in the Clarke-Error grid were reduced but not effectively removed when applying a client basis set to the data. Application of the visit specific basis revealed no inherent clusters in the glucose predictions and significantly improved prediction accuracy between individuals and within an individual between visits. This illustrates the effectiveness of the disclosed method versus the previous methods in effectively compensating for interferences related to tissue heterogeneity, patient-to-patient variation, instrument related variation, and physiological variation through time.
[0114] The preferred embodiments disclosed herein have been described and illustrated by way of example only, and not by way of limitation. Other modifications and variations to the invention will be apparent to those skilled in the art from the foregoing detailed disclosure. While only certain embodiments of the invention have been specifically described herein, it will be apparent that numerous modifications may be made thereto without departing from the spirit and scope of the invention.
[0115] Accordingly, the invention should only be limited by the Claims included below.
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A solution for reducing interference in noninvasive spectroscopic measurements of tissue and blood analytes is provided. By applying a basis set representing various tissue components to a collected sample measurement, measurement interferences resulting from the heterogeneity of tissue, sampling site differences, patient-to-patient variation, physiological variation, and instrumental differences are reduced. Consequently, the transformed sample measurements are more suitable for developing calibrations that are robust with respect to sample-to-sample variation, variation through time, and instrument related differences. In the calibration phase, data associated with a particular tissue sample site is corrected using a selected subset of data within the same data set. This method reduces the complexity of the data and reduces the intra-subject, inter-subject, and inter-instrument variations by removing interference specific to the respective data subset. In the measurement phase, the basis set correction is applied using a minimal number of initial samples collected from the sample site(s) where future samples will be collected.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional No. 60/611,553 filed Sep. 20, 2004, and which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention is generally related to vehicle stability control. More particularly, the invention relates to the control of damping components as part of a vehicle stability control.
BACKGROUND OF THE INVENTION
Steering stability and performance of a vehicle are largely characterized by the vehicle's understeer and oversteer behavior. The vehicle is in an understeer condition if the vehicle yaw is less than the operator steering input, where turning the steering wheel more does not correct the understeer condition because the wheels are saturated. The vehicle is in an oversteer condition if the vehicle yaw is greater than the operator steering input. Surfaces such as wet or uneven pavement, ice, snow or gravel also present vehicle stability and handling challenges to the driver. Similarly, in a panic or emergency situation, such as during obstacle avoidance, a driver may react by applying too much steering or failing to counter-steer to bring the vehicle back to its intended path. In any of these cases, the actual vehicle steering path deviates from the intended steering path.
Modern vehicles sometimes incorporate active vehicle control sub-systems that enhance operator comfort and safety, including sub-systems which address such deviations in the vehicle path. One such subsystem is known as a vehicle stability enhancement (VSE) system that assists the vehicle operator in providing vehicle handling. The VSE system helps the vehicle operator maintain control during rapid or emergency steering and braking maneuvers and can correct for understeer and oversteer conditions. The VSE system senses wheel speed, steering angle, vehicle speed and yaw rate. The VSE system uses these inputs to reduce engine torque and apply vehicle braking to maintain the vehicle travel along the intended path.
Another active vehicle control sub-system is known as an active front steering (AFS) system for providing automatic front-wheel steering. AFS systems employ a steering actuator system that receives an operator intended steering signal from a hand wheel sensor, a vehicle speed signal and a vehicle yaw rate signal, and provides a correction to the operator steering signal to cause the vehicle to more closely follow the vehicle operator's intended steering path to increase vehicle stability and handling. The AFS system is able to provide steering corrections much quicker than the vehicle operator's reaction time, so that the amount of operator steering is reduced. In such applications, the AFS system includes yaw rate measurements and feedback control to generate an additional steering input to the front wheels.
Semi-active suspension systems are also incorporated into some modern vehicles and are generally characterized by dampers which are controlled to change the suspension characteristics of the vehicle based on road conditions, vehicle speed, yaw and other considerations. Variable fluid-based dampers are known having discrete damping states and continuously variable damping states. Variability in damping may be attained by variable orifice devices or controlled viscosity fluids (e.g. magnetorheological (MR) or electrorheological (ER)) within the damping device. Variable dampers are used predominantly to achieve low speed ride comfort and high speed handling enhancement. However, variable damping techniques are known to enhance vehicle stability in certain understeer and oversteer situations.
The VSE, AFS and suspension control systems are generally effective at maintaining vehicle stability in light of slowly varying or static road conditions. However, severe and rapidly transient road conditions (e.g. pot holes) effect inputs which may significantly disrupt stability controls when active.
Therefore, it is desirable to account for transient road conditions in vehicle stability systems and minimize the undesirable effects thereof on such systems and controls so that the systems can provide the intended vehicle path across a variety of slowly and rapidly changing road conditions.
SUMMARY OF THE INVENTION
The present invention actively controls vehicle suspension damping as part of a vehicle stability control. A vehicle has a semi-active suspension including a plurality of controllable suspension dampers. In accordance with one aspect of the present invention, a method for vehicle stability suspension control includes determining turning direction for the vehicle and damper motion direction for each of the plurality of controllable suspension dampers. Open loop damping commands are determined for the plurality of controllable suspension dampers. Closed loop damping commands are also determined for the plurality of controllable suspension dampers. Control of each of the plurality of controllable suspension dampers is carried out in accordance with respective ones of the open loop and closed loop damping commands as a function of turning direction and respective damper motion direction. The closed loop damping commands are preferably implemented in conjunction with vehicle oversteer and understeer events. The open loop and closed loop damping commands are determined based on respective pluralities of vehicle dynamics metrics including vehicle speed, vehicle lateral acceleration and steering wheel angle.
In accordance with another aspect of the present invention, a method for vehicle stability suspension control includes providing vehicle stability control critical and non-critical combinations of vehicle corner dampers, damper motion directions, and vehicle turning directions. A feedback damper control signal is provided to the vehicle stability control critical combinations and a feedforward damper control signal is provided to the vehicle stability control non-critical combinations. The feedback and feedforward damper control signals are determined based on respective pluralities of vehicle dynamics metrics including vehicle speed, vehicle lateral acceleration and steering wheel angle.
In accordance with another aspect of the present invention, a control apparatus for the vehicle suspension system includes a feedback controller effective to provide a suspension damper feedback command, wherein the feedback controller includes a respective plurality of vehicle dynamics metrics. The control apparatus for the vehicle suspension system further includes a feedforward controller effective to provide a suspension damper feedforward command, wherein the feedforward controller includes a respective plurality of vehicle dynamics metrics. And, the control apparatus for the vehicle suspension system also includes a suspension damper command arbitrator effective to determine which of the feedback command and the feedforward command is used to control each of the controllable suspension dampers, wherein the suspension command arbitrator includes a respective plurality of vehicle dynamics metrics. The feedback controller preferably includes vehicle yaw rate error and vehicle lateral velocity error. And, the respective pluralities of vehicle dynamics metrics of the feedback controller and the feedforward controller include vehicle speed, vehicle lateral acceleration and steering wheel angle.
In accordance with another aspect of the present invention, a method for suspension control includes determining vehicle turning direction and a respective damper motion direction for each vehicle corner damper. During a vehicle stability enhancement suspension control, for example vehicle oversteer or understeer events, vehicle corner dampers corresponding to predetermined control critical combinations of vehicle turning direction and respective corner damper motion direction are closed loop controlled whereas vehicle corner dampers corresponding to predetermined control non-critical combinations of vehicle turning direction and respective corner damper motion direction are open loop controlled.
These and other advantages and features of the invention will become apparent from the following description, claims and figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block schematic diagram illustrating a controlled vehicular damping system in accordance with the present invention;
FIG. 2 is a control schematic diagram illustrating a preferred implementation of the damper feedback control of FIG. 1 in accordance with the present invention;
FIG. 3 is a table of exemplary vehicle yaw rate proportional gain calibrations for the control of FIG. 2 exemplifying the preferred relationship to vehicle speed and lateral acceleration in accordance with the present invention;
FIG. 4 is a detailed block schematic diagram illustrating a preferred implementation of the damper command arbitration block of FIG. 1 in accordance with the present invention; and
FIG. 5 is a table illustrating critical and non-critical corner damper and motion combinations for use by the damper command arbitration block of FIG. 2 in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference first to FIG. 1 , a schematic block diagram of a vehicle 11 suspension damper control system in accordance with the present invention is illustrated. The vehicle 11 provides a plurality of vehicle dynamics metrics 12 from sensors or derivations, including vehicle yaw rate ({dot over (ψ)}), vehicle lateral acceleration (α y ), vehicle speed (V x ), steering wheel angle (δ) and individual damper positions (P n ). The system includes a plurality of suspension dampers 13 individually associated with the respective suspension corners of the vehicle 11 . Each damper effects a damping force (F d ) upon vehicle 11 in accordance with damper commands 16 , for example control currents for effecting a desired damping response in a MR based damper. The system further includes damper command arbitration block 15 for determining damping forces for application to the plurality of dampers based on a closed loop suspension feedback command 18 , a suspension feedforward command 14 , and exemplary vehicle dynamics metrics including vehicle understeer/oversteer conditions 20 and vehicle yaw rate ({dot over (ψ)}) as further described herein below.
Closed loop suspension feedback command 18 is determined in accordance with an exemplary feedback control as follows. Vehicle speed (V x ) and steering wheel angle (δ) are provided to yaw rate command block 17 . A desired yaw rate command ({dot over (ψ)} DES ) is calculated by yaw rate command block 17 , for example as disclosed in U.S. Pat. Nos. 5,720,533, 5,746,486 and 5,941,919, all of which are assigned to the assignee of the present invention and are hereby incorporated herein by reference.
Vehicle speed (V x ), steering wheel angle (δ) and lateral acceleration (α y ) are provided to lateral velocity command block 19 . A desired lateral velocity command (V yDES ) is calculated by lateral velocity command block 19 , for example as disclosed in U.S. Pat. No. 6,035,251, which is assigned to the assignee of the present invention and is hereby incorporated herein by reference.
Lateral velocity estimator 21 is provided with vehicle yaw rate ({dot over (ψ)}), vehicle lateral acceleration (α y ) and vehicle speed to estimate therefrom the vehicle lateral velocity (V yEST ). An estimate of lateral velocity can be made through integration of vehicle lateral velocity rate ({dot over (V)} y ) as represented by the following relationship among the inputs to block 21 :
{dot over (V)} y =α y −{dot over (ψ)}· V x (1)
However, due to characteristic sensor bias and degradation of an integrated signal caused thereby, it is preferred to utilize a diminishing, integrator effective to substantially eliminate the effect of the bias on the integrated output. Further details respecting such an integration technique implementation in a stability control application can be found in U.S. Pat. No. 6,056,371, which is assigned to the assignee of the present invention and is hereby incorporated herein by reference.
Desired yaw rate command ({dot over (ψ)} DES ), calculated by yaw rate command block 17 is compared to vehicle yaw rate ({dot over (ψ)}) at node 23 to determine vehicle yaw rate error ({dot over (ψ)} ERR ). Similarly, desired lateral velocity command (V yDES ) calculated by lateral velocity command block 19 is compared to vehicle lateral velocity (V yEST ) at node 25 to determine vehicle lateral velocity error (V yERR ). Both error signals, ({dot over (ψ)} ERR ) and (V yERR ), are provided to feedback control block 27 for use in calculating the suspension feedback command for input to the command arbitration block 15 .
FIG. 2 illustrates an exemplary control within feedback control block 27 . Therein, proportional and derivative (PD) components of the suspension feedback command from both error signals, ({dot over (ψ)} ERR ) and (V yERR ), are determined. Vehicle lateral velocity rate error ({dot over (V)} yERR ) may be determined from vehicle lateral velocity error (V yERR ) through traditional derivative processing techniques. Alternatively, the lateral velocity rate error ({dot over (V)} yERR ), is determined with the lateral velocity rate ({dot over (V)} y ), as calculated in lateral velocity estimator 21 and assumption that the lateral velocity rate command is null. With such assumptions, the lateral velocity rate error is substantially equivalent to the lateral velocity rate as shown in the relationship below.
{dot over (V)} yERR≈{dot over (V)} y (2)
A lateral velocity derivative gain (K dVy ) is applied to the vehicle lateral velocity error derivative ({dot over (V)} yERR ), and the resultant component provided to summing node 28 . A lateral velocity proportional gain (K pVy ) is similarly applied to the vehicle lateral velocity error (V yERR ), and the resultant component provided to summing node 28 . Vehicle yaw rate error derivative ({umlaut over (ψ)} ERR ) is determined from yaw rate error ({dot over (ψ)} ERR ). A yaw rate derivative gain (K d{dot over (ψ)} ) is applied to the vehicle yaw rate error derivative ({umlaut over (ψ)} ERR ), and the resultant component provided to summing node 28 . A yaw rate proportional gain (K p{dot over (ψ)} ) is similarly applied to the yaw rate error ({dot over (ψ)} ERR ), and the resultant component provided to summing node 28 . The various gains in the PD control of feedback control block 27 are vehicle specific calibration values. Particularly preferred yaw rate proportional gain (K p{dot over (ψ)} ), is characterized as functions of vehicle speed (V x ), and vehicle lateral acceleration (α y ). More particularly, the general character of the yaw rate proportional gain (K p{dot over (ψ)} ), is such that the gain increases with increasing vehicle speed and increases with increasing absolute value of vehicle lateral acceleration. This general character of a preferred yaw rate proportional gain (K p{dot over (ψ)} ) is further illustrated in the table of FIG. 3 . Similarly with respect to the yaw rate derivative gain (K d{dot over (ψ)} ), the gain preferably is characterized as function of vehicle speed (V x ), and vehicle lateral acceleration (α y ). And, more particularly, the general character of the yaw rate derivative gain (K d{dot over (ψ)} ) is such that the gain increases with increasing vehicle speed and increases with increasing absolute value of vehicle lateral acceleration. Particularly preferred lateral velocity proportional gain (K pVy ) is also characterized as function of vehicle speed (V x ), and vehicle lateral acceleration (α y ). And, more particularly, the general character of the lateral velocity proportional gain (K p{dot over (ψ)} ), is also such that the gain increases with increasing vehicle speed and increases with increasing absolute value of vehicle lateral acceleration. Similarly with respect to the lateral velocity derivative gain (K dVy ), the gain preferably is also characterized as function of vehicle speed (V x ), and vehicle lateral acceleration (α y ). And, more particularly, the general character of the lateral velocity derivative gain (K dVy ) is such that the gain increases with increasing vehicle speed and increases with increasing absolute value of vehicle lateral acceleration.
Closed loop suspension feedback control as described immediately above is particularly responsive to the types of relatively rapid, transient and severe changes is road conditions that may have an undesirable destabilizing influence upon the vehicle, particularly a vehicle already under some form of vehicle stability control as described herein above.
Feedforward control block 29 is used in calculating the suspension feedforward commands 14 for input to the command arbitration block 15 . Vehicle lateral acceleration (α y ), vehicle speed (V x ), steering wheel angle (δ) and damper positions (P n ) are provided to feedforward control block 29 . Preferably, the feedforward control block 29 implements the well-known skyhook suspension model utilizing a fictitious inertial grounding of the damper in determining the resultant suspension feedforward command 14 .
Understeer/oversteer behavior block 31 includes vehicle yaw rate ({dot over (ψ)}), vehicle lateral acceleration (α y ), vehicle speed (V x ) and steering wheel angle (δ) inputs for use in determining resultant signals identifying current vehicle understeer/oversteer conditions. Preferably, the resultant vehicle understeer/oversteer conditions 20 are represented in the form of oversteer and understeer flags which definitively indicate whether there is significant oversteer or understeer behavior or the behavior is indeterminate or insignificant with respect to oversteer or understeer for purposes of the present control. Any suitable method for characterizing vehicle behavior as oversteer or understeer can be utilized. An exemplary preferred determination of such understeer and oversteer flags is set forth in co-pending U.S. patent application Ser. No. 10/978,982 filed Nov. 1, 2004, assigned to the assignee of the present invention, the contents of which are hereby incorporated herein by reference.
With reference now to FIG. 4 , the damper command arbitration block 15 is presented in further preferred detail. An unsigned (i.e. absolute value or magnitude) suspension feedback command is provided to total damping block 41 to calculate the total damping command which represents an aggregate damping force from all four vehicle corner dampers. Unsigned suspension feedback command and understeer and oversteer flags (K USF , K OSF ) from understeer/oversteer behavior block 31 are provided to block 43 which determines a signed suspension feedback command. By convention, negatively signed commands correspond to understeer whereas positively signed commands correspond to oversteer. The signed suspension feedback command is then provided to a gain block 45 whereat the ratio of front and rear split (i.e. distribution) of total damping force is calculated (F/R split command). The total damping command from block 41 and the F/R split command from block 45 are then provided to F/R distribution block 47 to calculate the total front suspension damping force and the total rear suspension damping force commands. It is generally well understood in the art that understeer behavior can be improved with a damping distribution weighted toward the rear of the vehicle and oversteer behavior can be improved with a damping distribution weighted toward the front of the vehicle. Side-to-side distribution block 49 next determined from the total front suspension damping force and the total rear suspension damping force commands the respective side-to-side distribution of damping force. In the present example, the distribution is simply 50% to each of the respective vehicle corner dampers associated with the corresponding front and rear damping force commands. The output from the side-to-side distribution block 49 comprises four corner specific suspension feedback damping commands (LF, RF, LR and RR).
The four corner specific suspension feedback damping commands are provided to damper motion resolver block 51 . Additionally, damper motion resolver block 51 includes vehicle yaw rate ({dot over (ψ)}) and the suspension feedforward commands from the feedforward control block 29 . The damper motion resolver block 51 determines damper motion dependant damping force commands in accordance with the criticality of the damper motion to the feedback control maintaining vehicle stability in light of potentially destabilizing ride events. The four corner specific suspension feedback damping commands are therefore further resolved into jounce and rebound commands for the control of the damping forces at the respective vehicle corner dampers.
In a preferred embodiment, the suspension feedforward command will be used to command the damping force for the corners and non-critical damper motion combinations. And, the suspension feedback command will be used to command the damping force for the corners and critical damper motion combinations. The matrix of FIG. 5 illustrates the critical and non-critical corner damper and motion combinations. For example, the feedback control in a vehicle executing a right turn maneuver experiencing an oversteer event would exhibit increasing suspension damper feedback commands corresponding to the front corners and decreasing suspension damper feedback commands corresponding to the rear corners in order to arrest the oversteer event. In contrast, a vehicle executing a right turn maneuver experiencing an understeer event would exhibit increasing suspension damper feedback commands corresponding to the rear corners and decreasing suspension damper feedback commands corresponding to the front corners in order to arrest the understeer event. Since the vehicle is in a right turn, the control critical damper motion and vehicle corner combinations are, as set forth in FIG. 5 , jounce for the left front and rear corners and rebound for the right front and rear corners. Similarly for the right turn, the control non-critical damper motion and vehicle corner combinations are, as set forth in FIG. 5 , rebound for the left front and rear corners and jounce for the right front and rear corners. The damper command arbitration block 15 would implement the feedback commands to the control critical damper motion and vehicle corner combinations and implement the feedforward commands to the control non-critical damper motion and vehicle corner combinations. The matrix combinations of FIG. 5 may be implemented, for example, through vehicle calibration tables corresponding, for example, to vehicle turning direction and vehicle stability control flags. By the present invention, the closed loop damper control is implemented only on the vehicle corner dampers and in the direction of damper motion critical to the yaw dynamics of the vehicle thereby minimizing the effects of such control on potentially destabilizing ride events which may occur during the application of the closed loop control.
The invention has been described with respect to certain exemplary embodiments. However, it is to be understood that various modifications and alternative implementations of the invention without departing from the scope of the invention as defined in the following claims.
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A vehicle comprises a semi-active suspension including controllably adjustable suspension dampers. Open loop and closed loop damper commands are determined for each damper and, depending upon turning direction and damper motion, each damper is controlled with one of the open loop and closed loop damper commands.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fibrous structure (either of the woven or non-woven type, natural or synthetic etc.). As it is well known, such fibrous structures are used in many industrial applications, such as those given hereafter by way of illustration without any limitation:
hygienic articles (feminine as well as medical/surgical) such as diapers, sanitary napkins, incontinence guards, wipes, wound dressing, face masks and the like; industrial applications such as for use in isolation products (thermal, electrical) or filtration products, or else floor coverings; textile products.
2. Description of Related Art
Depending on the kind of fibrous structures and applications considered, properties of hydrophilicity and/or adhesion will be particularly looked for.
Taking the example of non-woven materials, they are produced from comparatively hydrophobic synthetic fibres such as, for example, fibres of polypropylene or polyethylene which are treated and/or apertured in order to make the materials liquid permeable.
In order to obtain fluid absorbent articles which exhibit good wicking ability, a high total and local fluid uptake capacity, good fluid retaining capacity and a high degree of surface dryness, such articles are usually built up of a plurality of different non-woven fibrous structures having different functions. One major problem when constructing fluid absorbent articles of this kind is, however, that it is difficult to obtain optimal wettability i.e. an optimal degree of hydrophilicity which remains unchanged after the article has been exposed to wetting. Furthermore, it is difficult to obtain stable wetting characteristics in absorbent articles which are stored for an extended period of time.
In WO 91/05108, it has been experimentally shown that there is a connection between increased surface area and increased rate of absorption. The patent application relates to fibres which have been provided with a porous layer attached to the surface of the fibres. The porous layer increases the specific surface of the fibres which implies that absorbent material containing such fibres obtains an improved rate of absorption and wicking ability.
The porous layer is created by impregnating fibrous material with hydrophilic chemicals while the fibres are kept in a dry or in a wet state in the form of dewatered fibre pulp or in the form of an aqueous suspension of fibres, respectively. The treatment may be performed by bringing the fibres into contact with the hydrophilic chemicals for instance by spraying fibres in a formed absorbent layer with a chemical solution or by mixing the chemicals with a fibre suspension wherein the chemicals are added as solids, in a solution, or in any commercially available form.
Regarding fluid permeable cover sheets for use in absorbent articles such as diapers, incontinence guards and sanitary napkins, wherein the cover sheet is intended to be in contact with the body of a user during use, it is important that the cover sheet could stand repeated wettings.
In other words, the cover sheet should remain fluid permeable even after the absorbent article has been exposed to fluid impact several times. Furthermore, it is important that the cover sheet can accept a large amount of fluid during a short interval of time. Another important property of the fluid permeable cover sheet is the ability to exhibit high surface dryness even after having been exposed to several wettings. In order to obtain a cover sheet having the desired properties, it is important that the cover sheet exhibits an optimal, i.e. a desired, degree of hydrophilicity and that the degree of hydrophilicity varies only within a very limited range when the fibrous structure is wetted or when it is subjected to ageing.
As well known to the man skilled in the art, the literature of these fields talk about the properties of “hydrophilicity” or “wettability” of a substrate, or else of “adhesion” of a third body on a substrate and often report measurements of “surface tension”, “contact angle” and “peeling test” to evaluate such properties.
A commonly used method for increasing the wettability of fluid permeable cover sheets for use as cover sheets in absorbent articles, is to treat the material with surfactants. Non-woven materials used as cover sheets for absorbent articles are usually made of synthetic materials which are inherently hydrophobic and which have been treated with surfactants in order to become wettable and readily permeable to fluids. The treatment is usually carried out by coating the hydrophobic material with a surfactant. In order for a material to be fluid wettable, the contact angle between the surface of the material and the fluid must be less than 90°. However, a problem in connection with using cover sheets which have been coated with a surfactant is that such cover sheets exhibit decreasing fluid permeability with repeated wetting. The reason for this is that the applied surfactants are not firmly attached to the surface of the cover material and will be detached from the cover material and solved in body fluid during the first wetting. At subsequent wettings the amount of surfactant which remains on the surface of the cover sheet is therefore considerably reduced, resulting in impaired fluid permeability.
Another problem in relation to the use of articles having surfactant-coated cover sheets is that the surfactant compounds may migrate from the cover sheet to the skin of the user, thereby causing skin irritation.
An additional problem with absorbent articles having cover sheets of this kind is that during storage of the article the surfactants may migrate from the cover sheet into the absorbent structure, resulting in the fluid permeability of the cover sheet being insufficient even at the first fluid impact.
Still another problem with surfactant-coated cover sheets is that the method of applying the surfactant is less attractive from an environmental point of view since the surfactant agent is usually applied to the surface of the material in the form of a solution which, for instance, is sprayed over the surface and causes the surfactant to be emitted into the ambient air.
The present invention provides a fibrous structure of the kind mentioned in the introduction. The fibrous structure exhibits when desired a well defined rate of wetting, i.e. a predetermined degree of hydrophilicity which is substantially unaffected by wetting of the fibrous structure, and/or good properties of adhesion which are substantially unaffected by wetting of the fibrous structure.
Furthermore, with the present invention a fibrous structure is provided, wherein the desired, predetermined degree of hydrophilicity and adhesion properties are maintained even after the structure has been stored for a period of time. Accordingly, the present invention offers a hygienic product having a well defined and controlled course of wetting.
A fibrous structure in accordance with the invention is primarily distinguished by one or several types of polar silicon-containing compounds, being bound to at least one portion of the surface of the fibrous structure by interaction between the surface and the silicon-containing compounds.
As previously mentioned, the fibrous structure according to the invention exhibits a predetermined degree of hydrophilicity and adhesion properties which are substantially unaffected by wetting of the fibrous structure.
In accordance with one embodiment, the silicon-containing compound consists of a compound of the type SiO x H y wherein x preferably is in the range of 1 to 4, and y preferably in the range of 0 to 4.
An advantage with a fibrous structure of this type is that the wetting characteristics of the structure has proved to be substantially constant during wetting and that the fibrous structure is comparatively resistant to ageing.
Without being in anyway limited by the following theoretical explanation of why a hydrophilic surface having polar silicon-containing compounds exhibits a stable hydrophilicity and adhesion properties both after repeated wetting and after ageing of the material structure, one could think that the polar silicon-containing compounds form a kind of clusters which are sufficiently large to inhibit reorientation of polymer chains and, accordingly, the ageing phenomenon. However, the theory is not fully developed and should accordingly not be regarded as being binding to the invention.
As already mentioned, the fibrous structures in accordance with the invention exhibit at least one polar silicon-containing material surface, or portion of a surface. However, it is possible according to the invention to apply silicon-containing compounds to both surfaces of a sheet of material. Further, one or both surfaces of the material may exhibit one or more delimited areas having polar silicon-containing compounds.
According to one aspect of the invention, the fibrous structure comprises one or more non-woven materials.
According to one further aspect of the invention, the fibrous structure of the invention may, for instance, be used as fluid permeable cover sheet for absorbent articles or as a fluid transfer layer between the fluid permeable cover sheet and the absorbent structure in an absorbent article, or for the absorbent structure itself.
According to another aspect of the invention, the fibrous structure of the invention may be used as a liquid absorbing wipe, or as a component in a wipe or the like.
In still another aspect of the invention, the fibrous structure may comprise one or more tissue layers.
As well known to the man skilled in the art, the term “tissue” commonly covers fibrous material based on cellulose or cellulose in combination with synthetic fibres and typically used in the manufacture of household items such as kitchen towels, toilet paper, or napkins, in the manufacture of industrial wipes for absorption of different liquids, or else for the manufacture of layers entering the structure of absorbent articles such as diapers, incontinence guards, sanitary napkins or the like.
The invention additionally concerns an absorbent article such as a diaper, an incontinence guard, a sanitary napkin or the like comprising an absorption body being enclosed between a fluid impermeable cover layer and a fluid permeable cover layer, said article comprising at least one portion comprising a fibrous structure in accordance with the invention.
The fibrous structure may constitute a part or all of the fluid pervious cover layer and/or of a fluid transfer layer positioned between the fluid pervious cover layer and the absorption body.
In a hygienic product for fluid absorption purposes and being made of a plurality of individual layers, fluid transfer between the different layers is of great importance both for the rate of wicking within each individual layer and for the total fluid uptake capacity of the hygienic product. From the above discussion it appears that in fluid absorbent articles of this kind it is very important that all layers of material exhibit a well-defined and stable degree of hydrophilicity which only varies to a very limited extent with wetting and ageing.
According to one of the aspects of the invention, the liquid permeable cover sheet, the fluid transfer layer, and the absorption body have different degrees of hydrophilicity.
According to one of the preferred embodiments of the invention, the fluid transfer layer of the hygiene article comprises a set of several fibrous structures according to the invention, the set of fibrous structures presenting a gradient of degrees of hydrophilicity.
The invention further concerns a hygienic product such as a wipe, a wound dressing or the like, comprising a fibrous structure in accordance with the invention.
The invention further concerns a method for producing a fibrous structure having one or more types of polar silicon-containing compounds bound to at least a portion of a surface of the fibrous structure. The method is primarily distinguished by the fact that the fibrous structure is submitted to an atmosphere comprising excited and unstable species, as-obtained through the application of an electrical discharge to an initial mixture comprising a carrier gas, an oxidant, and at least one type of silicon-containing gaseous compound.
An advantage with a method of this kind, is that it is carried out under dry conditions which implies that the silicon-containing compound does not have to be solved in a solvent before application which means that the method is advantageous from an environmental point of view.
In accordance with a preferred embodiment, the treatment is based on an electrical discharge led in a gaseous mixture, leading to the formation of a plasma.
As well known, a plasma is a gaseous medium containing ions, radicals, electrons, excited and unstable species. It can be obtained through supplying to a gaseous mixture a sufficient amount of energy, at a defined pressure, for example very low pressure or atmospheric pressure.
All the species of the plasma can react between them and/or with the components of the gaseous mixture to create new ions, radicals, and excited species.
When it is carried out at atmospheric pressure with a high voltage electrical signal as energy supply, the plasma is commonly called “corona”.
According to this preferred embodiment, the fibrous structure is therefore submitted to an electrical discharge, in presence of a gaseous mixture comprising at least one type of silicon-containing gaseous compound, oxygen or other oxygen-containing gas, and a carrier gas.
According to another embodiment of the invention, the fibrous structure is submitted to a treatment atmosphere as-obtained in post-discharge of an electrical discharge applied to a gaseous mixture comprising at least one type of silicon-containing gaseous compound, oxygen or other oxygen-containing gas, and a carrier gas (the fibrous structure is here submitted to the treatment atmosphere outside the discharge).
In any case, the unstable and excited species of the atmosphere react with the polymer chains of the surface of the fibrous structure, leading to the formation of radicals of said polymer chains. These radicals can then react with the species present in their vicinity forming this way new bondings and new functional groups on the surface. Functional groups which are relevant to the present invention are polar silicon-containing groups. The functional groups this way introduced on the surface of the material are much more strongly bound to the surface than an active substance which has been applied as a conventional coating.
A method for corona treatment is described in U.S. Pat. No. 5,576,076, U.S. Pat. No. 5,527,629 and U.S. Pat. No. 5,523,124. The gas mixture is based on a carrier gas which usually is nitrogen, a silicon-containing compound and an oxidant. The treatment creates a layer of material having a glassy, hydrophilic surface.
The disclosed method is suitable for use in connection with the invention. However, the invention is not limited to the method described in the above entioned applications, but comprises all types of gas phase treatments in which polar silicon-containing groups are introduced to a surface of a fibrous structure.
In accordance with a preferred embodiment the silicon-containing compound in the gas mixture is a silane compound. Some examples of such compounds are Si n H n+2 where n preferably is from 1 to 4, silicon hydroxide, halogenated silanes, alkoxysilane or organosilane. The oxidant is preferably oxygen or other oxygen-containing gases such as, for instance, CO, CO, NO, N 2 O or NO 2 . The carrier gas may consist of nitrogen, argon, helium, or a mixture thereof.
According to one of the embodiments of the invention, prior to being treated with the medium comprising unstable and excited species, resulting from the application of an electrical discharge to the gaseous mixture comprising the silicon-containing gaseous compound, an oxidant and a carrier gas, the fibrous structure has been in a first step submitted to a corona discharge under air (surface preparation).
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the present invention will become apparent from the following detailed description of preferred embodiments thereof in connection with the appended drawings in which:
FIG. 1 shows a diaper seen from the side which is intended to be facing a user during use; and
FIG. 2 shows an instrument for measuring the contact angle for individual fibers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The diaper 100 which is shown in FIG. 1 comprises a fluid permeable cover sheet 101 , a fluid impermeable cover sheet 103 and an absorption body 105 enclosed between the cover sheets 101 , 103 . The fluid impermeable cover sheet 103 may consist of a fluid impermeable plastic film, a sheet of non-woven material which has been provided with a fluid resistant coating or any other type of flexible sheet material which resists fluid penetration. Generally, it is an advantage if the fluid impermeable cover sheet 103 is breathable at least to some extent, implying that water vapor may pass through the cover sheet.
The covering sheets 101 , 103 have a planar extension which is somewhat greater than the planar extension of the absorption body 105 and comprise edge portions 107 which protrude beyond the peripheral edge of the absorption body 105 . The cover sheets 101 , 103 are joined within the protruding edge portions 107 by means of, for instance, adhesive or welding with heat or ultrasonically.
Further, the diaper 100 has two longitudinally extending side edges 123 , 125 , a front end edge 109 and a rear end edge 111 , and exhibits a front portion 113 , a rear portion 115 , and an intermediate crotch portion 117 which is narrower than the end portions 113 , 115 .
In addition, elements 119 , 121 are arranged along the side edges 123 , 125 at the crotch portion 117 of the diaper. The purpose of the elastic elements 119 , 121 is to provide a means for keeping the diaper in sealing contact around the legs of a user when the diaper is being worn. An additional elastic element 127 is arranged along the rear end edge 111 and is provided in order to give the diaper 100 a certain degree of extensibility and conformability and to act as a sealing means against waist leakage.
A tape tab 129 , 131 is arranged at each side edge 123 , 125 close to the rear end edge 111 . The tape tabs 129 , 131 constitute fastening means for the diaper 100 and permit the diaper 100 to be formed into a garment enclosing the lower part of the wearer's body in a manner similar to that of a pair of underpants. The tape tabs 129 , 131 cooperate with a receiving area 133 arranged on the fluid impermeable cover sheet 103 at the front portion 113 of the diaper. The receiving area 133 may be constituted by a reinforcing material which has been laminated to the fluid impermeable cover sheet 103 . By reinforcing the cover sheet the diaper 100 may be closed and reopened without affecting the adhesive properties of tape tabs 129 , 131 or causing the fluid impermeable cover sheet 103 to rupture.
It is, of course, possible to use any of a number of different alternative types of fastening elements. Some examples of such alternative fastening elements are hook and-loop surfaces, press studs, tying ribbons, or similar.
The absorption body 105 usually comprises one or more layers of cellulose fibres, such as fluffed cellulose pulp.
In addition to cellulosic fibres the absorption body 105 may comprise superabsorbent material which is a material in the form of fibres, particles, granules, film or the like and which has the ability to absorb fluid in an amount corresponding to several times the weight of the superabsorbent material itself. Superabsorbent materials bind the absorbed liquid and form a liquid-containing gel.
The absorption body 105 may further comprise a binding agent, shape stabilizing means, or the like. It is also possible to use additional absorbent layers in order to improve the absorption properties, such as different types of liquid dispersing inserts or material layers.
The absorption body 105 may be chemically or mechanically treated in order to change the absorption characteristics.
A commonly employed way of improving the wicking ability of an absorbent structure is to provide the absorption body with a pattern of compressed areas. Furthermore, it is possible to use absorbent materials such as absorbent non-woven materials, absorbent foams, or the like. Likewise, all conceivable combinations of suitable absorbent materials may be used.
The fluid permeable cover layer 101 comprises one or more layers of material wherein at least one layer of material consists of a fibrous structure in accordance with the invention.
A fibrous structure in accordance with the invention can enter the structure of an upper layer 106 which during use of the diaper 100 will be in contact with the body of the user and/or of a lower fluid transfer layer 108 which is situated between the upper, skin-contacting layer 106 and the absorption body 105 which is arranged beneath the fluid permeable cover layer 101 and/or of the absorption body 105 . In case of both the upper, skin-contacting layer 106 , the absorption body, and the fluid transfer layer 108 being fibrous structures in accordance with the invention it is advantageous if those layers exhibit mutually different degrees of hydrophilicity. This may, for instance, be achieved by using gas mixtures of different composition when treating the different fibrous structures.
The invention is not restricted to any particular type of material. Accordingly, the choice of polymer, fibre thickness or density of fibres is dependent on the type of article (for example absorbent article) for which the fibrous structure is intended as well as the function and location of the fibrous structure in the article (searching for hydrophilicity properties or else for example for adhesion properties).
By way of illustration, fibrous structures are commonly made of polypropylene, polyethylene, polyester, and their co-polymers. However, the invention should not be restricted to these polymers.
One example of another type of useful polymers are biodegradable polymers. In order for biodegradable materials to perform well as a fluid pervious cover sheet it is usually necessary to treat the material with a hydrophilic agent or to perforate the material. As has been previously mentioned, the usual way of accomplishing wettability in a fibrous sheet material is by coating the material with surfactants which are less environmentally friendly than desired. Accordingly, the present invention provides a means for creating a fluid permeable cover sheet having environmentally beneficial properties both with respect to biodegradability and because the use of surfactants can be avoided.
Examples of fibrous structures according to the invention are hereafter described.
EXAMPLE 1
ESCA Measurements
In order to examine the chemical composition of the surface of a material the chemical analysis was performed by electron spectroscopy, ESCA. In ESCA the material surface is irradiated with X-rays. The high energy X-rays result in electrons being emitted from the surface of the material.
The binding energy of an emitted electron is obtained from:
E b =hν−E k
E b =the binding energy of the electron E k =the kinetic energy of the electron hν=the radiation energy.
The energy of the X-rays is known and the kinetic energy is obtained by measuring the velocity of the electron.
Accordingly a value for the binding energy of the emitted electron may be obtained which implies that the chemical composition of the surface can be identified.
Samples of Example 1
1a. Untreated polypropylene non-woven material.
2a. Polypropylene non-woven material which has been corona treated according to the invention to introduce polar silicon-containing groups on the surface of the material.
2b. Polypropylene non-woven material which has been washed after having been corona treated.
The operating conditions under which the samples 2a and 2b were treated according to the invention are as follows:
Speed of the web=26 m/min. Width of the web=0.65 m Electrical power of corona=1690 W Flow rate of N 2 =94 l/min. Flow rate of N 2 O=0.39 l/min. Flow rate of SiH 4 =0.115 l/min.
The web was here treated in two steps: in a first step, corona treated under air, and in a second step, corona treated with injection of the here above described gaseous mixture.
When the material is washed, this is done by being submerged in a container with distilled water. The temperature of the distilled water is 37° C. The material is left in the water for 15 seconds and is hereafter removed from the water and laid out flat to dry.
Results of example 1—Concentration of oxygen and silicon (%) on the surface of the material
Sample
1
2a
2b
O
0.7
31.9
35.2
Si
—
9.2
11.2
The results show that the corona-treated non-woven material according to the invention exhibits an oxygen concentration which is 31.9% and a silicon concentration which is 9.2% on the surface of the material. The oxygen and silicon concentrations are maintained even after washing of the material as is evident from sample 2b.
EXAMPLE 2
Using a Set of Cahn Scales to Determine the Fibre Contact Angle.
Wilhelmy's method was used to determine the fibre wetting angle. The measurement was performed using a set of Cahn scales 200 , which is shown in FIG. 2 . During the measuring interval a fibre 201 is vertically suspended in an extremely sensitive set of beam scales 202 . A liquid container 205 is placed on a movable table 206 directly beneath the fibre 201 . When the fibre 201 is immersed in the liquid 203 a liquid meniscus is formed around the fibre, affecting the fibre 201 with a vertical force.
The force which arises between the liquid 203 and the fibre 201 can be either positive or negative, depending on the surface characteristics of the fibre and the liquid. An attraction force which is a positive force will arise when the contact angle between the fibre and the liquid is less than 90°. When the system has a contact angle which is greater than 90° the liquid and the fibre will repel each other which implies force. The attraction or repelling force is determined by means of the set of beam scales. The force is related to the contact angle in accordance with:
F=γ L p cos θ+ mg−ρ L lgA
F=registered force (N) γ L =liquid surface energy (J/m 2 ) p fibre circumference (m) θ=contact angle in the interface fibre-liquid-air (°) m mass of mounted fibre (kg) g gravitational constant (m/s 2 ) ρ L =liquid density (kg/m 3 ) l=wet fibre length (m) A=cross-sectional fibre area (m 2 ).
The second term in the equation represents the weight of the mounted fibre. The third term is what is known as the buoyancy-force, which is the weight loss which arises as a result of the volume of liquid which is pushed aside. In a computer (not shown) and equipped with a calculation program for determination of contact angles these two parameters are usually being compensated for which simplifies the equation into:
F=γ L p cos θ
The advancing contact angle and the receding contact angle specify if the dynamic contact angle is measured when a liquid is advancing over a dry surface or when a liquid is receding from a wet surface. Accordingly, the value for the advancing contact angle is obtained when the fibre is lowered into the liquid and the value for the receding contact angle is obtained when the fibre is withdrawn from the liquid.
The set of beam scales 202 has three pans (see FIG. 2 ). A first pan A has an accuracy of 10 −6 , which makes it suitable for measuring contact angles for fibres. However, the set of scales may also be used to determine surface energy for liquids wherein a less sensitive, second pan B is used. The set of scales is tared by placing balancing weights in a third pan C.
In order to avoid that air draught, dust or the like will interfere with the measurement the pans and the moveable table 206 are protected by slidable glass screens 207 . In addition, the screens make it possible to control air humidity and temperature. In order to avoid disturbing vibrations during the course of the measurement the set of scales is placed on a foundation (not shown).
The table on which the liquid container 205 is placed can be raised and lowered by means of an engine. The speed of the table 206 is controlled by the computer and is specified before the start of a measurement. Other parameters which are fed into the computer before starting the measurement is the surface energy of the liquid and the circumference of the fibre 210 .
Before starting the measurement, a fibre 201 is mounted on a piece of tape 208 with a part of the fibre being free from the tape. The mounted fibre 201 is gripped by a metal clip 209 and is suspended from the first pan A. The set of scales 202 has before then been tared with only the metal clip 209 being suspended from the first pan A. A test liquid 203 having known surface energy is placed in the liquid container 205 on the table 206 below the fibre 201 .
The fibre 201 should hang perpendicularly to the surface of the liquid 210 and must be absolutely still, the set of scales showing a stable value, before the measurement is started.
When a measurement is started the computer registers a base line whereafter the table 206 is raised. When one or a few millimeters of the fibre 201 has been dipped into the liquid 203 the computer is ordered to stop the table.
Subsequently, the table 206 is lowered. During the course of the test the variation of the force along the fibre is shown on the screen of the computer. When the measurement is completed representative portions is selected from the advancing and the receding curves, respectively. Next, the computer calculates the contact angles employing Wilhelmy's equation.
Contact angle measurements were performed on single fibres taken from a 18 g/m 2 nonwoven material consisting of polypropylene. The fibres were dipped into a liquid container with distilled water.
Samples of Example 2
1a. polypropylene fibres from an untreated nonwoven material;
1c. after storage of the untreated non-woven material of 1a. for three months;
2a. polypropylene fibres from a non-woven material which has been corona treated according to the invention in order to introduce polar, silicon-containing groups to the surface of the material;
2b. after washing of the corona treated non-woven material in 2a;
2c. after storage of the corona treated non-woven material in 2a for five weeks (no washing);
2d. after washing and subsequent storage of the corona treated non-woven material in 2a for five weeks.
The operating conditions under which the samples 2a, 2b, 2c and 2d were treated according to the invention are as follows:
Speed of the web=26 m/min Width of the web=0.65 m Electrical power of corona=1690 W Flow rate of N 2 =94 l/min Flow rate of N 2 O=0.39 l/min Flow rate of SiH 4 =0.115 l/min.
The web was, in a first step, corona treated under air and in a second step, corona treated with injection of the here above described gaseous mixture.
When the material is washed, this is done by being placed in a container with distilled water. The temperature of the distilled water is 37° C. The material is left in the water for 15 seconds and is thereafter removed from the water and laid out flat to dry. The contact angle is measured for individual fibres from the washed nonwoven material.
results of example 2
Sample
Contact angle (Advancing/Receding)
1a
99/93°
1c
98/90°
2a
50/25°
2b
58/31°
2c
50/19°
2d
52/23°
The results show that untreated polypropylene fibres have a contact angle which is over 90′, implying that such fibres are hydrophobic. Polypropylene fibres from a non-woven material which has been corona treated according to the invention to introduce polar silicon-containing groups to the surface of the material do on the other hand, exhibit a considerably lower contact angle as is shown by the results for samples 2a-d. After washing of the corona treated nonwoven material the contact angle has been changed from 50° to 58° for the advancing angle and from 25° to 31° for the receding angle which implies that the degree of hydrophilicity is maintained at a relatively constant level after washing of the material.
Sample 2c concerns fibres from the corona treated non-woven material which has been stored for five weeks after the first measurement and the second measurement as performed in order to determine the effect of ageing on the material.
The advancing angle was found to be 50° both for the fibres of the stored nonwoven material and for the fibres from the non-woven material which had not been stored. The receding angle was found to be 25° for the unstored material and 19° for the material which had been stored which implies that the degree of hydrophilicity was substantially unaffected after a five weeks storage.
Finally, sample 2d concerns polypropylene fibres from a corona treated nonwoven material which was washed and then stored for five weeks. The degree of hydrophilicity of sample 2d is almost constant as compared to the unstored and unwashed sample 2a which indicates that the introduced polar silicon-containing groups are stably bound to the fibrous surface.
EXAMPLE 3
Determination of Liquid Penetration Time for a Sheet of Material
In order to determine the liquid penetration time for the fibrous structure, the EDANA test method no. 14-20-06 W25 used. The method measures the time which is required for a predetermined amount of liquid to pass through a topsheet of nonwoven material wherein the nonwoven material is in contact with a standard absorbent material arranged beneath the nonwoven material.
The standard absorbent material consists of 5 layers of filter paper, ERT FF3 100×100 mm. When performing the measurement the filter papers are placed on a base plate of plexiglass. A non woven sample is placed on top of the filter papers with the side which is intended to be facing the skin of a user facing upwards. A strike-through plate of the brand LISTER from Lenzing AG is placed on top of the sample, taking care that the strike-through plate is well centred. An instrument for measuring penetration time is placed above the strike-through plate with the distance between the liquid exit pipe on the instrument for measuring penetration time and the strike-through plate being 30 mm.
5.0 ml test liquid is measured and poured into the liquid container on the instrument, thereafter the measurement is started. The instrument for measuring penetration time is of the same brand as the strike-through plate.
The measurement was performed on a nonwoven material consisting of polypropylene and having a basis weight of 18 g/m 2 . The test liquid was a 0.9% NaCl-solution.
Samples of Example 3
1a. untreated polypropylene non-woven material;
2a. polypropylene nonwoven material which has been corona treated according to the invention in order to introduce polar silicon containing groups to the surface of the material;
2b. after washing of the corona treated nonwoven material of 2a.
The operating conditions under which the samples 2a and 2b were treated are as follows
Speed of the web=26 m/min Width of the web=0.65 m Electrical power of corona=1690 W Flow rate of N 2 =94 l/min Flow rate of N 2 O=0.39 l/min. Flow rate of SiH 4 =0.115 l/min.
The web was, in a first step, corona treated under air and in a second step, corona treated with injection of the here above described gaseous mixture.
The material is washed by being placed in a container with distilled water. The distilled water has a temperature of 37° C. The material is left in the water for 15 seconds and is subsequently removed from the water and laid out flat to dry.
Results of example 3
Sample
Time (seconds)
1
>300
2a
2.7
2b
2.9
The results show that the untreated nonwoven material 1a exhibits a penetration time which is over 300 seconds which implies that the liquid does not penetrate through the nonwoven material during the period of measuring which is 300 seconds (5 minutes). The nonwoven material of sample 2b which has been corona treated according to the invention to introduced polar silicon containing groups to the surface of the material exhibits a penetration time which is 2.9 seconds which is almost equal to the penetration time for the unwashed corona treated nonwoven material.
The invention shall not be regarded as being restricted to the embodiments which have been described herein. Accordingly, a plurality of further variants and modifications are conceivable within the scope of the appended claims.
Therefore, if the invention and all its advantages have been particularly described and illustrated in the case of non-woven fibrous structures used in the baby diaper field, as will be clearly apparent to the man skilled in the art, the invention finds a much larger field of application, including for example woven fibrous structures, of either the natural or synthetic type.
Besides the hygienic field, many other fields of application can be envisaged within the scope of the present invention, with in each case different kinds of properties that can be looked for and reached according to the invention (hydrophilicity, adhesion, anti-stain treatment . . . ).
Some of those hundreds of uses have been illustrated at the beginning of the present description.
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A fibrous structure is described for use in hygienic articles such as diapers, sanitary napkins, incontinence guards, wipes and the like, having one or more polar, silicon containing compounds bound to at least one portion of the surface of the fibrous structure by interaction between the surface and the silicon containing compounds. The fibrous structure exhibits a predetermined degree of hydrophilicity and adhesion properties which are substantially unaffected by wetting of the fibrous structure. Absorbent, hygienic and textile articles comprising such a fibrous structure are also described.
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PRIORITY CLAIM
[0001] This patent application claims priority from copending U.S. Provisional Patent Application Ser. No. 61/256,840, filed Oct. 30, 2009, and entitled, “Device, System and Method For Remote Identification, Management And Control Of Separate Wireless Devices By Linked Communication Awareness And Service Location,” the contents of which are hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] With the expanded use of mobile wireless communication devices for voice, data, email and short message services (SMS), significant concerns have arisen with respect to the potential adverse and other impacts that can arise from the use of wireless devices during user activities in various static and mobile environments. These concerns include, for example, distraction and safety concerns in connection with the use of handheld wireless devices for voice, data, email and/or SMS communications while driving. In response to these concerns, several states have in recent years even banned the use of handheld voice communication devices and text messaging in moving vehicles. In addition, insurers have modified premiums to reflect potential increased liability from such usage in moving vehicles and in other high risk environments.
[0003] Because of potential significant legal and financial exposure from the increased usage of wireless devices in moving vehicles, companies and enterprises have sought to mitigate these risks by prohibiting usage of wireless devices by their agents or employees in moving vehicles and/or limiting the activities that can take place on those devices when a vehicle is in operation or in a high risk environment. Such prohibitions have had limited effectiveness in significant part because such employees and/or agents have their own wireless devices and cell phones that can be used personally in such high risk environments and activities effectively beyond the control of the Company or enterprise.
[0004] Current prohibitions and limitations on agent and employee usage are not effective due to the potential of misbehavior of the agent or employee. Accordingly. substantial operational, financial and legal risk remains for companies and enterprises from the uncontrolled and improper usage of employee and/or agent controlled wireless devices in moving vehicles and in other high risk environments for voice, voice mail, data, email and SMS communications.
[0005] What is needed is a device, method and system to mitigate the risk of harm that could occur when the user of the mobile wireless communication device is distracted from a particular task while using their mobile wireless communication device.
SUMMARY OF THE INVENTION
[0006] Systems and methods are operable to limit use of a Controlled Wireless Device within a controlled environment. An exemplary embodiment establishes a first wireless communication link between a Controlled Wireless Device and a Linked Context Aware Communication and Control Device (LCACCD) Platform, detects proximity of the Controlled Wireless Device to the controlled environment, communicates a control signal from the LCACCD Platform to the Controlled Wireless Device when the Controlled Wireless Device is within the controlled environment, and controls communications of the Controlled Wireless Device based upon the communicated control signal, wherein the Controlled Wireless Device is communicating over a second wireless link established with a wireless carrier network
[0007] An exemplary embodiment of the present invention identifies the existence and activation status of one or more controlled wireless devices. Examples of a controlled wireless device include, but are not limited to, a cell-phone, computer data terminal, smartphone or other wireless device (the “Controlled Wireless Device”). Typically, the Controlled Wireless Device is located in a company or enterprise controlled environment (the “Controlled Environment”) where it is desirable to control and/or prohibit use of the Controlled Wireless Device. Embodiments determine the activation and operating status of such controlled wireless devices (the “Device Activities”). In response to detecting operation of a controlled wireless device during an operation in a “Controlled Environment”, embodiments deploy and execute direct wireless commands and/or carrier network based commands to control and/or limit the usage of the Controlled Wireless Device when it is in the Controlled Environment. That is, when the Controlled Wireless Device is active and engaged, or is potentially engaged, embodiments control and/or limit operation of the Controlled Wireless Device to mitigate potentially risky communication activities during such Device Activities.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0008] Embodiments of a Linked Context Aware Communication and Control Device (LCACCD) Platform include a device, system and/or method for identifying the existence and location of a Controlled Wireless Device when in, and/or in proximity to, the Controlled Environment. Accordingly, Device Activities while in the Controlled Environment are controlled and/or limited.
[0009] The Controlled Environment is a predefined geographic region in which control of the Controlled Wireless Device is desirable. For example, a work or task area associated with a particular commercial activity may be defined as the Controlled Environment. To illustrate, it may be desirable to control operation of the Controlled Wireless Device when a train conductor is operating a train at a train station or the like. Thus, the Controlled Environment may be some predefined geographic region relating to the train station.
[0010] Alternatively, or additionally, the Controlled Environment may be a predefined operating environment. For example, operation of a vehicle, or the vehicle itself, may be defined as the Controlled Environment. To illustrate, it may be desirable to control operation of the Controlled Wireless Device when the driver of an automobile is operating the automobile. Thus, the Controlled Environment may be defined to occur when the vehicle is turned on, is moving, or the like.
[0011] Embodiments of the LCACCD Platform are communicatively integrated with a direct wireless enabled and/or wireless carrier network enabled link and command system to limit and control the operation of the Controlled Wireless Device when it is in, or within proximity to, the Controlled Environment.
[0012] In order to determine the presence of the Controlled Wireless Device, and/or identify any ongoing Device Activities by the Controlled Wireless Device while in or in proximity to the Controlled Environment, a wireless communication link may be established between the Controlled Wireless Device and the carrier network on which it operates (the “Carrier Network”) at least when the Controlled Wireless Device. Additionally, or alternatively, a wireless communication link may be established directly with a LCACCD Platform wireless device located in, in proximity to, and/or near to, the Controlled Environment. FIGS. 1 and 2 , described in greater detail below, show various wireless links and wireless air interface technologies and methods by which this wireless connection may be realized.
[0013] Exemplary non-limiting wireless communication technologies include one or more of the following (the “Airlink Technologies”):
[0014] 1. Wide area network communications through a Carrier Network using one or more of the following air interface (wireless) technologies and/or other similar or related air interface technologies:
a. Code Division Multiple Access (CDMA) b. CDMA Rev A c. Global System for Wireless (GSM) d. High Speed Data Packet Access (HSDPA) e. Global Packet Radio Service (GPRS) f. Orthogonal Frequency Division Multiplexing (OFDM) g. WiMax h. Long Term Evolution (LTE)
[0023] 2. Private Wide Area Networks using one or more of the following technologies and/or similar or related air interface technologies
a. Private Mobile Radio b. Trunked Radio Systems
[0026] 3. Paging and MobiTex Networks
[0027] 4. Citizens Band (CB) Radio
[0028] 5. Direct wireless connectivity between the LCACCD Platform Wireless
[0029] Device and the Controlled Wireless Device using one or more of the following air interface technologies and/or other similar or related air interface technologies:
a. WiFi b. WiMax c. Code Division Multiple Access (CDMA) d. CDMA Rev A e. Global System for Wireless (GSM) f. High Speed Data Packet Access (HSDPA) g. Global Packet Radio Service (GPRS) h. Orthogonal Frequency Division Multiplexing (OFDM) i. WiMax j. Long Term Evolution (LTE)
Any suitable wireless communication technology may be used in the various embodiments to establish the wireless communication links.
[0040] Upon the establishment of connectivity with the Controlled Wireless Device, either directly with the LCACCD Platform Wireless Device or through the Carrier Network, the determination of proximity of a Controlled Wireless Device, and optionally an occurrence of Device Activities, within the Controlled Environment may be determined by one or more of the following:
[0041] 1. The receipt, review and analysis of data generated from Global Position Satellite (GPS) devices in one or both of the Controlled Wireless Device and/or the LCACCD Platform.
[0042] 2. The receipt, review and analysis of data generated from accelerometers in one or both of the Controlled Wireless Device and the LCACCD Platform.
[0043] 3. The receipt, review and analysis of voice pattern measurement and recognition to determine location and the operating relationship between the Controlled Wireless Device and the LCACCD Platform.
[0044] 4. The receipt, review and analysis of audio pattern measurement and recognition to determine location and the operating relationship between the Controlled Wireless Device and the LCACCD Platform.
[0045] 5. The receipt, review and analysis of relative location and operating relationship between the Controlled Wireless Device and the LCACCD Platform, and whether or not the Controlled Wireless Device is in the LCACCD Platform using network reporting and control information as follows:
a. Radio tower hand-off, location and timing for the Controlled Wireless Device. b. Carrier Network registration messages for the Controlled Wireless Device. c. Carrier Network reported GPS and movement information including:
i. Location ii. Time iii. Speed iv. Direction of travel v. Relative altitude vi. Any or all combinations of the foregoing
[0055] 6. Any combination of the foregoing.
[0056] Once it is determined that the Controlled Wireless Device is in the Controlled Environment and engaging in, or about to engage in, high risk or prohibited Device Activities, the following commands and/or instructions in a control signal can be issued to avoid the high risk and/or prohibited Device Activities by the Controlled Wireless Device:
[0057] 1. The blocking, rerouting, buffering and/or storing and forwarding of voice calls, voice messages, emails, data and/or SMS messages otherwise deliverable to the Controlled Wireless Device and/or the LCACCD Platform.
[0058] 2. The delivery of voice calls, voice messages, emails, data and/or SMS messages based upon a change in location or status of the Controlled Wireless Device and/or the LCACCD Platform.
[0059] 3. The delivery of alerts so that the status of the Controlled Wireless Device and/or the LCACCD Platform can be changed to allow for receipt, acknowledgement and/or review of voice calls, voice messages, emails, data transmissions and/or SMS messages that have been previously blocked, rerouted, buffered and/or stored for forwarding. (For example, but not limited to, the alert may indicate the exiting of the Controlled Wireless Device 11 from the controlled environment so that uncontrolled communications by the Controlled Wireless Device are allowed over the wireless carrier network).
[0060] For example, but not limited to, an incoming voice call to the Controlled Wireless Device may be blocked when the Controlled Wireless Device is within the controlled environment. The received voice call may be redirected to a voice mail accessibly by the Controlled Wireless Device. In one embodiment, the availability of the voice mail is indicated to the Controlled Wireless Device when the Controlled Wireless Device is no longer within the controlled environment. The Controlled Wireless Device may then indicate the availability of the voice mail to its user. In another embodiment, availability of the voice mail is indicated by the Controlled Wireless Device to the user when the voice mail is received, but only allow user access to the voice mail is not provided until the Controlled Wireless Device is no longer within the controlled environment.
[0061] FIG. 1 is an overview of an embodiment of a Linked Context Aware Communication and Control Device LCACCD Platform 10 system in communication with the same network provider 13 for both the LCACCD Platform 10 and an exemplary Controlled Wireless Device 11 . The Controlled Wireless Device 11 is located within the Controlled Environment 12 . The LCACCD Platform 10 may optionally be connected wirelessly through the common Carrier Network 13 .
[0062] Alternatively, or additionally, connectivity to the Company Command and Control Server Database 15 may be established with the Controlled Wireless Device and/or the LCACCD Platform 10 via the Carrier Network 13 . Further instructions as necessary for control of actions by, or limitations on, the Controlled Wireless Device are in part, or in whole, furthermore controlled or directed by the Common Single Carrier Network Provider operational data-base or Home Location Register (HLR) 17 .
[0063] Alternatively, or additionally, connectivity may be established between the Controlled Wireless Device 11 and the LCACCD Platform 10 via a direct wireless link 16 . Thus, the LCACCD Platform can detect the Controlled Wireless Device and/or directly control the Controlled Wireless Device. Further, the LCACCD Platform may optionally be physically located to or in proximity to the Controlled Environment 12 , or may be remote from the Controlled Environment 12 .
[0064] FIG. 2 is an overview of an alternative embodiment of a Linked Context Aware Communication and Control Device and Platform system in communication with the different carrier network providers 13 , 14 for both the LCACCD Platform 10 and the Controlled Wireless Device 11 when the Controlled Wireless Device 11 is located within the Controlled Environment 12 .
[0065] The LCACCD Platform 10 physical location and operational relationship with the Controlled Wireless Device 11 may be connected wirelessly through Carrier Network One 13 and Carrier Network Two 14 . Alternatively, or additionally, connectivity may be provided to the Command and Control Server Database 15 , Alternatively, or additionally, connectivity may be established between the Controlled Wireless Device 11 and the LCACCD Platform 10 through a direct wireless link 16 .
[0066] Further instructions as necessary for actions by, or limitations on, the Controlled Wireless Device 11 are, in part or in whole, furthermore controlled or directed by the Network One operational data-base or Home Location Register (HLR) 17 . Further instructions as necessary for actions by or limitations on the Controlled Wireless Device 11 are in part or in whole furthermore controlled or directed by the Network Two operational data-base or Home Location Register (HLR) 18 .
[0067] FIG. 3 is an embodiment of an exemplary LCACCD Platform 10 . The exemplary LCACCD Platform 10 includes a processor system 302 , a memory 304 , a Controlled Wireless Device transceiver 306 , a Carrier Network transceiver 308 , an optional Controlled Wireless Device detector 310 , and an optional GPS device 316 . The above-described components are communicatively coupled together via communication bus 312 . Control logic 314 resides in memory 304 . In alternative embodiments of the LCACCD Platform 10 , the above-described components may be communicatively coupled to each other in a different manner. For example, one or more of the above-described components may be directly coupled to the processor system 302 , or may be coupled to the processor system 302 via intermediary components (not shown). Further, additional components (not shown) may be included in alternative embodiments of the LCACCD Platform 10 .
[0068] The Controlled Wireless Device transceiver 306 supports communications with the Controlled Wireless Device 11 . The Carrier Network transceiver 308 supports communications with the Carrier Networks. In the exemplary embodiment, the transceivers 306 , 308 are illustrated as separate components so as to support communications using different media types and/or formats. Alternatively, the transceivers 306 , 308 may be a single transceiver if compatible communication technologies are employed. It is appreciated that any suitable transceiver device or system may be used, and that the transceivers 306 , 308 may have a variety of components therein which are not described or illustrated herein for brevity. For example, but not limited to, the transceivers 306 , 308 may include as components a receiver and a transmitter device or system. Further, such components themselves may be separate devices or systems. Further, transceivers 306 , 308 may use any suitable wireless communication medium. For example, a wireless signal may employ a radio frequency (RF), an infrared, a visible light, an ultraviolet, or a microwave frequency. Accordingly, the transceivers 306 , 308 are configured to transmit and/or receive any suitable communication communication media. Alternatively, or additionally, the transceivers 306 , 308 may be configured to couple to a wire-based system and receive communications over a wire-based system, such as, but not limited to, a cable system or the Internet.
[0069] The optional Controlled Wireless Device detector 310 is configured to detect proximity of the Controlled Wireless Device 11 to the LCACCD Platform 10 and/or proximity to the Controlled Environment 12 . For example, but not limited to, the Controlled Wireless Device 11 may include a suitable emitter that emits a detectable signal. When the Controlled Wireless Device detector 310 detects the signal emitted by the Controlled Wireless Device 11 , then suitable control actions can be initiated.
[0070] Control logic 314 is retrieved and executed by the processor system 302 to enable control functionality over the Controlled Wireless Device 11 as described herein. The processor system 302 may be any suitable processor or device. The processor system 302 may be a commercially available processor. In other embodiments, the processor system 302 may be a specially designed and fabricated processor, or may be part of a multi-purpose processing system.
[0071] FIG. 4 is an embodiment of an exemplary Controlled Wireless Device 11 . The exemplary Controlled Wireless Device 11 includes a processor system 402 , a memory 404 , a LCACCD Platform Device transceiver 406 , a Carrier Network transceiver 408 , an optional proximity signal emitter 410 , an optional GPS device 418 , and an optional accelerometer 420 . The above-described components are communicatively coupled together via communication bus 412 . The control logic 414 and the wireless device functionality logic 416 reside in memory 304 . In alternative embodiments of the Controlled Wireless Device 11 , the above-described components may be communicatively coupled to each other in a different manner. For example, one or more of the above-described components may be directly coupled to the processor system 402 , or may be coupled to the processor system 402 via intermediary components (not shown). Further, additional components (not shown) are included in alternative embodiments of the Controlled Wireless Device 11 .
[0072] The LCACCD Platform Device transceiver 406 supports communications with the LCACCD Platform 10 . The Carrier Network transceiver 408 supports communications with the Carrier Networks. In the exemplary embodiment, the transceivers 406 , 408 are illustrated as separate components so as to support communications using different media types. Alternatively, the transceivers 406 , 408 may be a single transceiver if compatible communication technologies are employed. It is appreciated that any suitable transceiver device or system may be used, and that the transceivers 306 , 308 may have a variety of components therein which are not described or illustrated herein for brevity. For example, but not limited to, the transceivers 406 , 408 may include as components a receiver and a transmitter device or system. Further, such components themselves may be separate devices or systems. Further, transceivers 406 , 408 may use any suitable wireless communication medium. For example, a wireless signal may employ a radio frequency (RF), an infrared, a visible light, an ultraviolet, or a microwave frequency. Accordingly, the transceivers 406 , 408 are configured to transmit and/or receive any suitable communication communication media. Alternatively, or additionally, the transceivers 406 , 408 may be configured to couple to a wire-based system and receive communications over a wire-based system, such as, but not limited to, a cable system or the Internet.
[0073] The optional proximity signal emitter 410 is configured to emit a detectable proximity signal that indicates proximity of the Controlled Wireless Device 11 to the LCACCD Platform 10 and/or proximity to the Controlled Environment 12 . The emitted detectable proximity signal is emitted with a predefined signal power that is configured to be detectable at a predefined range. When the controlled wireless device detector 310 is within the predefined range, the detectable proximity signal is detectable by the controlled wireless device detector 310 . When the controlled wireless device detector 310 is beyond the predefined range, the detectable proximity signal is not detectable by the controlled wireless device detector 310 . For example, but not limited to, the proximity signal emitter 410 may emit an infrared signal, a coded wireless signal, a wireless signal defined by at least one predefined frequency, or the like. When the above-described Controlled Wireless Device detector 310 detects the signal emitted by the proximity signal emitter 410 , then suitable control actions can be initiated.
[0074] Control logic 414 is retrieved and executed by the processor system 402 to enable control functionality by the Controlled Wireless Device 11 as described herein. For example, the control logic 414 may inhibit or otherwise control operation of the Controlled Wireless Device 11 . In some embodiments, control logic 414 is omitted, and control functionality is implemented in other devices and/or systems to control operation of the Controlled Wireless Device 11 .
[0075] The wireless device functionality logic 416 is retrieved and executed by the processor system 402 , or another suitable processor system, to enable the desired functionality of the Controlled Wireless Device 11 . For example, if the Controlled Wireless Device 11 is a mobile phone, then the wireless device functionality logic 416 would enable the Controlled Wireless Device 11 to operate as intended.
[0076] For convenience, the control logic 414 and the wireless device functionality logic 416 were illustrated and described as separate logic. In some embodiments, the control logic 414 and the wireless device functionality logic 416 may be integrated together, and/or integrated with other logic.
[0077] The processor system 402 may be any suitable processor or device. The processor system 402 may be a commercially available processor. In other embodiments, the processor system 402 may be a specially designed and fabricated processor, or may be part of a multi-purpose processing system.
[0078] The GPS devices 316 and 418 are configured to detect and/or determine the location of the LCACCD Platform 10 and the Controlled Wireless Device 11 , respectively. The determined location information may be used to determine if the Controlled Wireless Device is within the controlled environment, in proximity to the controlled environment, and/or in proximity to the LCACCD Platform 10 . For example, but not limited to, if the Controlled Wireless Device 11 is within the controlled environment, based upon location information determined by the GPS device 316 and/or the GPS device 418 , then the LCACCD Platform 11 may issue control instructions to the Controlled Wireless Device 11 . As another example, if the Controlled Wireless Device 11 is within some predefined distance of the LCACCD Platform 10 , a wireless communication link may be established between the Controlled Wireless Device 11 and the LCACCD Platform 10 , and/or the LCACCD Platform 11 may issue control instructions to the Controlled Wireless Device 11 .
[0079] The optional accelerometer 420 is configured to detect movement of the Controlled Wireless Device 11 . For example, the Controlled Wireless Device 11 may be in a vehicle. During operation of the vehicle, determined based upon detection of movement by the accelerometer 420 , the LCACCD Platform 11 may issue control instructions to the Controlled Wireless Device 11 .
[0080] In summary, what is disclosed are embodiments for the identification and context aware identification of the relationship and operational status of a LCACCD Platform 10 and an Controlled Wireless Device 11 . Accordingly, when the Controlled Wireless Device 11 is within, or in proximity to, a Controlled Environment 12 , embodiments are configured to control operation of the Controlled Wireless Device 11 . Such control actions include, but are not limited to, the blocking, rerouting, buffering and/or storing and forwarding of voice calls, voice messages, emails, data and/or SMS messages otherwise deliverable to the Controlled Wireless Device 11 .
[0081] It is appreciated that embodiments of the LCACCD Platform 10 may be configured to control a plurality of Controlled Wireless Devices 11 . For example, if the Controlled Environment 12 is a vehicle, any number of Controlled Wireless Devices 11 that are anticipated to be within the vehicle could be configured to be controlled by embodiments of the LCACCD Platform 10 . Further, embodiments of the LCACCD Platform 10 may be configured to concurrently control multiple Controlled Wireless Devices 11 .
[0082] The scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.
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Systems and methods are operable to limit use of a Controlled Wireless Device within a controlled environment. An exemplary embodiment establishes a first wireless communication link between a Controlled Wireless Device and a Linked Context Aware Communication and Control Device (LCACCD) Platform, detects proximity of the Controlled Wireless Device to the controlled environment, communicates a control signal from the LCACCD Platform to the Controlled Wireless Device when the Controlled Wireless Device is within the controlled environment, and controls communications of the Controlled Wireless Device based upon the communicated control signal, wherein the Controlled Wireless Device is communicating over a second wireless link established with a wireless carrier network.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to locker accessories. More particularly, it relates to a dart game including darts designed for use with a metal locker and a target decal that can be attached to a locker door.
BACKGROUND OF THE INVENTION
[0002] A dart game system consists of darts and a target. The target is partitioned into regions and is marked with symbols, allowing users to play various games involving throwing the darts at the target. The regions of the target have meaning of significance within those games adapted to a particular target layout. A player attempts to excel by throwing her darts so that they stick to regions of the target associated with high scores within the context of the game at hand.
[0003] A variety of different target layouts and games have been created. All the games emphasize accuracy in throwing the darts at specific regions of the target. The target is typically mounted or printed on the surface of a dart board. Classical dart boards used in taverns are made of cork, straw, or paper.
[0004] According to the official rules of the World Darts Federation, “darts . . . shall not exceed an overall length of 30.5 cm, nor weigh more than 50 grams. Each dart shall consist of a needle shaped point which shall be fixed to a barrel. At the rear of the barrel there shall be attached a flighted stem, which may consist of separate parts.” (WDF Playing and Tournament Rules, 6th Rev. Ed., Dec. 1, 2003) Historically, the flighted stem contained feathers, which have been replaced in many modern darts with fins. Each fin or feather is approximately planar, with the plane of each fin including the common centerline of the barrel and the point. The metal point at the tip of the dart sticks to the target by penetrating through the surface into the fabric of the underlying board.
[0005] Needle-nose darts can cause injuries to the players, bystanders, the wall on which the board is mounted, or other nearby objects. This safety consideration has led recently to a variety of new materials and designs for dart/target combinations in which the sharp points are replaced by flat surfaces. Many of the new game systems use darts with tips that consist wholly or partially of magnets. The magnet tips cause the darts to stick to surfaces that contain ferromagnetic material. According to the American Heritage Dictionary, “ferromagnetic” is defined as: “Of or characteristic of substances such as iron, nickel, or cobalt and various alloys that exhibit extremely high magnetic permeability, a characteristic saturation point, and magnetic hysteresis.” Ferromagnetic material has the capability of being turned into a magnet, but which might not itself be magnetic. Magnetic darts sometimes employ dart tips that are rare-earth magnets, which are significantly stronger than more common iron magnets (e.g., Jonsson, U.S. Pat. No. 5,775,694; Gittens, U.S. Pat. No. 5,613,694).
[0006] Some magnetic darts, such as those described by Kettlestrings (U.S. Pat. No. 4,119,316) and Seymour (U.S. Pat. No. 6,062,997), differ significantly in both shape and structure from traditional needle-nose darts, because they are designed for use primarily by children. But many magnetic darts retain the traditional elongated barrel and flighted stem design (e.g., Jonsson, U.S. Pat. No. 5,775,694).
[0007] Prior art magnetic dart game systems contain a target board including either a rigid layer of magnetic material or a relatively rigid rubber layer impregnated with magnetic material. Jonsson (U.S. Pat. No. 5,775,694) suggests covering a board that includes magnetic material with a printed plastic decal target, attached to the board with an adhesive, which is easy to remove from the board
SUMMARY OF THE INVENTION
[0008] The present invention dart game consists of magnetic darts and a matching target designed for use in a metal locker, such as those commonly found in a school or an athletic facility. A locker has very limited space for the occupant to store possessions. A prior art magnetic dart has a barrel of length approximately equal to that of typical traditional pointed darts. Such a long dart, sticking to a target mounted on the inside of a locker door, will protrude unnecessarily far into the interior volume of the locker when the door is shut. As the locker door is being closed or opened, the dart can come into contact with other locker contents—coats and other clothing, books, athletic gear, footwear, and shelves. In consequence, the dart may become dislodged and fall, or might even disturb other items stored in the locker. From this standpoint, darts smaller than those of the prior art are generally preferable as locker darts.
[0009] On the other hand, the skill in every dart game consists of accurately targeting the darts, so a dart should have a barrel length large enough to fit conveniently within a human hand. These two opposing length scale considerations suggested to the inventors the ideal size of the magnetic locker darts described herein, having a central barrel portion (i.e., between the retainer enclosing the magnetic tip and the fins) that just comfortably fits between an adult's thumb (having a width of approximately 24 mm) and forefinger. The dart of the preferred embodiment of the present invention has a length of about 50 to 70 mm.
[0010] Because of its short length and strong magnetic tip, a locker dart can be helpful for purposes other than dart games. In a manner analogous to tacks on a message board, a dart can be used to post a sheet of paper, fabric, or other thin material on the inside of the locker door or elsewhere within the locker. The posted material is held between the magnet tip of the dart and the metal surface of the locker. Alternately, a lightweight article, such as a pair of swim goggles, can be hung from a dart, where the dart so employed serves as a peg.
[0011] One aspect in which the locker darts game system of the present invention differs from the prior art is that it includes a target but no board. Its target contains essentially no metal or metal-impregnated surfaces or layers. Instead, the system takes advantage of the magnetic material present in a locker door, external to the product itself, to attract the magnetic dart tips. The target is printed on a thin sheet of plastic material. Once a backing is peeled off, the plastic sheet will adhere to a locker surface, by static electricity in the preferred embodiment. Of course, the target will also stick to various other objects having relatively smooth metal surfaces, such as some refrigerator doors and clothes washers, providing alternative environments where the darts game can be played.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an isometric drawing of several lockers, one of which contains the present invention.
[0013] FIG. 2 is an isometric drawing of a prior art magnetic dart.
[0014] FIG. 3 is an isometric drawing of the magnetic dart of the present invention.
[0015] FIG. 4 is a longitudinal view of a dart of the present invention showing details of the nose section and the tail section.
[0016] FIG. 5 is a longitudinal view of the dart of the present invention illustrating various dimensions.
[0017] FIG. 6 is a longitudinal view showing how the geometry of a dart of the present invention relates to gripping the dart with a human hand.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The locker dart game of the present invention is used within a locker 100 made of ferromagnetic material such as steel or iron. FIG. 1 shows a row of such metal lockers 100 , one with an open door 110 . Attached to the door 110 is a target 700 decal. A locker dart 300 is stuck to the target 700 (or more precisely to the door 110 behind the target 700 ). Two other locker darts 300 are being used to post a slip of paper 120 to the inside of the locker door 110 . The locker door 110 is typically steel, a ferromagnetic material.
[0019] FIG. 2 illustrates a typical prior art magnetic dart 200 . It preserves much of the look and feel of a competition needle-nose dart, including a tip 210 and an elongated barrel 220 that terminates in a flighted stem 230 . The length of the prior art dart 200 shown is 100 mm (3.9 inches). The magnet tip 210 is a rare-earth magnet. Rare earth magnets have significantly stronger magnetic properties, and retain their magnetic properties better after repeated collision impacts, than ferrite magnets, which are more conventional. The feathers 240 of the flighted stem 230 are plastic fins 240 .
[0020] FIG. 3 shows the locker dart 300 of the present invention. Like the prior art magnetic dart 200 , it has a rare-earth magnet tip 310 , a barrel 320 ending in a flighted stem 330 , and fins 340 . The most significant difference in the locker dart 300 of the present invention from the prior art magnetic dart 200 is its substantially shortened barrel 320 .
[0021] FIG. 4 is an longitudinal view of the locker dart 300 in the preferred embodiment of the present invention. The dart is fabricated from three components: the magnet tip 310 , a metal nose section 400 , and a plastic tail section 410 . The nose section 400 is divided longitudinally into three axially symmetrical segments: a hollow tip retainer 420 , a nose taper 430 , and a hollow nose barrel 440 . The magnet tip 310 is bonded by adhesive within the tip retainer 420 (as shown with dashed lines in the figure), with a thin portion protruding at the tip whereby the dart can stick magnetically to ferromagnetic material. The tail section 410 consists of a stem 330 and four attached fins 340 . The stem 330 is divided into a tail barrel 450 , the tip-ward portion of which is bonded with adhesive to the inside of the nose barrel 440 (as shown with dashed lines in the figure); and a tail barrel taper 460 . Each fin 340 is divided longitudinally into a fin expansion segment 470 , a fin mid-segment 480 , and a fin contraction segment 490 . The barrel 320 consists of the nose barrel 440 , the exposed part of the tail barrel 450 , and the tail barrel taper 460 .
[0022] FIG. 5 shows the important dimensions of the preferred embodiment. These are the diameter (9 mm) 655 of the magnet tip 310 ; the diameter (11 mm) 660 of the tip retainer 420 ; the diameter (7 mm) 665 of the nose barrel 440 ; the diameter (4 mm) 670 of the tail barrel 450 ; the width (13 mm) 680 of a fin 340 ; the radial dimension (26 mm) 675 of the tail section 410 ; the overall length (59 mm) 600 of the locker dart 300 ; the protrusion (1 mm) 620 of the magnet tip 310 ; the length (18 mm) 610 of the nose section 400 ; the length (39 mm) 605 of the (exposed) tail section 410 ; the length (4 mm) 640 of the tip retainer 420 ; the length (11 mm) 625 of the nose barrel 440 ; the length (7 mm) 650 of the cylindrical (exposed) portion of the tail barrel 450 ; the length (4 mm) 630 from the tail end of the nose section 400 to the start of the fins 340 ; the length (15 mm) 615 of the (exposed) stem 330 ; and the length (8 mm) 635 of the fin contraction segment 490 . Variations of up to ±20% for those dimensions greater than 5 mm, and up to ±50% otherwise, are considered approximately the same as these measurements as that term is considered relative to this invention.
[0023] As illustrated by FIG. 6 , the locations of the nose taper 430 and the fin expansion segment 470 have been separated just enough for a person to comfortably hold the dart 300 in that region, which constitutes the grip 500 of the dart 300 . An adult thumb 510 has a width of about 20 to 25 mm, with a curved “pad” that matches the approximately curved surface provided by the combination of the nose taper 430 , the nose barrel 440 , the tail barrel 450 , and the fin expansion segment 470 . The 23 mm length 645 of this grip 500 is chosen to balance the need for a small dart 300 in the locker 100 environment with the need to be able to comfortably hold and accurately throw the dart 300 . The overall length (59 mm) of the locker dart 300 (shown as length 600 in FIG. 6 ) is scaled to be equal to the length (23 mm) 645 of the grip 500 multiplied by approximately 2.5.
[0024] The shorter length of the locker dart 300 compared to the typical prior art dart 200 minimizes interference between the dart 300 and the contents of the locker 100 when the locker door 110 is being opened or closed. The rare-earth magnet tip 310 makes a single locker dart 300 sufficiently strong that it can be used to “tack” a sheet of paper 120 to an inside wall of the locker as illustrated by FIG. 1 . The shorter length of the locker dart 300 also reduces the probability that the locker dart 300 will be accidentally dislodged. FIG. 1 also shows two locker darts 300 tacking slips of paper 120 to the inside of the door 110 .
[0025] The shorter length (59 mm) 600 also improves the usefulness of a locker dart 300 compared to the prior art as a peg from which to hang things within the locker 100 . Torque is the product of moment arm length (distance from a pivot axis) and force. An object of a given weight will apply more torque to a longer peg (i.e., dart) when suspended from its tail end than will the same object suspended near the tail of a shorter peg. Thus, a longer prior art magnetic dart 200 will only support a lighter suspended load, not to mention its increased likelihood of being dislodged by contact with other locker 100 contents. A locker dart 300 of the present invention can usefully suspend a lightweight object such as a pair of swim goggles.
[0026] These benefits are obtained by the present invention locker dart 300 having a grip portion of approximately 23 mm and a length of approximately 59 mm. With the term approximately being defined as ±20% for these dimensions, the grip can range from 18 mm to 28 mm, and the overall length can range from 47 mm to 71 mm. These extremes are optimally restricted so that the ratio of overall length to grip length remains between 2:1 and 3:1.
[0027] These length measurements are clearly dependent upon the definition of the “grip” for the locker dart 300 . The above description defines the grip 500 as the area running from the nose taper 430 to the fin expansion segment 470 where a person naturally grips the locker dart 300 . In FIG. 5 , the length 645 of the grip 500 is shown from the beginning of the nose taper 430 to the end of the fin expansion portion 470 . However, one can easily imagine a fin 340 design without a separation between the fin expansion segment 470 and the fin mid segment 480 . In some circumstances, such as where there is no such separation, or where the separation between the fin expansion 470 and the find mid segment 480 occurs more than half-way through the length of fin 340 , a different definition can be used to define the grip 500 . In these circumstances, the grip 500 is still defined on one side by the nose taper 430 and the other side by the beginning of the fin 340 extending away from the tail barrel 450 . More specifically, the length of grip 500 can be defined by the beginning of the nose taper 430 to that portion of the fin 340 that first extends away from the nose tail barrel 450 to the same radial distance as the tip retainer 420 . In FIG. 5 , this distance is 21 mm. Consequently, by subtracting a single millimeter from this dimension and adding a single millimeter to the previously determined grip length, it is clear that the present invention can be defined as a locker dart 300 having a grip portion between 20 to 24 mm, ±20%.
[0028] The target 700 of the present invention is divided into regions having meaning within the context of a dart game. The target 700 can be made of a sheet of thin plastic material, as in the current invention, or any other essentially non-magnetic thin material, such as paper or fabric. In the preferred embodiment, the target 700 is a plastic that adheres to the locker 100 surface by static electricity. It is also within scope of the invention for the rear side of target 700 to be coated with non-permanent, removable adhesive. The target is packaged with a removable and disposable backing layer, which when removed allows the target 700 to be applied like a decal to a surface of a metal locker 100 . The present invention includes the target 700 in a package with the darts 300 , but does not include any surface on which the target 700 can be placed. Functionality of the target 700 of the present invention requires a ferromagnetic metal surface external to the product, such as the inside of a locker door or, for example, the side of a refrigerator, washing machine, or filing cabinet to which the decal can be affixed.
[0029] The present invention is not to be limited to all of the above details, as modifications and variations may be made without departing from the intent or scope of the invention. Consequently, the invention should not be limited by the specifics of the above description, but rather be limited only by the following claims and equivalent constructions.
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Magnetic locker darts with a grip region of length equal to the width of a human thumb provide throwing accuracy while minimizing contact with other locker contents. The target is a decal that can be attached to the inside of a metal locker door or other metal appliance.
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RELATED APPLICATIONS
This application is related to U.S. patent application Ser. No. 11/111,834, entitled, “Aircraft Engine Nacelle Inlet Having Access Opening For Electrical Ice Protection System”, filed even date herewith by the same inventors as the present application, and having substantially the same specification.
BACKGROUND
The invention relates to ice protection systems for aircraft, and more specifically relates to an aircraft equipped with a low power high efficiency electrical ice protection system.
The accumulation of ice on aircraft wings and other structural members in flight is a danger that is well known. Such “structural members” include any aircraft surface susceptible to icing during flight, including wings, stabilizers, rotors, and so forth. Ice accumulation on aircraft engine nacelle inlets also can be problematic. Attempts have been made since the earliest days of flight to overcome the problem of ice accumulation. While a variety of techniques have been proposed for removing ice from aircraft during flight, these techniques have had various drawbacks that have stimulated continued research activities. One approach that has been used is so-called thermal ice protection. In thermal ice protection, the leading edges, that is, the portions of the aircraft that meet and break the airstream impinging on the aircraft, are heated to prevent the formation of ice or to loosen accumulated ice. The loosened ice is blown from the structural members by the airstream passing over the aircraft.
In one form of thermal ice protection, heating is accomplished by placing an electrothermal pad(s), including heating elements, over the leading edges of the aircraft, or by incorporating the heating elements into the structural members of the aircraft. Electrical energy for each heating element is derived from a generating source driven by one or more of the aircraft engines. The electrical energy is intermittently or continuously supplied to provide heat sufficient to prevent the formation of ice or to loosen accumulating ice.
With some commonly employed thermal ice protection systems, the heating elements may be configured as ribbons, i.e. interconnected conductive segments that are mounted on a flexible backing. When applied to a wing or other airfoil surface, the segments are arranged in strips or zones extending spanwise or chordwise along the aircraft wing or airfoil. When applied to the engine inlet the heating elements can be applied either in the circumferential or radial orientation. One of these strips, known as a spanwise parting strip, is disposed along a spanwise axis which commonly coincides with a stagnation line that develops during flight. Other strips, known as chordwise parting strips, are disposed at the ends of the spanwise parting strip and are aligned along chordwise axes. Other zones, known as spanwise shedding zones, typically are positioned on either side of the spanwise parting strip at a location intermediate the chordwise parting strips.
In one preferred form of ice protection, an electrical current is transmitted continuously through the parting strips so that the parting strips are heated continuously to a temperature above 32 degrees Fahrenheit. In the spanwise shedding zones, on the other hand, current is transmitted intermittently so that the spanwise shedding zones are heated intermittently to a temperature above about 32 degrees Fahrenheit.
One problem associated with providing such electrothermal ice protection systems on the nacelle inlets of aircraft engines involves providing sufficient numbers of access openings in the inner or outer barrels of the engine inlet for accessing and servicing the heating equipment such as heater elements and associated components. Providing such access openings proximate to the leading edge of the nacelle inlet can create non-smooth interruptions or protuberances along the otherwise smooth aerodynamic surface of the engine inlet. These interruptions or protuberances can interfere with the desired natural laminar airflow into and around the engine inlets, and may contribute to the creation of unwanted noise and drag.
Therefore, there is a need for a thermal ice protection system for the nacelle inlet of an aircraft engine that provides effective ice protection action, that includes a plurality of conveniently positioned service access openings for use in servicing and maintaining the ice protection system components, and that maintains a smooth aerodynamic inlet shape that results in substantially natural laminar airflow along the critical surfaces of the inlet.
SUMMARY OF THE INVENTION
In one aspect, the present invention is directed to an electric ice protection system for an aircraft engine nacelle having an inner barrel and an outer barrel. The ice protection system comprises an engine inlet cowling having an outer lip configured for engagement with at least a portion of the outer barrel, an inner lip configured for engagement with at least a portion of the inner barrel, and a leading edge extending between the outer and inner lips; at least one parting strip electrical heater attached to the cowling proximate to the leading edge; and a plurality of shed zone electrical heaters arranged side by side on either side of the parting strip electrical heater.
In another aspect, the present invention is directed to an aircraft engine nacelle comprising an inner support comprising an outer barrel portion, an inner barrel portion, and a forward wall connecting the outer and inner barrel portions; and a removable inlet cowling attachable to the inner support, the removable inlet cowling having an outer lip, an inner lip, and a leading edge extending between the outer and inner lips, and at least one ice protection electrical heater associated with the leading edge portion of the removable inlet cowling.
In yet another aspect, the present invention is directed to an aircraft engine nacelle heater assembly for an aircraft engine nacelle having an inner barrel, an outer barrel, a forward wall connecting the inner and outer barrels, and a first electrical connector on the forward wall. The heater assembly comprises an inlet cowling removably connectable to an aircraft engine nacelle and configured to cover at least a portion of the inner barrel and at least a portion of the outer barrel, when connected to said aircraft engine nacelle; and at least one ice protection electrical heater associated with the inlet cowling, the ice protection electrical heater including a second electrical connector; wherein the second electrical connector is configured to connect to the first electrical connector, when the inlet cowling covers the inner and outer barrel portions.
In still another aspect, the present invention is directed to a method of preventing ice accumulation on an aircraft engine nacelle inlet having an airflow stagnation line therealong. The method comprises continuously heating the aircraft engine nacelle inlet along a stagnation line that extends at least partly along a circumference of said aircraft engine nacelle inlet; and sequentially heating the aircraft engine nacelle inlet within spaced zones on each side of the stagnation line so as to prevent ice buildup on the aircraft engine inlet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portion of an aircraft engine having a nacelle inlet thermal ice protection system according to the invention;
FIG. 2 is a perspective view of the aircraft engine of FIG. 1 with the inlet cowling detached;
FIG. 3 is an enlarged perspective view of a forward portion of the aircraft engine of FIGS. 1 and 2 ;
FIG. 4 is a cross-sectional view of a nacelle inlet for an aircraft engine according to the invention;
FIG. 5 is an exploded cross-sectional view of the nacelle inlet of FIG. 4 with the inlet cowling detached;
FIG. 6 is a rear perspective view of a portion of an aircraft engine showing an ice protection electrical heater arrangement on the inner surface of an inlet cowling;
FIG. 7 is a front perspective view an inlet cowling showing the ice protection electrical heater arrangement of FIG. 6 ;
FIG. 8 is a rear perspective view of the inlet cowling of FIG. 7 showing placement of ice protection electrical heaters on an inner surface of the inlet;
FIG. 9 a shows a cross-sectional view of a cowling in which the heater is part of an inner layer of the cowling; and
FIG. 9 b shows a cross-sectional view of a cowling in which the heater is part of an outer layer of the cowling.
DETAILED DESCRIPTION
FIG. 1 shows a portion of an aircraft engine nacelle 100 equipped with one embodiment of a nacelle inlet thermal ice protection assembly 10 according to the invention. The engine nacelle 100 includes a substantially cylindrical inner barrel 102 and a concentric outer barrel 104 . The nacelle inlet assembly 10 is disposed on the forward edges of the engine's nacelle inner and outer barrels 102 , 104 . The nacelle inlet assembly 10 has a smooth aerodynamic shape that substantially promotes natural laminar airflow along the forwardmost surfaces of the engine nacelle 100 .
As shown in FIG. 2 , the nacelle inlet assembly 10 includes a removable inlet cowling 40 . The inlet cowling 40 includes an inner lip 16 , an outer lip 14 , and a leading edge portion 12 connecting the two. The aft edge 18 of the outer lip 14 mates with the nacelle inlet assembly 10 along a split line 60 . The aft edge 18 and split line 60 are positioned a substantial distance downstream of the leading edge portion 12 , thereby providing a smooth, aerodynamic surface on the outer lip 14 between the leading edge 12 and the split line 60 . The lip cowling 40 may be a single continuous 360° airfoil that covers an entire engine inlet, or may comprise a plurality of separable, arcuate cowling segments placed in a circumferential arrangement. In one embodiment, the separable cowling segments have airfoil cross-sections that are placed side by side in a circumferential arrangement.
As shown in FIGS. 2 and 3 , the nacelle inlet assembly 10 further includes a forward support 30 . The support 30 may be substantially permanently connected to the inner and outer barrels 102 , 104 of the aircraft engine nacelle 100 , or may be integrally constructed therewith. The forward support 30 provides strength and rigidity to the nacelle inlet assembly 10 . As shown in FIG. 3 , the forward support 30 includes an inner barrel portion 32 , an outer barrel portion 36 and a forward wall portion 34 connecting the inner and outer barrel portions. The forward support 30 may house a plurality of spaced ice protection electrical heater switch boxes 28 for relaying electric power to the ice protection system's heaters, which are described in detail below. As shown in FIG. 6 , electric power from a pylon electrical junction box 20 may be supplied to one or more control boxes 26 via power feeder harness 24 , and may be supplied from the control box 26 to the heater switch boxes 28 via power supply harnesses 27 .
As shown in FIGS. 2 and 3 , the outer barrel portion 36 of the forward support 30 includes a plurality of circumferentially spaced service access openings 38 therethrough. Each of the service access openings 38 is located proximate to one or more associated heater switch boxes 28 , and provides access to at least one of the heater switch boxes 28 from outside the outer barrel portion 36 .
As shown in FIGS. 1 and 4 , when the inlet cowling 40 is installed on the forward support 30 , the outer lip 14 covers each of the respective service access openings 38 in the outer barrel portion 36 of the forward support 30 . Therefore, this arrangement precludes the need for an individual cover for each service access opening 38 . This arrangement also provides a continuous smooth aerodynamic lip surface 14 proximate to the leading edge 12 that helps promote natural laminar airflow across the nacelle during flight.
As shown in FIGS. 1 , 2 and 3 , the inlet cowling 40 is connected to the forward support 30 along both aft edges 18 , 19 by pluralities of suitable removable fasteners 50 . For example, the fasteners 50 may include bolts, rivets, or other suitable fasteners having substantially flush profiles. Preferably, the fasteners are of a type that is easily installed and removed by service personnel.
Further details of the nacelle inlet assembly 10 are shown in FIGS. 4 and 5 . As shown in FIG. 4 , the inlet cowling 40 substantially conforms to the shape of the forward support 30 except for a ice protection electrical heater pocket 80 formed between the leading edge 12 of the cowling 40 and the forward wall 34 of the forward support 30 . The pocket 80 provides space for a plurality of ice protection ribbon heaters 70 a , 70 b , 70 c , 72 mounted on the inner surface of the leading edge 12 of the inlet cowling 40 , as well as for an electrical connector 76 which connects to electrical connector 74 mounted on the forward wall 34 .
The first and second electrical connectors 74 , 76 automatically connect to one another, making a plug and socket-type connection, when the inlet cowling 40 is adjusted from a first position in which it is separated from the inner and outer barrel portions to a second position in which it covers the inner and outer barrel portions. Alternatively, connectors 74 and 76 may be electrically connected (or disconnected) by manually attaching (or detaching) a cable extending between the two. Electric power is supplied to the heaters 70 a , 70 b , 70 c , 72 from the heater switch boxes 28 via heater supply harness 29 and electrical connectors 74 . In the embodiment shown, the electrical connectors 74 are mounted on the forward wall 34 of the forward support 30 .
As shown in FIG. 4 , the inner barrel portion 32 of the forward support 30 may include an acoustic portion 33 , known to those skilled in the act, for attenuating engine noise. In the arrangement shown, the aft edge 19 of the inner lip 16 adjoins the forward support 30 at a position that is immediately forward (or upstream of) of the acoustic portion 33 .
FIGS. 4 and 5 show the maintenance and service access features of the nacelle inlet assembly 10 . With the inlet cowling 40 removed, the service access openings 38 are uncovered, and various ice protection electrical heating equipment such as the heater switch boxes 28 , heater supply harnesses 29 , power supply harnesses 27 , and electrical connectors 74 can be easily accessed by service personnel extending his or her hand 150 through the service access openings 38 . In addition, the removed inlet cowling 40 provides ready access to the ice protection electrical heaters 70 a , 70 b , 70 c , 72 , and associated electrical connectors 76 mounted on the inside surfaces of the cowling 40 . If required, the removable inlet cowling 40 can be easily replaced with a second inlet cowling 40 , and can be separated from an associated engine nacelle 100 for remote service or repair.
FIGS. 6 and 7 show one possible arrangement for the ice protection electrical heaters 70 a , 70 b , 70 c , and 72 . First, one or more parting strip heaters 72 are provided along an inner surface of the leading edge 12 of the removable cowling 40 . Preferably, each parting strip heater 72 is positioned to be substantially coincident with an airflow stagnation line along the engine inlet's leading edge 12 . Second, a plurality of shed zone heaters 70 a , 70 b , 70 c are provided in substantially side by side relation along the inside surface of the leading edge 12 , thereby substantially covering the entire inside surface of the leading edge 12 . Although adjacent shed zone heaters may abut one another if they are electrically isolated from each other, more preferably, they are spaced apart from one another by a gap of between about 0.04″ to about 0.5″; other gap spacings may also be employed. In this arrangement, power can be supplied substantially constantly to the parting strip heater(s) 72 to provide more or less continuous ice protection along the airflow stagnation line.
Power also can be intermittently supplied to the shed zone heaters 70 a , 70 b , and 70 c to shed accumulated ice on either side of the stagnation line. In the arrangement shown, for example, pulses of electrical power may be supplied in sequence to shed zone heaters 70 a , to shed zone heaters 70 b , to shed zone heaters 70 c , again to shed zone heaters 70 a , etc. The distribution of electric power to the various heaters 70 a , 70 b , 70 c , and 72 is controlled by one or more electrical supply control boxes 26 . This cyclic rationing of electric power between the various shed zone heaters 70 a , 70 b , 70 c acts to minimize the amount of electric power that must be derived from an aircraft's finite electrical generation capacity, while effectively providing ice protection to the engine inlet's leading edge 12 .
It is understood that one may operate the heating system such that all shed zone heaters designated 70 a are active for a first period of time, then all shed zone heaters designated 70 b are active for a second period of time and finally all shed zone heater designated 70 c are active during a third period of time. It is further understood that these three periods of time need not necessarily be of equal duration and that they need not necessarily be contiguous—i.e., there may be some intervening periods during which none of these three sets of shed zone heaters is on. It is also understood that other numbers of sets of heaters may be provided—for instance, two sets, four sets, or five sets, etc.
FIG. 8 shows one possible arrangement for installing the heaters 70 a , 70 b , 70 c , 72 on the inner surface of the inlet cowling 40 . In this arrangement, a parting strip heater 72 is mounted on the inner surface of the lip cowling 40 proximate to the underside of the airflow stagnation line at the leading edge 12 . Next, a plurality of shed zone heating pads 70 a , 70 b , 70 c are applied over the parting strip heater 72 such that the heater pads 70 a , 70 b , 70 c cover substantial portions of the inside surface of the leading edge 12 on each side of the parting strip heater 72 . The heaters 70 a , 70 b , 70 c , 72 may be any type of substantially flat, foil, or ribbon heater capable of supplying sufficient heat energy to the cowling 40 to effectively de-ice the cowling 40 while in service. The heating elements 70 a , 70 b , 70 c , 72 may be configured as “ribbons”, i.e. interconnected conductive sections, that are mounted on a flexible backing. For example, the low-power electric heaters 70 a , 70 b , 70 c , 72 may be like the ice protection electrical heaters described in U.S. Pat. No. 5,475,204, assigned to Goodrich Corporation. Alternatively, the ice protection electrical heaters 70 a , 70 b , 70 c , 72 may be like those described in U.S. patent application Ser. No. 10/840,736, filed on May 6, 2004. The disclosures of U.S. Pat. No. 5,475,204 and U.S. patent application Ser. No. 10/840,736 are hereby incorporated by reference in their entireties. And so, when in use, adjacent portions of the inlet cowling may be sequentially heated by alternatingly supplying current to the plurality of electrical ribbon heaters. Suitable electric wiring 74 supplies electric power to the ice protection electrical heaters 70 a , 70 b , 70 c , 72 from one or more heater switch boxes 28 .
FIG. 9 a shows a cross-section of an inlet cowling 40 a in which the ice protection electrical heater is spaced apart from the ice 950 by one or more layers. The structural skin 904 of the cowling 40 a provides support for the layers above. These layers include a first insulation layer 906 , a heater layer 908 atop the first insulation layer, a second insulation layer 910 atop the heater layer 908 , and an erosion shield 912 atop the second insulation layer 910 . Heat from the heater layer 908 passes through the second insulation layer 910 and the erosion shield to melt the ice 950 .
In one embodiment, the thickness of the inlet cowling is on the order of 0.1″-0.2″. The structural skin 904 is formed of a metallic or composite material having a thickness between about 0.02″ and 0.10″; the first insulation layer 906 is formed of an electrically inert (i.e., electrically insulative) material having a thickness between about 0.01″ and 0.04″; the heater layer 908 comprises electrical heaters formed of a metallic or conductive material on a nonconductive plastic film or other substrate and having a thickness between about 0.005″ and 0.020″; the second insulation layer 910 is formed of an electrically inert (i.e., electrically insulative) but thermally conductive material having a thickness between about 0.01″ and 0.04″; and the erosion shield 912 comprises a thermally conductive metallic skin or coating having a thickness between about 0.002″ and 0.020″.
Instead of being mounted on the inner surface of the inlet cowling 40 as shown in FIGS. 4-6 , the ice protection electrical heaters 908 may be mounted on the outer surface. When positioned on the outer surface, the ice protection electrical heaters are more directly exposed to the ice and so the energy efficiency of the system may improve. Through holes may be formed in some of the underlying layers of the cowling 40 at spaced apart intervals to accommodate wires and other connections to deliver current to the ice protection electrical heaters. FIG. 9 b shows a cross-section of an inlet cowling 40 b in which the heater forms the outer surface of the cowling 40 b . Again, the structural skin 924 of the cowling 40 b provides support for the layers above. These layers include a first insulation layer 926 , and a heater layer 928 atop the first insulation layer 924 , all having substantially the same composition and thickness ranges discussed above with respect to FIG. 9 a . In this instance, however, the heater layer 928 is exposed to the elements and so must also serve as the erosion shield.
In both FIGS. 9 a and 9 b , a wire or cable 930 provides current to the heater layers 908 , 928 preferably, the wire is connected to the heater via an electrical solder connection 932 , as seen in these figures. It is understood in these figures that each of the heater layers may comprise multiple individual ice protection electrical heaters.
Engine inlets in accordance with the present invention may realize efficient ice protection with lower weight inlet structure, as compared to a conventional hot air thermal anti-ice (TAI) system. Furthermore, eliminating the pressures and temperatures associated with a traditional TAI system simplifies certain aspects of nacelle design. For instance, traditional split lines between the inlet major components are driven by the thermal anti-ice system and the acoustic requirements. The electrical system of the present invention generally does not rely upon these limitations and may therefore allow for these locations to be optimized for other design criteria. As an example, moving the traditional split line between the inlet lip and the outer barrel aft improves the aerodynamic performance of the inlet and allows the lip to be incorporated into a design that promotes natural laminar flow while also covering an access opening.
The above description of various embodiments of the invention is intended to describe and illustrate various aspects of the invention, and is not intended to limit the invention thereto. Persons of ordinary skill in the art will understand that certain modifications may be made to the described embodiments without departing from the invention. All such modifications are intended to be within the scope of the appended claims.
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An aircraft engine nacelle inlet is provided with an inlet cowling. The inlet cowling includes an inner lip, an outer lip, and a leading edge portion connecting the inner and outer lips. Heating elements are provided proximate the leading edge, either on an inside surface of the cowling or on an outside surface. An inner barrel portion and an outer barrel portion of the nacelle inlet define a space therebetween. Ice protection-related equipment such as controllers, cables, switches, connectors, and the like, may reside in this space. One or more access openings are formed in the outer barrel to enable an operator to gain access to this equipment. The inlet cowling attaches to the inner and outer barrels with its outer lip extending sufficiently far in the aft direction to cover the access opening. When the cowling is removed, the access opening is uncovered, thereby permitting access to the equipment.
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[0001] This application is a continuation in part of U.S. patent application Ser. No. 13/880,049, which claims the benefit of the earlier filing date of May 31, 2013. Claims 1 and 4 of this application are revised from claim 1 of U.S. patent application Ser. No. 13/880,049, respectively, claims 2 , 3 and 5 of this application corresponds to claims 2 , 3 and 5 of U.S. patent application Ser. No. Claims 1 and 4 of this application are revised from claim 1 of U.S. patent application Ser. No. 13/880,049, respectively, and claims 6 and 7 are new.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an automatic sewing machine, and more particularly to a sewing direction control apparatus for sewing machine.
[0004] 2. Description of the Prior Art
[0005] Computer control sewing machines are usually used to embroider complicated patterns automatically rather than manually, whereby to enhance the quality of the embroidery pattern, or used to stitch buttons or create decorative patterns on sewing products, whereby to improve sewing speed or accuracy. The existing computer control sewing machine essentially comprises a clamp on a work platform to clamp and fix the sewing product to be embroidered, the clamp is driven by a movement device to perform two-dimensional movement on the work platform with respect to the sewing head of the sewing machine, and the sewing product will move along with the clamp, so that patterns can be embroidered on the sewing product.
[0006] The sewing head of the existing computer control sewing machines is designed to be able to sew the sewing product only in a specific direction, so that the sewing product has to be inserted from the specific direction into the sewing head and should be aligned to the needle, then the sewing thread above the sewing machine can be formed into a loop to form lock stitch seam by cooperating with the sewing thread from the thread spool which is at the lower portion of the sewing machine. However, when moving in a two-dimensional manner along the work platform, the sewing product might approach the needle from any direction, resulting in poor stitching or deviation of sewing thread.
[0007] To solve the above defects, U.S. Pat. No. 4,498,404 discloses an automatic sewing apparatus which uses a manipulator arm to replace the conventional 2D movement device. The manipulator arm includes three rotation axes, so that the sewing product can be better controlled by the manipulator arm to rotate between the needle and the work platform, ensuring that the sewing product is kept being inserted into the sewing head from a specific direction. An Italian patent B093A 000113 discloses another sewing apparatus, wherein a lever with a needle is arranged above the needle plate of the sewing head, and below the needle plate is disposed a thread shaft with a hook. The lever and the thread shaft rotate together to maintain the relative position between the needle and the hook unchanged, ensuring that the sewing product is kept being inserted into the sewing head from a specific direction.
[0008] However, the above two sewing apparatuses still have the following disadvantages:
[0009] 1. for automatic sewing machines, the sewing product must be moved intermittently and rapidly a very small distance at a time during sewing operation, so that the manipulator arm for moving the sewing product should have excellent acceleration ability and should be capable of precisely controlling the distance that the sewing product moves, resulting in a high manufacturing and maintenance cost of the manipulator arm.
[0010] 2. there are various types of automatic sewing machines, however, the positioning device which maintains the relative position between the needle and the hook unchanged by using the synchronous rotation of the lever and the thread shaft is inapplicable to the sewing machines with cylinder bed head. Therefore, it is still unable to solve the sewing direction problem.
[0011] The present invention has arisen to mitigate and/or obviate the afore-described disadvantages.
SUMMARY OF THE INVENTION
[0012] The primary objective of the present invention is to provide a low cost sewing direction control apparatus for sewing machine which provides accurate sewing operation and is suitable for use in various automatic sewing machines.
[0013] To achieve the above objective, a sewing direction control apparatus for sewing machine in accordance with the present invention comprises:
[0014] a base plate being an X-Y planar surface with an X direction and a Y direction, a lateral edge of the base plate in the X direction being provided with a drive portion which includes a gap and two assembling holes at two ends of the gap;
[0015] a transmission element being a circular ring-shaped structure mounted on the base plate and centrally provided with a circular cavity and a threaded surface around an outer peripheral surface thereof, the transmission element being disposed on the base plate and having the threaded surface protruded out of the gap of the drive portion, a sewing product being fixed at a bottom of the cavity and located corresponding to the needle;
[0016] a slide rack disposed at an outer surface of the drive portion of the base plate and provided with a passage aligned to the gap of the drive portion, and two abutting protrusions aligned to the two assembling holes of the drive portion, the slide rack being provided with a Y-direction displacement mechanism and an X-direction displacement mechanism to drive the slide rack to move in X and Y directions, the Y-direction displacement mechanism pushing the two abutting protrusions to move into the two assembling holes, and the X-direction displacement mechanism driving the slide rack and the base plate to move in the X direction; and
[0017] a driving element mounted on the slide rack and including a disc-shaped driving unit, the disc-shaped driving unit being formed with a threaded surface around an outer peripheral surface and extending out of the passage of the slide rack, the slide rack driving the driving unit to move in the Y direction, so that the driving unit is able to engage with the threaded surface to simultaneously rotate the transmission element and the sewing product, or the driving unit is able to disengage from the threaded surface to stop the transmission element from rotation.
[0018] The sewing direction control apparatus for sewing machine in accordance with the present invention uses teeth engagement to perform highly accurate, intermittent and fast movement, therefore, the direction control apparatus of the present invention has low cost, and is suitable for various types of automatic sewing machines. In addition, the base plate and the slide rack are connected in the same Y direction while being able to move synchronously in the X direction, and the transmission element can be controlled to rotate or stop rotation by the engagement or disengagement between the threaded surface of the transmission element and the driving unit of the driving element, such arrangements prevent the problem that the sewing direction is not readily controllable in case of multi-directional connection. Furthermore, with the slide rack, the driving element is movable in the Y direction, so that it can be engaged with the threaded surface to rotate the transmission element during sewing, and when sewing stops, the driving element will be disengaged from the threaded surface to improve safety of the sewing direction control apparatus for sewing machine of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective view of a sewing direction control apparatus for sewing machine in accordance with a preferred embodiment of the present invention;
[0020] FIG. 2 is a cross sectional view of the sewing direction control apparatus for sewing machine in accordance with the preferred embodiment of the present invention;
[0021] FIG. 3A is an operational view showing that the slide rack of the present invention moves away from the base plate;
[0022] FIG. 3B is an operational view showing that the slide rack of the present invention is engaged with the base plate;
[0023] FIG. 4 is a perspective view of a sewing direction control apparatus for sewing machine in accordance with another preferred embodiment of the present invention;
[0024] FIG. 5 is a cross sectional view of the sewing direction control apparatus for sewing machine in accordance with the another preferred embodiment of the present invention;
[0025] FIG. 6 is an operational view of the sewing direction control apparatus for sewing machine in accordance with the another preferred embodiment of the present invention; and
[0026] FIG. 7 is a side view of FIG. 3A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The present invention will be clearer from the following description when viewed together with the accompanying drawings, which show, for purpose of illustrations only, the preferred embodiment in accordance with the present invention.
[0028] Referring to FIGS. 1 and 2 , a sewing direction control apparatus for sewing machine in accordance with a preferred embodiment of the present invention comprises a base plate 10 , a transmission element 20 disposed on the base plate 10 , a sewing plate 30 disposed in the transmission element 20 to fix a sewing product A, and a slide rack 40 and a driving element 50 disposed at one side of the base plate 10 .
[0029] The base plate 10 is rectangular and centrally provided with a hole 11 and a flange 12 around the hole 11 . The base plate 10 is an X-Y planar surface with an X direction and a Y direction. A lateral edge of the base plate 10 in the X direction is provided with a drive portion 15 which includes a gap 151 and two assembling holes 152 at two ends of the gap 151 .
[0030] In this embodiment, as shown in FIG. 1 , the base plate 11 is further provided with two protrusions 13 which are located adjacent to the hole 11 and a corner of the base plate 11 , and the drive portion 15 is a lateral plate disposed along the lateral edge of the base plate 10 .
[0031] The transmission element 20 is a circular ring-shaped structure located around the hole 11 of the base plate 10 . As shown in FIG. 2 , the transmission element 20 is centrally provided with a circular cavity 21 , an annular slot 211 around the bottom of the circular cavity 21 , and a plurality of positioning pins 212 disposed at the bottom of the cavity 21 and located around the bottom of the annular slot 211 . An annular engaging portion 22 extending outward from the bottom of the cavity 21 is formed with an annular groove 221 which is located around the periphery of the transmission element 20 . The annular groove 221 and the cavity 21 open in opposite directions and separated from each other by the wall of the cavity 21 . The transmission element 20 is provided with a threaded surface 23 around the outer peripheral surface of the annular engaging portion 22 . The annular groove 221 of the transmission element 20 is located corresponding to the flange 12 of the base plate 10 , namely, the flange 12 is received in the annular groove 221 , and an annular bearing 24 is disposed between the flange 12 and the annular groove 221 to enable the transmission element 20 to rotate with respect to the flange 22 . The transmission element 20 is disposed on the base plate 10 and has the threaded surface 23 protruded out of the gap 151 of the drive portion 15 . In this embodiment, the transmission element 20 is provided with four spaced positioning pins 212 .
[0032] The sewing plate 30 is a circular structure received in the cavity 21 of the transmission element 20 and provided with a plurality of ears 31 around a periphery thereof. The ears 31 each have a pivot hole 311 and are located corresponding to the positioning pins 212 of the transmission element 20 in such a manner that the positioning pins 212 of the transmission element 20 are inserted in the pivot holes 311 of the sewing plate 30 , so as to fix the sewing plate 30 to the annular slot 211 of the transmission element 20 . In this embodiment, the sewing plate 30 is provided with four spaced ears 31 to cooperate with the positioning pins 212 .
[0033] The slide rack 40 , as shown in FIG. 1 , is disposed on the X-Y surface and fixed at the outer surface of the drive portion 15 of the base plate 10 . The slide rack 40 a rectangular structure which is centrally provided at a top surface thereof with a rack plate 41 which is located higher than the X-Y surface. The slide rack 40 is provided with a passage 42 aligned to the gap 151 of the drive portion 15 , and two abutting protrusions 43 aligned to the two assembling holes 152 of the drive portion 15 . The slide rack 40 is provided with a Y-direction displacement mechanism 44 and an X-direction displacement mechanism 45 , so that the slide rack 40 is capable of moving in both X and Y directions, the Y-direction displacement mechanism 44 makes the two abutting protrusions 43 move into the two assembling holes 152 , and the X-direction displacement mechanism 45 drives the slide rack 40 and the base plate 10 to move in the X direction.
[0034] In this embodiment, the Y-direction displacement mechanism 44 and the X-direction displacement mechanism 45 can be a linear guideway or ball screw, which are used independently or together to make the slide rack 40 move in X and/or Y direction. When the Y-direction displacement mechanism 44 and the X-direction displacement mechanism 45 are ball screws, as shown in FIG. 7 , the Y-direction displacement mechanism 44 is provided with a slide hole 441 formed in the slide rack 40 and extending in the Y direction, a Y-direction screw 442 screwed in the slide hole 441 , and a servo motor 443 which is disposed at the end of the screw 442 to drive the slide rack 40 to move with respect to the Y-direction screw 442 . The X-direction mechanism 45 includes a slide block 451 which is mounted on the slide rack 40 and disposed in the X direction, an X-direction screw 452 screwed with the slide block 451 , and a servo motor 453 which is disposed at the end of the X-direction screw 452 to drive the slide rack 40 to move with respect to the X-direction screw 452 .
[0035] When the Y-direction displacement mechanism 44 and the X-direction displacement mechanism 45 are linear guideways, the Y-direction displacement mechanism 44 includes a Y-direction slide block (not shown) disposed on the slide rack 40 , a Y-direction rail (not shown) extending in the Y direction, and a power source (not shown) for moving the Y-direction slide block. The X-direction displacement mechanism 45 includes an X-direction slide block (not shown) mounted on the slide rack 40 , an X-direction rail (not shown) extending in the X direction, and another power source (not shown) for driving the X-direction slide block to move in the X direction.
[0036] The driving element 50 , as shown in FIG. 1 , is mounted on the slide rack 40 and comprises a servo motor 51 disposed on the rack plate 41 , a driving shaft 511 located below the servo motor 51 and inserted in the rack plate 41 , and a driving unit 52 connected to one end of the driving shaft 511 . The driving unit 52 is a disc structure. In this embodiment, around the outer peripheral surface of the driving unit 52 is formed a threaded surface, and the end of the driving shaft 511 is connected to the center of the driving unit 52 . The driving unit 52 is located on the X-Y surface and extends out of the passage 42 of the slide rack 40 , and the slide rack 40 drives the driving unit 52 to move in the Y direction, so that the driving unit 52 can be meshed with the threaded surface 23 to simultaneously rotate the transmission element 20 and the sewing product A.
[0037] A control element 60 , as shown in FIGS. 1 , 3 A and 3 B, is pivoted to the two protrusions 13 of the base plate 10 and comprises a control unit 61 and an elastic unit 62 . The control unit 61 is reversed U-shaped and includes an operating section 611 , a connecting section 612 and an engaging section 613 . A conjunction between the operating section 611 and the connecting section 612 is pivoted to one of the protrusions 13 adjacent the transmission element 20 , so that the operating section 611 and the engaging section 613 approximately extend in the direction X and toward the transmission element 20 , and the free end of the engaging section 613 is a threaded structure. The elastic unit 62 is approximately L-shaped and includes a stationary section 621 and an abutting section 622 . A connecting hole 623 is formed at the conjunction between the stationary section 621 and the abutting section 622 to enable the elastic unit 62 to be pivoted to the one of the protrusions 13 adjacent the transmission element 20 in such a manner that the end of the stationary section 621 of the elastic unit 62 is pressed against another one of the protrusions 13 which is located farther away from the transmission element 20 , and the end of the abutting section 622 is pressed against the connecting section 612 of the control unit 61 .
[0038] As shown in FIG. 3A , when the base plate 10 moves away from the slide rack 40 , the connecting section 612 of the control unit 61 will be pushed by the abutting section 622 of the elastic unit 62 , the engaging section 613 of the control unit 61 will be engaged with the threaded surface 23 of the transmission element 20 , and the driving unit 52 of the driving element 50 will be disengaged from the transmission element 20 to enable the transmission element 20 to be engaged with and fixed by the control unit 61 . As shown in FIG. 3B , when the base plate 10 move toward the slide rack 40 , the operating section 611 of the control unit 61 will be pushed by the abutting protrusion 43 of the slide rack 40 , so that the engaging section 613 of the control unit 61 will be disengaged from the threaded surface 24 of the transmission element 20 , and the driving unit 52 of the driving element 50 will be engaged with the threaded surface 24 of the transmission element 20 to enable the transmission element 20 to be rotated by the driving unit 52 .
[0039] The abovementioned are the structural relations of the main components of the first preferred embodiment. It is to be noted that the present invention also provides another embodiment; its structure is explained as follows.
[0040] Referring to FIGS. 4 and 5 , in this embodiment, around an outer peripheral surface of the annular engaging portion 22 of the transmission element 20 is provided a driven belt 25 , and a driving belt 53 winds around the driven belt 25 and the driving unit 52 of the driving element 50 to rotate the transmission element 20 . At a corner of the base plate 10 is disposed a pallet 14 which is higher than the X-Y surface. The servo motor 51 of the driving element 50 is inserted in the pallet 14 , the driving shaft 511 of the servo motor 51 is connected to the driving unit 52 , the driven belt 25 of the transmission element 20 located toward the driving unit 52 , and the driven belt 53 winds around the driven belt 25 and the driving unit 52 of the driving element 50 . When the servo motor 51 rotates the driving unit 52 , the driving unit 52 will drive the transmission element 20 to rotate on the base plate 10 via the driving belt 53 . In this embodiment, the driven belt 25 and the driving belt 53 are timing belts, which are engaged with each other via teeth engagement.
[0041] FIG. 6 shows that the sewing direction control apparatus for sewing machine in accordance with the present invention is used in combination with a needle 71 of a sewing head 70 . As shown in FIG. 6 , when the slide rack 40 moves toward the base plate 10 , the sewing product A is fixed on the sewing plate 30 and located corresponding to the needle 71 of the sewing head 70 , and the preset sewing path of the needle 71 extends along the direction Y. The transmission element 20 is rotated by the driving element 50 . Meanwhile, the sewing product A is caused to rotate clockwise, so that the sewing direction is maintained tangent to the rotation direction of the sewing product A, thus fixing the sewing direction of the sewing machine, making the sewing machine perform sewing operation by moving along the desired sewing direction, and consequently improving the sewing speed and quality. Furthermore, the sewing direction control apparatus for sewing machine in accordance with the present invention uses teeth engagement to perform highly accurate, intermittent and fast movement, therefore, the direction control apparatus of the present invention has low cost, and is suitable for various types of automatic sewing machines.
[0042] In addition, the base plate and the slide rack are connected in the same Y direction while being able to move synchronously in the X direction, and the transmission element can be controlled to rotate or stop rotation by the engagement or disengagement between the threaded surface of the transmission element and the driving unit of the driving element, such arrangements prevent the problem that the sewing direction is not readily controllable in case of multi-directional connection. Furthermore, with the slide rack, the driving element is movable in the Y direction, so that it can be engaged with the threaded surface to rotate the transmission element during sewing, and when sewing stops, the driving element will be disengaged from the threaded surface to improve safety of the sewing direction control apparatus for sewing machine of the present invention.
[0043] While we have shown and described various embodiments in accordance with the present invention, it is clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention.
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A sewing direction control apparatus for sewing machine, comprising: a base plate, a circular ring-shaped transmission element dispose on the base plate and a driving element with a driving unit. During sewing, the driving unit drives the transmission element, rotating a sewing product placed at the center of the transmission element with the driving element, thereby controlling the sewing direction of the sewing product, and thus improving the sewing accuracy. The direction control apparatus has low cost, and is suitable for various types of automatic sewing machines.
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This invention claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 60/879,639 filed Jan. 10, 2007.
FIELD OF THE INVENTION
The present invention relates to a firearm, and particularly, to an ambidextrous bolt catch device, apparatus, system and method on a semi-automatic or fully automatic firearm that retains the bolt and bolt carrier mechanism in a rearward position.
BACKGROUND AND PRIOR ART
Bolt catch devices for hand-held firearms are known in the art, especially in handguns and combat rifles. The purpose of a bolt catch device on any firearm is to retain the principal members of the bolt or bolt carrier mechanism in a rearward position. The rear-hold position is desirable as a safety measure to allow an unobstructed view of the chamber of a firearm; to provide access to the chamber area for cleaning or clearing an obstruction, or other maintenance; as a signal to the operator that the magazine is empty; and to provide a means for rapid reloading, by holding the bolt group to the rear while the empty magazine is removed and a new magazine is installed.
Some members of the M16/M4 family of firearms have a bolt catch that is actuated so that it holds the bolt group rearward after the last round is fed from the magazine.
When the bolt catch device is actuated manually the bolt group is released and allowed to move forward under spring pressure, chambering the first round from a new magazine.
On most firearms the bolt catch is located on one side of the receiver, making it difficult and sometimes impossible to actuate with a single hand while aiming the firearm. On the M16/M4 rifle, for example, the bolt catch is on the left side of the receiver where actuation is generally accomplished with the palm of the left hand, when the firearm is held on the right shoulder. The design of the M16/M4 bolt catch is such that it is a single element functioning at one end as the component holding the bolt group rearward and at the other end offering a knurled protrusion on the end of a lever as a point for actuation.
Ambidextrous bolt catches are found almost exclusively on semi-automatic pistols, and take the form of a latch or other device that keeps the slide to the rear after the last round is fired.
The known prior art includes several patents describing bolt catch device arrangements for firearms or ambidextrous magazine catch and release mechanisms that are used in a clip change when the last round is fired from a magazine. The function of a bolt catch device is significantly different than the function of a magazine catch, but the use of an ambidextrous means for operating each mechanism is the reason for including such prior art in the list below.
U.S. Pat. No. 3,540,142 to Vartanian et al. describes a bolt stop mechanism for a semi-automatic firearm with a spring that engages the bolt stop to bias against a pin. The bolt stop is pivotally mounted in the firearm receiver and is movable into and out of engagement with the bolt by pushing the end of the latch and releasing it.
U.S. Pat. No. 3,750,531 to Angell et al. requires a safety lever to be pushed up to a horizontal position, the action operates to lock the strike to prevent it from traveling down the striker tunnel in a dual protection safety device for semi-automatic pistol.
U.S. Pat. No. 4,429,479 to Johnson describes a magazine latch release mechanism for repeating rifles.
U.S. Pat. No. 4,521,985 to Smith et al. shows an ambidextrous magazine release.
U.S. Pat. No. 4,620,134 to Beretta describes a retaining mechanism for rifle magazines, wherein a hook is engaged in the slot of a magazine that is fixed to a spring-loaded arm located transversely in the body of the weapon; the hook can be operated from both sides of the weapon.
Garrett in U.S. Pat. No. 5,519,954 uses two springs, houses the pivoting mechanism in a protruding base and is specifically designed for use as an ambidextrous magazine release.
U.S. Pat. No. 5,636,465 to Johnson describes a spare magazine carrier. FIG. 8 shows a plunger mounted within a tubular housing and biased outwardly, or leftward, by a helical spring surrounding a portion of the plunger.
U.S. Pat. No. 5,726,376 to Menges et al. in FIG. 1 shows locking levers with catching shoulders to prevent accidental firing of weapon.
U.S. Pat. No. 5,741,996 to Ruger et al. in FIG. 2 shows a slide and a slide stop latch.
U.S. Pat. No. 6,257,114 to Murello describes a firing lever mechanism for firearms with a locking lever pivotally mounted that cooperates with a slide and stop pin that is engaged to lock the slide into position.
U.S. Pat. No. 7,047,864 to Spinner et al. FIG. 4 and FIG. 5 show a magazine shaft with cross boring, swivel shaft with levers, a catch on lever, left-handed shooter holding the weapon with left hand can now press on the pivoting lever and release the slide unit for forward movement.
U.S. Pat. No. 7,103,998 to McGarry describes a camblock assembly for a firearm having a guide rod to resist movement of a reciprocating slide.
U.S. Patent Publ. No. 2003/0208940 to Johnson describes a bolt catch operating lever attached to the left side of receiver with a pivot pin. The bolt catch engages the bolt to hold it in a rearward position using a detachable lateral extender mechanism; lever is pressed to the right, the catch is disengaged and releases the bolt that is moved forward by a spring.
U.S. Patent Publ. No. 2005/0000138 to Kiss in FIG. 2 and FIG. 5 shows a bolt catch device pivotally mounted on a rivet; the lever connects with and transverse the channel shaped receiver with bottom wall; there is a return spring; a sensor lever rotates the catch device upward; the head of the lever is returned by spring forces of the magazine and inhibits the forward movement of the carrier locking the bolt carrier.
Garrett in U.S. Patent Publication 2006/0,123,683 describes an ambidextrous magazine catch having a rod with a threaded portion that is pivotally attached to a lever and guided transversely through an orifice. The ambidextrous magazine catch has a single spring, engages and disengages the magazine slot of magazine by depressing lever.
The above patents disclose the state of the art in relation to bolt catch devices and ambidextrous magazine catches or releases for firearms; however, with regard to bolt catch devices, there is still a need for an ambidextrous, quick, easy to secure, reliably functioning bolt catch device to retain the bolt and bolt carrier mechanism in a rearward position after the last round is fed from the magazine.
Improvements are needed so that a bolt catch device can be engaged with ease and dexterity with one hand by either a right-handed shooter or a left-hand shooter of a weapon. Such an improvement saves valuable time in the field and significant costs in inventory. There is no longer a need for different weapon assemblies based on whether a shooter is right-handed or left-handed. Such improvements will mean that weapons are safer and universally acceptable to all users; the present invention meets these needs.
SUMMARY OF THE INVENTION
The present invention, which shall be subsequently described in greater detail, provides a new bolt catch device designed to provide an ambidextrous, safe, reliable, easily activated method for retaining the bolt group in a rearward position compared to previous types. The design and precision with which the bolt catch device of the present invention is made contributes many advantages over the prior art. The new and novel features include, but are not limited to, a vertical lever pin in an effective arrangement of three other components: a bolt catch finger, a lever, a plunger rod with a spring and plunger head for use principally, but not limited to, the M16/M4 family of rifles.
The first objective of the present invention is to provide an ambidextrous bolt catch device that can be operated from both the left and right sides of a firearm.
The second objective of the present invention is to provide an ambidextrous bolt catch device that can be actuated with one hand.
The third objective of the present invention is to provide an ambidextrous bolt catch device for easy use by either a right-handed shooter or a left-handed shooter of a firearm.
The fourth objective of the present invention is to provide an ambidextrous bolt catch device for a firearm that allows an unobstructed view of the empty chamber of a firearm.
The fifth objective of the present invention is to provide an ambidextrous bolt catch device for a firearm that permits unobstructed access to the chamber area for cleaning or clearing an obstruction.
The sixth objective of the present invention is to provide an ambidextrous bolt catch device for a firearm for the M16/M4 family of weapons.
The seventh objective of the present invention is to provide an ambidextrous bolt catch device for a firearm that provides a signal to the operator that the magazine is empty.
The eighth objective of the present invention is to provide an ambidextrous bolt catch device for a firearm that facilitates the rapid reloading of a firearm by holding the bolt group to the rear while the empty magazine is removed and a new magazine is inserted.
An ambidextrous bolt catch device for firearms, including a bolt catch finger connected to a receiver of a firearm by a pivot pin, a first release lever located on a right side of the firearm and attached to the receiver of the firearm with a vertical pin, a second release lever located on a left side of the firearm and integral to the bolt catch finger, a plunger rod assembly having a first end abutting a base of the bolt catch finger on the left side of the firearm and a second end connected to the first release lever on the right side of the firearm, thus providing a fully assembled bolt catch device that holds the bolt and bolt carrier in a rearward position and releases the bolt and bolt carrier to move forward and chamber communication for the firearm.
The plunger rod assembly includes a torsion spring surrounding the first end of the plunger rod, held in place by a plunger head, the torsion spring creates tension and causes rotation of the bolt catch finger in a downward position when the first release lever and second release lever are pressed laterally toward the right side and the left side of the weapon and when the first release lever and second release lever are pulled laterally away from the right side and the left side of the firearm, the bolt catch finger rotates to an upward position.
The bolt catch finger can be shaped from a solid material. The solid metal is at least one of steel, stainless steel, and an iron alloy. The bolt catch finger can be fabricated using metal injection molding (MIM).
A method of preventing a bolt carrier of a firearm from moving forward after firing ammunition, the method can include steps of moving a first lever and a second lever of an ambidextrous bolt catch device that is attached to a firearm laterally away the first side and the second side of the firearm and simultaneously pushing a plunger rod against the bias of the spring that causes the rotation of a bolt catch finger in an upward position, blocking the forward motion of a bolt and bolt carrier by the bolt catch finger in a upward position.
The step of moving the first lever and the second lever is accomplished manually with one hand selected from at least one of a right hand and a left hand. The step of moving the first lever and the second lever is accomplished mechanically with the rearward movement of the bolt carrier and bolt after the last round of ammunition is fired.
A method of releasing a bolt carrier of a firearm for forward movement to chamber ammunition in a firearm, the method includes the steps of moving a first lever and a second lever of an ambidextrous bolt catch device that is attached to a firearm laterally toward the first side and the second side of the firearm and releasing pressure on the spring bias of the plunger rod causing the rotation of a bolt catch finger in a downward position, and releasing the bolt and bolt carrier to move forward and chamber ammunition in the firearm.
The step of moving the first lever and second lever can be accomplished manually with one hand selected from at least one of a right hand and a left hand.
A firearm with bolt catch firing system, can include a combination of a rifle having a magazine receptical and a removable magazine, a bolt catch finger connected to a receiver of the rifle by a pivot pin, a first release lever located on a right side of the rifle and attached to the receiver of the rifle with a vertical pin, a second release lever located on a left side of the rifle and integral to the bolt catch finger, and a plunger rod assembly having a first end abutting the base of the bolt catch finger on the left side of the rifle and a second end connected to the first release lever on the right side of the rifle, thus providing a fully assembled bolt catch device that holds the bolt and bolt carrier in a rearward position and releases the bolt and bolt carrier to move forward and chamber ammunition for the rifle.
The plunger rod assembly can include a torsion spring surrounding the first end of the plunger rod, held in place by a plunger head, the torsion spring creates tension and causes rotation of the bolt catch finger in a downward position when the first release lever and second release lever are pressed laterally toward the right side and the left side of the weapon and when the first release lever and second release lever are pulled laterally away from the right side and the left side of the rifle, the bolt catch finger rotates to an upward position.
The bolt catch finger can be shaped from a solid metal. The solid metal can include at least one of steel, stainless steel, and an iron alloy. The bolt catch finger can be fabricated using metal injection molding (MIM). The rifle can be a semi-automatic weapon. The rifle can be a fully automatic weapon, and can be selected from one of a M16 firearm and M4 firearm.
Further objects and advantages of this invention will be apparent from the following detailed description of a presently preferred embodiment, which is illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
Referring particularly to the drawings for the purposes of illustration only, and not limitation:
FIG. 1 is a side perspective view of an assembled ambidextrous bolt catch device with a bolt catch finger holding the bolt and bolt carrier in a rearward position.
FIG. 2 is an exploded view of an ambidextrous bolt catch device in position for assembly in the receiver of a firearm.
FIG. 3 is a front view of the assembled ambidextrous bolt catch device in lowered position allowing passage of the bolt group to and from the chamber during firing of ammunition from a magazine.
FIG. 4 is a perspective view of an ambidextrous bolt catch device showing major parts and positions for assembly in a firearm.
FIG. 5 is a front view of an assembled ambidextrous bolt catch device in raised position with directional arrows for moving parts.
FIG. 6 is a top view of the ambidextrous bolt catch device of FIG. 5 showing movement of the lever on the right side the firearm in the direction of arrow j.
FIG. 7 is a front view of the assembled ambidextrous bolt catch in a raised position retaining the bolt group in a rearward position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
It would be useful to discuss the meanings of some words used herein and their applications. “Firearm” is used herein to refer to all weapons to which an ambidextrous bolt catch device can be installed, such as those having or capable of being manufactured with mounting holes in the receiver. A preferred weapon for installing the present invention is the M16/M4 family of weapons.
The directional terms “lateral,” “horizontal,” “vertical,” “front,” “forward,” “rear,” “rearward,” “right,” “left,” “above,” and “below” refer to the firearm when held in the normal firing position.
Listed below are the components of the ambidextrous bolt catch device assembly shown in FIGS. 1-7 .
10 Bolt catch device on right side of firearm 12 Plunger 14 Spring 16 Plunger Head 18 Bolt catch device pin 19 Vertical lever pin 20 Bolt catch finger 22 Knurled pad of bolt catch device integral to bolt catch finger on left side of firearm 25 Bolt 28 Section of lower receiver that contains bolt carrier 30 Bolt carrier 40 Section of lower receiver to which magazine is attached 50 Magazine 150 Pivot pin a hole in mid-section of right lever b hole in distal end of right lever c ninety degree bend in plunger rod d threaded end of plunger rod e through hole in lower receiver for plunger rod f vertical hole in lower receiver that receives vertical lever pin h horizontal movement to left of firearm i horizontal movement to right within through hole e j horizontal movement to right of firearm k vertical movement in direction above firearm
As state earlier, and shown in FIGS. 1-7 , the ambidextrous bolt catch device of the present invention has four main components including a vertical lever pin that attaches and engages in an efficient manner a pivoting bolt catch finger with a knurled pad for hand control on the left side of a firearm; a plunger configuration with a plunger rod, a spring and plunger head that connect the right and left sides of the bolt catch device; and a bolt catch device for hand control on the right side of a firearm.
In FIG. 1 , a bolt catch finger 20 is pivotally mounted on the lower receiver 40 of a firearm with a portion extending into the receiver to retain the bolt group, which is a combination of a bolt 25 and bolt carrier 30 . The bolt catch finger 20 holds the bolt group in a rearward position. A lever 10 on the right side and a knurled pad 22 (not shown) on the left side are depressed separately, depending on whether the operator is left-handed or right-handed, to release the bolt group 25 , 30 and allow its forward motion.
The right side view of a firearm in FIG. 1 shows the ambidextrous bolt catch assembly in the customary location of bolt catch assemblies, offering the advantage of user familiarity and component commonality. The bolt catch device 10 for the right handed user is positioned in the lower receiver 40 which holds ammunition in the magazine 50 .
FIG. 1 also shows the bolt catch finger 20 in a raised position holding the bolt 25 and bolt carrier 30 in a rearward position. This is a signal to the user that the last round of ammunition has been fired.
FIG. 2 is an exploded view of the ambidextrous bolt catch device of the present invention as it would be assembled in a weapon. Bolt catch device 10 fits flush into the right side of the lower receiver 40 when the bolt catch finger is not engaged or in the raised position. The nesting of lever 10 in a pocket formed into the receiver 40 side wall eliminates a snag hazard for the shooter and prevents a potential problem in military or police operations. Lever 10 is rotationally fastened to the lower receiver 40 and also connected to the firearm by various pins and pivots.
FIG. 2 shows a vertical lever pin 19 that is held in place by a bolt catch pin 18 . The vertical lever pin 19 passes through a first hole a in the mid-section of lever 10 , pivotally mounting it to a vertical hole f in the lower receiver 40 . A plunger rod 12 extends from the left side to the right side of the weapon; with a ninety degree bend c at the end connecting to the lever 10 by a second hole b, in the distal end of lever 10 . The connection to lever 10 is opposite threaded end d of plunger rod 12 .
Still referring to FIG. 2 , the 90 degree bend c in the plunger rod 12 extends to and abuts the base of the bolt catch finger 20 thereby eliminating the need for a connecting pin and increasing the reliability of the system. The plunger rod 12 operates in a through-hole e in the lower receiver 40 on a plane that is perpendicular to the motion of the bolt group 25 , 30 . A spring 14 and plunger head 16 are fastened to the plunger rod 12 by a threaded interface d. The complete ambidextrous bolt catch assembly can be securely fitted to a weapon and will not be easily lost during disassembly.
FIG. 3 is a front view of the assembled ambidextrous bolt catch of the present invention with the bolt catch 20 in a lowered position. After a round of ammunition is placed in the weapon, the user can use either the right-hand trigger finger to press lever 10 in the direction of the receiver 40 side wall, actuating vertical lever pin 19 to engage plunger rod 12 connected to spring 14 and plunger head 16 allowing the mechanics to rotate the bolt catch 20 in a downward rotation, which releases the bolt 25 (not shown).
Further reference to FIG. 3 shows that when the bolt catch finger 20 is in a downward position it partially obstructs the opening through which the bolt 25 and bolt carrier 30 move. The protruding portion is situated so that when the last round is fired, the bolt carrier group 25 , 30 go over the top of the bolt catch finger 20 when it's in the downward position. Once the bolt carrier group slides over the empty magazine and the magazine follower rotates the bolt catch, it is now ready to stop the bolt before it comes forward again. When the bolt comes forward in the lower receiver the bolt catch will mate up with a “lug” on the bolt, thus preventing the bolt carrier from moving further forward.
FIG. 4 is a perspective view of the ambidextrous bolt catch device showing the main components, the vertical lever pin 19 securing the bolt catch device 10 on the right side of the firearm to the indentation on the side of the weapon that houses or nests the lever 10 , thus preventing snag hazard for the user. The plunger rod 12 connects lever 10 to the end with the ninety degree bend and extends to the opposite side of the weapon where the plunger head 16 abuts the base of the bolt catch finger 20 having an integrally formed knurled pad 22 mounted on the weapon with a pivoting hinge 150 . The ambidextrous hand controls, lever 10 on the right side of the weapon and knurled pad 22 on the left side of the weapon are clearly shown in FIG. 4 . It should be understood that the shape and surface treatment of the lever and knurled pad can be in any configuration known and used by persons skilled in the art of ergonomics and are not limited to the configurations shown herein.
FIG. 5 shows the bolt catch device with the bolt catch finger 20 rotating upward in the direction of arrow k. The bolt catch finger 20 will rotate upward when you have an empty magazine in the lower receiver 40 . The bolt group passes over the magazine and the magazine spring pushes the magazine follower against the bolt catch finger, which creates the rotational action. Lever 10 is pushed outward when bolt catch finger 20 is rotated upward. When bolt catch finger 20 is rotated its flat surface pushes against plunger head 16 which is fastened to plunger rod 12 . The resulting actions cause lever 10 to rotate outwards in the direction of arrow j.
Alternatively, the user can pull knurled pad 22 in the direction of arrow h or pull lever 10 away from the side of the weapon in the direction of arrow j. This motion of the hand controls causes the plunger rod 12 to move in the direction of arrow i creating mechanical leverage that raises the bolt catch finger 20 in such a manner that its stops the bolt group from moving forward, as shown in FIG. 7 .
FIG. 6 is an enlarged drawing of a top view of the bolt catch device of the present invention when the bolt catch finger 20 is in the raised position and lever 10 on the right side has pivoted outwards in the direction of arrow j. FIG. 6 shows that lever 10 does rotate outward, but not very far from the lower receiver 40 .
FIG. 7 is a front view of the assembled ambidextrous bolt catch of the present invention with the bolt catch finger 20 in a raised position. The bolt 25 of the firearm has traveled past the bolt catch finger 20 after the final round of ammunition is fired; this causes the plunger 12 to compress spring 14 and plunger head 16 so that bolt catch finger 20 pivots on the pivot pin 150 and raises the bolt catch finger 20 to a position that stops the bolt 25 from traveling forward. Also shown in FIG. 7 is the position of lever 10 held by vertical lever pin 19 . The lever 10 does pivot outwards in FIG. 7 when bolt group is in the rearward position; however, the lever 10 does not rotate outwards very far from the lower receiver 40 . The outward rotation of lever 10 is illustrated in the enlarged drawing of FIG. 6 showing a top view of the device with lever 10 pivoted outward from the side of the firearm.
When all components are assembled in the lower receiver 40 , and there is a magazine 50 removably attached to the lower receiver 40 , the ambidextrous bolt catch device functions as follows. First, the bolt 25 of the firearm travels past the bolt catch finger 20 when the final round of ammunition is fired or when the operator pulls lever 10 laterally to the right and away from the side of the lower receiver 40 or manually pulls the knurled pad 22 laterally to the right and away from the left side of the firearm causing the bolt catch finger 20 to rotate upward and stop the bolt 25 from traveling forward.
When the bolt group moves rearward over an empty magazine cartridge, the magazine spring pushes the magazine follower against the bolt catch finger, which mechanically creates a rotational action that causes the bolt catch finger 20 to rotate upward, block the forward movement of the bolt 25 and signal the user of the weapon that the magazine is empty and needs to be replaced or refilled. When the next ammunition round is placed into the weapon, the bolt 25 must be released from the bolt catch finger 20 to allow the bolt 25 to push the ammunition into the chamber of the weapon.
The release of bolt 25 is accomplished manually. On the right side of the firearm, the operator pushes lever 10 towards the sidewall of lower receiver 40 allowing the mechanics of the spring bias plunger rod assembly to rotate the bolt catch finger 20 in a downward rotation, which then releases the bolt 25 . On the left side of the firearm, a left-handed user is able to press knurled pad 22 of the bolt catch finger 20 laterally towards the left side of the firearm creating tension on the torsion spring of the plunger rod assembly and cause the rotation of the bolt catch finger in a downward position, releasing the bolt 25 .
Thus, when the first release lever and second release lever are pressed or moved laterally toward the right side and the left side of the firearm, the bolt catch finger 20 rotates to a downward position and when the first release lever and second release lever are pulled or moved laterally away from the right side and the left side of the firearm, the bolt catch finger rotates to an upward position. The movement of the first and second levers can be accomplished manually or mechanically. The plunger rod assembly with torsion spring and plunger head allows the creation of tension and subsequent rotation of the bolt catch finger 20 to an upward or downward position, as desired, in the operation of a firearm.
The novel design of the ambidextrous bolt catch device has a right-hand side of the weapon release point (lever 10 ) and a left-hand side of the weapon release point (knurled pad 22 ).
The ambidextrous bolt catch device is designed to have a single spring 14 keeping constant resistance on the plunger head 16 . When the bolt catch finger 20 is in its raised position, it compresses the spring allowing the plunger 12 to be pushed outwards, and allowing the lever 10 to swing out in a horizontal or lateral direction from the right side of the firearm as shown in FIG. 6 .
The bolt catch finger 20 is fabricated from 17-4 gauge stainless steel; carefully machined from a one-piece block that pivots upward and downward on pivot pin 150 . The bolt catch finger 20 can also be manufactured using metal injection molding (MIM).
After assembly or manufacture, the ambidextrous bolt catch device of the present invention functions as a unit that does not have loose parts or parts that can fall off involuntarily. The ambidextrous bolt catch device assembly can be installed or removed from a weapon during disassembly and cleaning. This new design allows the operation of a bolt catch device with one hand for either a right-handed or left-handed shooter.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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An ambidextrous bolt catch device, apparatus, system and methods for using are provided. Four main components include a bolt catch finger, lever system and plunger rod assembly with torsion spring. The lever system includes a right release lever and a left release lever; the left lever is an integral part of the bolt catch finger. The plunger rod assembly abuts and connects the right and left levers; a torsion spring on the rod creates tension causing rotation of the bolt catch finger in a downward or upward position. In an upward position, the bolt catch finger engages the bolt, retains the bolt in a rearward position, and signals the operator that the magazine is empty. The bolt engaged by the finger is held rearward in a safe, reliable manner to allow an unobstructed view of the firearm chamber until manually released using either the right or left release lever.
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FIELD OF THE INVENTION
[0001] The present invention is in the field of topical personal care products and specifically concerns preservative systems suitable for aqueous products that may be certified organic.
BACKGROUND
[0002] Consumer demand for organic products is well established in many parts of the world. While we may generally think of food products in relation to organic certification, there is also a growing market for organic non-food items, including cosmetic and dermatologic compositions. The following was reported in Cosmetics & Toiletries magazine (Oct. 2, 2006):
Organic personal care products were reported to achieve US$282 million in sales in 2005, according to the Organic Trade Association's 2006 Manufacturer Survey. According to the survey, non-food organic product sales totaled US$744 million, which was up 28% from 2004. The survey also reported that 61% of respondents for food and non-food categories displayed the USDA organic seal on their products, many of them responding that the seal helped to sell their products.
[0004] The definitions of “organic product”, “organic ingredient”, “certified organic” and the like, have been evolving for some time, and international standards are only slowing converging. Government authorities have developed organic standards for cosmetics labeling to varying degrees. In the United States for example, a task force headed by the National Standards Foundation is due to draft standards for organic personal care products, by Summer 2007. It is expected that the proposed organic personal care standards will be similar to the organic foods standards promulgated by the US Department of Agriculture (USDA) through its National Organic Program (NOP). Currently, personal care products certified under USDA regulations may bear one of the approved logos, but there are no regulations in place to prevent non-certified products from labeling their products “organic”. The laws and regulations of the National Organic Program are promulgated under 7 U.S.C. 94.6501-94.6523 and 7 C.F.R. 205, herein incorporated by reference, in their entirety.
[0005] In Japan, organic products are defined under the Organic Japanese Agricultural Standard (JAS). In India, it's the NPOP Regulation (National Programme for Organic Production). In some parts of the world non-governmental organizations are proliferating standards for organic products and offering certification services. Organizations like Ecocert International offer organic cosmetic certification based on standards developed by Ecocert. Ecocert also verifies organic product standards against regulations in Europe, Japan and the United States. Other European-based organic cosmetic certifying organizations include the Soil Association Standards for Health and Beautycare Products, in Great Britain, and AIAB (Associazione Italiana per l'Agricoltura Biologica) Regulation, in Italy. These and other organizations are actively seeking harmonization, with the aim of proposing a uniform European regulation for organic cosmetic certification. In April, 2007, The Organic Farmers & Growers, an organic food inspector and licensor in Great Britain, announced its own standard for organic certification of cosmetics and personal care products. The standard is reportedly based on EU Organic Regulation (EC2092/91) and the Nordic Ecolabelling Standards. In Europe, Ecocert cosmetic certification is, perhaps, the most sought after certification. Although the Ecocert certification for cosmetics is voluntary, Ecocert's Cosmetics Department has, according to their website, certified more than 130 companies and more than 18,000 cosmetic products worldwide. Thus, a demand is growing among producers, handlers, processors and retailers, for organic certification services based on regionally and globally recognized standards.
[0006] At the time of filing this application, the USDA has yet to promulgate rules specific to the cosmetic industry. However, officially, the cosmetics industry is permitted to apply for NOP certification by adhering to the rules as they exist for the food industry. It should be borne in mind that the NOP standards were written for agricultural production and address the methods, practices and substances used in producing and handling crops, livestock, and processed agricultural products. The NOP requirements apply to the way the product is created and not necessarily to measurable properties of the product itself.
[0007] It is important to note that the terms “organic” and “natural” do not have the same meaning. In the present context, natural refers to not being synthetically or artificially produced. “Organic” also refers to the method of production, as well as methods of handling, storing, processing, packaging, shipping, etc. Organically produced food cannot be produced using excluded methods, and the same holds for cosmetics, even when all of the ingredients are natural. Thus, a NOP certified cosmetic product not only has the requisite level of “natural” ingredients, but the methods of production and handling of the ingredients and final product also conform to defined standards. This is a very stringent requirement for cosmetics and comparatively few cosmetics on the market, today, bear a NOP certification. According to “E-BEAUTY News” (no. 82), a beauty industry newsletter published by beauty-on-line.com, “In practice, these stringent requirements prevent from using the NOP Final Rule for the certification of most cosmetic products.”
[0008] Typically, NOP standards for organic certification include one or more lists of approved and disapproved materials, categorized by functions, like preservatives, sunscreens and colorants, to name a few. As a general rule, most natural (non-synthetic) substances are allowed in organic production, while most synthetic substances are prohibited. Specific exceptions to the general rule are found in The National List of Allowed Synthetic and Prohibited Non-Synthetic Substances (7 C.F.R. 205.600-205.606), herein incorporated by reference, in its entirety.
[0009] The National Organic Program sanctions the use of four levels of organic labeling. These are: “100 percent Organic”, which means, in part, that a product contains 100 percent certified organic ingredients, not counting added water and salt; “Organic”, which means that a product contains at least 95% certified organic ingredients, not counting added water and salt and the remaining ingredients (up to 5% percent non-organic) come from the National Organic Standards Board's list of allowable substances; “Made with Organic Ingredients”, which means that a product contains at least 70% certified organic ingredients, not counting added water and salt; and if a label merely claims that a product contains organic ingredients, the implication is that the product contains less than 70% certified organic ingredients.
[0010] At present, Ecocert organic certification for cosmetics provides two labels. A “Natural Cosmetic” comprises “5% minimum of Organic Certified ingredients on the total of ingredients, which represents 50% of vegetable ingredients”. A “Natural And Organic Cosmetic” comprises “10% minimum of Organic Certified ingredients on the total of ingredients, which represents 95% of vegetable ingredients”. For both labels, at least 95% of the ingredients must be of “natural origin”, which is to say that no more than 5% of synthetic ingredients are permitted. Like the NOP standard in the US, those synthetic ingredients must come from an approved list.
[0011] Thus, all important standards in use today, allow for some level of synthetic materials in the final product. The Ecocert list of approved synthetic ingredients comprises preservatives and processing aids. By allowing synthetic preservatives, the Ecocert Organic Cosmetic standard is acknowledging that preservatives of natural origin may not be sufficiently effective in cosmetic products. Thus, the ECOCERT standard for organic cosmetics is less stringent than the NOP standard, which may account for the greater number of cosmetic products bearing an ECOCERT organic label.
[0012] The invention of a preservative system of natural origin would be beneficial because a cosmetic containing a natural preservative system is potentially certifiable by NOP, as organic. Certainly, a preservative system that meets NOP certification standards removes a significant hurdle, perhaps the greatest hurdle, in marketing NOP-certified organic cosmetics. Furthermore, Ecocert and perhaps other certification standards, specify a maximum level of synthetic ingredients in a product. Those certification standards are more easily achieved if the preservative system is natural and does not count against the permitted level of synthetic ingredients. Thus, a natural preservative system would greatly improve the ability of cosmetic manufacturers to achieve the two most sought after organic certifications, NOP and Ecocert, as well as increase the types of products that may be implemented as all natural.
[0013] An acceptable cosmetic should be preserved against, or contain an antimicrobial agent effective against, at least the following groups of microorganisms: molds (such as, Aspergillus niger ), yeasts (such as, Candida albicans ), gram positive bacteria (such as Staphylococcus aureus ), gram negative bacteria (such as Pseudomonas aeruginosa ), and enteric bacteria (such as E - coli ). Standards for preservation vary, but preservation testing is typically based on introducing a known level of microbial contamination into a product and then measuring the rate of kill over time. Details of preservation testing methods are promulgated by various organizations, including, for example, the US Pharmacopoeia and the CTFA. The US Pharmacopoeia and the CTFA employ a preservation standard of not more than 3 log reduction. Some manufacturers employ standards that are more rigorous than 3 log reduction. For example, it is not uncommon for antimicrobial efficacy of marketable products to be based on a 5 log reduction standard. 5 log reduction means that, within some defined period of time (seven days, for example), there is a 100,000 fold decrease in the number of bacteria, yeast and mold organisms present in the product. Thus, preservative systems that meet a 3 log reduction standard, in marketable cosmetic compositions, may be considered antimicrobially-effective, but a 5 log reduction standard is preferred by many producers and manufacturers. Furthermore, adequate preservation means that a product meets one or more preservation standards at various stages of development; i.e. in lab batches, in pilot scale up, in full scale production of marketable goods, in the hands of the consumer.
[0014] There are materials of natural origin that have preserving properties because they kill, prevent or otherwise inhibit microbial growth in situ. Various essential oils and plant extracts may fall into this category. However, at concentrations that are acceptable for topical products, the scope and duration of protection provided by these materials, is generally insufficient. Cosmetic and other topical products typically need to be preserved for weeks, months or even years against a broad spectrum of microbes. Some improvement in the situation is achieved by combining several essential oils and/or natural origin materials, but, in general, this has not led to an antimicrobial preservative system comparable to those of synthetic origin, that have become conventional in the cosmetic industry because of their broad applicability. Furthermore, essential oils and plant extracts introduce properties that may not be desirable in every product, like odor, irritation or allergic reaction.
[0015] U.S. Pat. No. 5,306,707 discloses perfume components of specific chemical structures that are antimicrobially effective in compositions comprising at least 25% water. A perfume component (not necessarily an essential oil) is “antimicrobially effective” if it requires at least three microbial inoculations to failure in a challenge test consisting of two microbes, Pseudomonas cepacia and Enterobacter cloacae. The product itself is considered preserved if the product also requires at least three microbial inoculations to failure in a challenge test. When read for all it discloses, the '707 reference discloses exactly one combination of perfume components that when used in shampoo or skin lotion, meets its own definition of what is antimicrobially effective. That combination is phenylacetic acid, cinnamic acid, phenylacetaldehyde, 2-methyl-2-hepten-6-one, phenylethyl formate, cis-3-hexenyl acetate, prenyl acetate, benzyl formate, cinnamic aldehyde. And furthermore, those nine perfume components were prepared in solution with at least 19 other compounds whose combined effect on microbes is unknown. The large number of perfume components needed to achieve some level of preservation, makes this system impractical for broad use in the plethora of cosmetic products that inhabit the marketplace. Furthermore, preservation was only demonstrated against Pseudomonas cepacia and Enterobacter cloacae. Effectiveness against molds (such as, Aspergillus niger ), yeasts (such as, Candida albicans ) and gram positive bacteria (such as Staphylococcus aureus ), was not demonstrated. Thus, the '707 reference fails to disclose a well preserved aqueous, cosmetic or personal care composition.
[0016] U.S. Pat. No. 4,966,754 discloses a method of preserving a cosmetic composition from the microbial action of Aspergillus niger, Candida albicans, Staphylococcus aureus and Pseudomonas aeruginosa, comprising incorporating into a cosmetic composition a mixture of essential oils: Linalool (ex. Bois de Rose), Geraniol (ex. Palmarosa), Lemongrass 80% rectified, Bois de Rose, Cedarwood Oil, Marjoram Oil, Cinnamon Bark Oil, Cardamon Oil, Neroli Bigarde Petals Oil, Vanilla Resinoid, Coriander Oil, Oakmoss empuree, Armoise Oil, Menthol Crystals laevo, Rose absolute concrete (wax) and wherein the antimicrobial essential oil is incorporated into the cosmetic composition by first dissolving the antimicrobial essential oil in a polyoxyethylene sorbitan ester wherein the ratio by weight of the sorbitan ester to the antimicrobial essential oil is in the range of 2:1 to 6:1 and adding the resulting sorbitan ester and essential oil mixture to the cosmetic composition in an amount to provide the antimicrobial essential oil in the cosmetic composition of at least 2% by weight of the cosmetic composition. Here again, the essential oil mixture is specific and impractical for broad use. Furthermore, preservation was not demonstrated against enteric bacteria (such as E - coli ). Thus, the '754 reference fails to disclose a well preserved aqueous, cosmetic or personal care composition.
[0017] Essential oils, in general, have very limited water solubility. Notwithstanding specific exceptions that may be found in the prior art, essential oils provide only limited protection for aqueous systems or aqueous phases of multiphase systems. Furthermore, to the extent that some essential oils (i.e. tea tree, citrus) and plant extracts provide preservative activity, they can also have adverse properties when applied to the skin in antimicrobial-effective quantities. Allergic reactions and generalized skin irritation are common concerns. Furthermore, natural preservatives themselves tend to deteriorate over time and lose efficacy, more so than synthetic preservatives. If that happens, the cosmetic composition would be subject to microbial attack and spoilage. Also of concern is the odor imparted by essential oils and the higher cost of natural origin ingredients compared to conventional synthetic preservatives. Because of its limitations, the use of essential oils and plant extracts for preservation has never achieved widespread use. Furthermore, essential oils are typically added to an oil phase, wherein the essential oils have their greatest preservation activity. If the oil phase is sequestered from the water phase, i.e. an oil-in-water emulsion, the essential oils may have little preservation effect in the water phase. Thus, water based and water containing cosmetic compositions commonly use alcohol as a preservative. In some certified organic products, in order to achieve adequate preservation, concentrations of alcohol in an aqueous phase may be as high as 15-20%. This level is too high for many types of personal care products. Such a high alcohol level may limit the types of products that a formulator can design or interfere with the aesthetic of the product. On the other hand, at lower levels of alcohol, sufficient preservation will probably not be achieved. Also, in NOP certified organic products (and perhaps other standards), the alcohol must be denatured in a manner proscribed by regulation. The cost and availability of certified organic alcohol may also be disadvantageous.
[0018] There remains a need for an effective preservative system (one that meets a 5 log reduction standard for molds, yeasts, gram positive bacteria, gram negative bacteria, and enteric bacteria), that has broad use in various types of cosmetics, particularly aqueous cosmetics that are certifiable organic.
[0019] Hypoiodite and hypothiocyanate are naturally occurring compounds known to have antimicrobial properties that make them effective preservation agents in aqueous preparations. One example of a system that generates hypoiodite and hypothiocyanate, in situ, is known as Biovert®, and is commercially available from Arch Personal Care. This system is described in U.S. Pat. No. 5,607,681 (herein incorporated by reference, in its entirety) and one example of its operation is as follows. A host system requiring preservation, such as an aqueous cosmetic preparation, is provided. Biovert is a two part system. The first is a substrate solution of glucose mixed with one or more salts of iodide and thiocyanate. Suitable iodide salts include potassium and sodium salts. Suitable thiocyanate salts include potassium, sodium, ammonium, ferric and cuprous salts. When introduced into the substrate solution, the iodide and thiocyanate ions are released from the salts. The substrate solution is incorporated into the aqueous cosmetic preparation thus infusing the preparation with iodide and thiocyanate ions. The second part of the Biovert® system is an enzyme solution comprising glucose oxidase and lactoperoxidase. In the presence of oxygen, which is available at the exposed surface of the preparation, glucose oxidase is broken down and hydrogen peroxide, H 2 O 2 , is released into the preparation. At this point, the original preparation is infused with iodide and thiocyanate ions, lactoperoxidase and hydrogen peroxide. In the presence of hydrogen peroxide (H 2 O 2 ), lactoperoxidase is capable of oxidizing the iodide ion into hypoiodite (OI − ) and the thiocyanate ion into hypothiocyanate (OSCN − ). After being generated in situ, hypoiodite and hypothiocyanate go to work against microbes in the aqueous preparation. This system is reportedly effective against bacteria, yeast and mold.
[0020] This system has the feature that when the supply of oxygen is cut off, as when the container holding the preparation is sealed, the oxygen in the container is depleted. When the oxygen seal is broken, the preservative system immediately goes back to work. There are two advantages to this feature. Firstly, without oxygen, the cascade of reactions is halted so that the preservative system is not depleted. Secondly, because oxygen in or near the product is scavenged, the preparation is protected from oxidative damage. The use of the Biovert® type system for protection against oxidation is disclosed in U.S. Pat. No. 5,972,355.
[0021] The Biovert® system is a natural preservative system. Glucose is a natural source of energy. Glucose oxidase and lactoperoxidase are naturally occurring enzymes. Hypoiodite and hypothiocyanate are naturally occurring inorganic salts. However, hypothiocyanate is not permitted in organic products. Thus the Biovert® system is all natural, yet unsuitable for use in products certified organic by NOP or other certification agents.
[0022] The web site of arch Personal Care Products discloses Biomimetic Bodywash BP-6 (http://www.archchemicals.com/Fed/PC/Docs/BP-6%20Biomimetic%20Bodywash.pdf). This Bodywash comprises the Biovert system, pink grapefruit fragrance (essential oil) and citric acid (a plant extract). However, for a number of reasons, this Bodywash is not certifiable as organic. First, the hypothiocyanate in Biovert is not organic. Also, the formula contains other non-certifiable ingredients that total more than 39% of the formula. Thus, this reference and the prior art in general, fail to disclose or suggest an aqueous topical composition that satisfies one or more widely recognized organic certification standards and which comprises an antimicrobial-effective, natural preservative system and which has no synthetic preservatives. Thus, there remains a need for such a composition.
OBJECTS OF THE INVENTION
[0023] A main object of the invention is to provide an aqueous topical composition that satisfies one or more widely recognized organic certification standards and which comprises an anti-microbial effective, natural preservative system having no synthetic preservatives.
[0024] Another object of the invention is to provide an aqueous topical composition that satisfies NOP and Ecocert certification standards and which comprises an anti-microbial effective, natural preservative system having no synthetic preservatives.
[0025] Another object of the invention is to provide an aqueous topical composition that satisfies NOP and Ecocert certification standards, wherein the preservative system efficacy meets a 5 log reduction standard commonly used in the field of cosmetics.
[0026] Another object of the invention is to provide an aqueous topical composition that satisfies NOP and Ecocert certification standards, wherein the preservative system comprises an in situ hypoiodite generator, at least one water based plant extract and at least one essential oil.
SUMMARY
[0027] The present invention is an aqueous topical composition that satisfies one or more widely recognized organic certification standard. The composition comprises a preservative system comprising an in situ hypoiodite generator, an essential oil blend and a plant extract blend. Preferably, the composition contains no synthetic preservatives, especially parabens. If alcohol is present, preferably it is at no more than about 5% concentration. Suitable aqueous compositions may contain an oil phase, such as oil-in-water emulsions. Preferably, the composition satisfies a seven day, 5 log reduction standard for anti-microbial activity against molds (such as, Aspergillus niger ), yeasts (such as, Candida albicans ), gram positive bacteria (such as Staphylococcus aureus ), gram negative bacteria (such as Pseudomonas aeruginosa ), and enteric bacteria (such as E - coli ).
DETAILED DESCRIPTION
[0028] One of the dual pathways of the enzyme-based Biovert® system leads to the generation of hypothiocyanate ions. Hypothiocyanate ions are unacceptable in topical compositions certified organic. In the compositions according to the present invention, this pathway, along with the microbicidal activity that it contributes, is removed from the system. According to U.S. Pat. No. 5,607,681 (see column 13),
“Omission of thiocyanate resulted in failure against mould . . . . These results indicate that at least four components, namely glucose oxidase, glucose, iodide and thiocyanate, are essential components required to give broad spectrum anti-microbial activity.”
[0030] Thus, by removing the thiocyanate ions from the enzyme-based preservative system, the present invention goes against the prior art. Surprisingly, this modified Biovert® system is still useful for preservation, and when used in combination with certain natural ingredients, provides adequate preservation in aqueous products that are certifiable organic. This includes NOP and Ecocert certification, as well as others.
[0031] Throughout the specification, the term “hypoiodite generator”, specifically means that no hypothiocyanate ions are produced. The enzyme-based hypoiodite generator of the present invention consists of an oxidase, a substrate for the oxidase, a peroxidase and an iodide species, with no thiocyanate species. Surprisingly, without the hypothiocyanate pathway, the enzyme-based, organic hypoiodite generator is still useful as part of an anti-microbially-effective natural preservative system for certifiable organic preparations.
[0032] By “anti-microbially effective” or the like, we mean that a preserving system or preserving agent meets at least a 3 log reduction standard for molds, yeasts, gram positive and gram negative bacteria, and enteric bacteria, preferably a 5 log reduction standard. A “well preserved” composition is one that comprises an anti-microbially effective preservative system.
Oxidase and Substrate
[0033] An appropriate oxidase is one which is able to catalyze the production of H 2 O 2 by oxidizing a substrate in the presence of water and oxygen. Examples of useful oxidases include glucose oxidase or galactose oxidase. Appropriate substrates for these enzymes are D-glucose or galactose, respectively. Precursors of these compounds are also useful, for example oligomers or polymers that can break down into the smaller sugar units. The amount of oxidase used is preferably about 150-4,000 U/kg of the total composition, a unit (U) being defined herein as the amount of enzyme required to catalyze 1.0 μmole of substrate per minute at 25° C., under optimal conditions. More preferably the amount of oxidase is at about 200-3,000 U/kg, and most preferably about 300-2,5000 U/kg. Nevertheless, U.S. Pat. No. 5,607,681 teaches that the amount of glucose oxidase may be decreased to about 25 to 4000 U/kg, preferably 75 to 3000 U/kg glucose oxidase, if the composition further comprises “at least one antioxidant, for example 1 to 10000 mg/kg, preferably 50 to 5000 mg/kg butylated hydroxytoluene, α-tocopherol or esters thereof or ascorbic acid, esters or salts thereof”.
[0034] The substrate for the oxidase is preferably provided in an amount of at least about 0.5-50 g/kg of total composition, preferably at least 1 g/kg, and more preferably at least 2 g/kg.
Peroxidase and Iodide Species
[0035] Compositions of the present invention include a source of iodide anions (I − ). The anions are generally incorporated into the system in the form of salts, such as potassium and sodium iodide salts, or mixtures thereof. A preferred weight concentration of iodide ions is about 5-200 mg/kg of the total composition and preferably about 10-150 mg/kg of the total composition.
[0036] An appropriate peroxidase is one which, in the presence of hydrogen peroxide (H 2 O 2 ), is capable of oxidizing the iodide ion into hypoiodite (OI − ). The peroxidase may be, for example, lactoperoxidase, myeloperoxidase, or horseradish peroxidase. The amount of peroxidase is preferably at least about 10 to 100,000 U/kg, more preferably 100-25,000 U/kg and most preferably 250-10,000 U/kg, particularly 500-7000 U/kg.
[0037] Adhering to the concentrations discussed above, the oxidase, substrate, peroxidase and iodide ions may be added to the topical composition separately or in pre-mixed forms. For example, the iodide ions may be prepared as part of the substrate. For example, the substrate may be an aqueous solution of glucose or galactose mixed with one or more salts of iodide. When introduced into the substrate solution, the iodide ions are released from the salts. Subsequently, when the substrate solution is incorporated into the aqueous cosmetic preparation, the preparation becomes infused with iodide ions. Furthermore, the oxidase and peroxidase may be premixed in solution and added simultaneously to the aqueous preparation.
[0038] Advantageously, we are able to achieve a well preserved aqueous composition having no synthetic preservatives, including alcohol, that satisfies one or more widely recognized organic certification standards, including NOP and Ecocert (assuming the remainder of the composition is certifiable as organic). Such compositions are new and non-obvious, as evidenced by the lack of such compositions on the market, even though demand for organic certified products is high.
[0039] Furthermore, organically certified alcohol is permitted in certified organic products. Therefore, the option of including organic alcohol is also within the scope of this invention. Organic alcohol may be used for its preservation activity or for any of its other qualities. The concentration of organic alcohol will be dictated by its function, and in general, the concentration may be well below 15-20%. For example, in compositions of the present invention disclosed herein, no more than 5% organic alcohol is used to dissolve a blend of essential oils, the preservative activity of the organic alcohol being incidental. Alcohol at a 5% concentration is incapable of providing complete preservation of an aqueous cosmetic composition. Thus, the organic alcohol-containing compositions disclosed herein are distinguished from prior art compositions having alcohol at levels of 15-20%, or more.
[0040] The phrase “satisfies one or more widely recognized organic certification standards” is used in this specification. The term “satisfies”, by itself, only implies that a composition meets one of the various levels of organic labeling described above. One factor that makes a composition according to the present invention unique is that the composition satisfies one or more widely recognized organic certification standards and is well preserved while containing no synthetic preservatives or, in some cases, at most 5% organic alcohol. By “widely recognized”, we mean those standards promulgated by an agency that a person of ordinary skill in the art would recognize as authoritative and in force. At a minimum, this includes all government and government-sponsored certification programs, like NOP. Quasi governmental and non-governmental agencies, like Ecocert, are also included, when those agencies would be recognized as authoritative by a person of ordinary skill in the art.
[0041] A second component of the present invention is one or more water soluble plant extracts. Typically, plant extracts are suitable for use in certified organic products and may provide additional preservative activity. This may be desirable if the activity of the enzyme-based, organic hypoiodite generator alone, does not perform up to established standards. In that case, additional efficacy (either intensity or spectrum) will be required and various water soluble plants extracts have been identified for their antimicrobial activity. Of particular importance in the present invention are water soluble plant extracts that provide anti-mold activity. These include, for example, quillaja saponaria wood, olea europaea (olive leaf), citrus aurantium amara (bitter orange) flower, citrus medica limonum (lemon), citrus paradise (grapefruit) seed, salix alba (willow) bark, Sasa Kurilensis water (bamboo), Kappaphycus alvareziil (seaweed), Arachis hypogaea seed (oat), punica granatum (pomegranate) juice, vaccinium myrtillus (blueberry) leaf, fragaria vesca (strawberry) fruit and robus idaeus (raspberry) fruit extracts. Compositions of the present invention that comprise an oil phase may preferably include one or more oil soluble plant extracts to aid in the preservation of the oil phase. Useful oil soluble plant extracts include rosmarinas officinalis (rosemary) leaf, solanum lycopersicum (tomato) seed, hinokitiol and tocopherol. At present Tocobiol® (from BTSA, Biotecnologías Aplicadas, S.L.) is the only tocopherol acceptable under some (i.e. NOP) certification standards.
[0042] In general, other than the usual concerns in cosmetic and organic formulation, there are no restrictions on the concentrations of plant extracts used in formulations according to the present invention. Nevertheless, suitably preserved compositions have been readily achieved wherein the total concentration of plant extracts contributing to preservation is about 5% or less. Thus, well preserved organic compositions are possible, with relatively low levels of plant extracts.
[0043] An optional component of the present invention is one or more essential oils. Typically, essential oils are suitable for use in certified organic products and may provide additional preservative activity, including anti-oxidant activity. Compositions of the present invention that comprise an oil phase will preferably include one or more essential oils to aid in the preservation of the oil phase. Various essential oils have been identified for their antimicrobial activity. These include, for example, eugenia caryophyllus (clove) bud, lavendula angustifolia (lavender), cananga odorata (ylang ylang) flower, citrus grandis (grapefruit) peel, citrus medica limonum (lemon) peel and thymus vulgaris (thyme). Also useful are: origanum, sweet orange, lemongrass, Chinese cinnamon, rose, eucalyptus, peppermint, rose geranium, meadowsweet, Chinese anise, orris, cinnamon, rosemary, cumin, neroli, birch, Melissa balm, juniper, sweet fennel garlic, cajeput, sassafras, heliotrope, anise, mustard, fir, pine, parsley and violet. There are many other antimicrobially active essential oils, and as long as a supplier of organically certified material can be found, these may be used in the certified organic compositions of the present invention. A person skill in the art may construct a blend of essential oils that provides some necessary or backup preservative activity. Three blends that have been useful at about 0.5% of the total composition are as follows.
[0044] Blend 1: eugenia caryophyllus (clove) bud oil, lavendula angustifolia (lavender) oil, cananga odorata (ylang ylang) flower oil, citrus grandis (grapefruit) peel oil, citrus medica limonum (lemon) peel oil, and thymus vulgaris (thyme) oil.
[0045] Blend 2: citrus medica limonum (lemon) peel oil, eugenia caryphyllos (clove) flower oil and cinnamomum cassia (cinnamon) leaf oil.
[0046] Blend 3: pimenta officinalis (allspice) leaf oil and eugenia caryphyllos (clove) flower oil.
[0047] In general, other than the usual concerns in cosmetic and organic formulation, there are no restrictions on the concentrations of essential oils used in formulations according to the present invention. Nevertheless, suitably preserved compositions have been readily achieved wherein the total concentration of essential oils contributing to preservation is about 0.5% or less. When using essential oils, the aroma contributed to the product by the essential oils must be considered. If it is undesirable to have the preservative essential oils contribute to the overall aroma of the product, then total essential oil concentrations may be limited to whatever level is considered undetectable. The exact level may be determined by a person of ordinary skill in the art, however, concentrations of essential oil blends disclosed herein, up to about 0.5%, have contributed to the overall preservation of the product, while avoiding a substantial effect on a product's aroma, as detected by the human nose. Thus, well preserved organic compositions are possible, with relatively low levels of essential oils. Of course, if the aroma is considered a benefit for the product, then more essential oil may be used in the product.
[0048] The aqueous organic compositions of the present invention can be in any form, particularly water-in-oil emulsions. The aqueous phase of the composition may be any cosmetically acceptable water based material, such as deionized water, or a floral water. Because the preservative system of the present invention is particularly suited for water based certified-organic compositions, water may be present in various amounts, for example up to 30%, more preferably up to 60% and most preferably up to 80% of the composition, by weight.
[0049] The oil phase may be any cosmetically or pharmaceutically acceptable organic material which is substantially insoluble in water. For example, organic sunflower oil, almond oil, castor oil, coconut oil, palm oil, olive oil, pumpkin seed oil, safflower oil, or sesame seed oil.
[0050] The aqueous organic compositions of the present invention may comprise optional components, depending on the intended end use. In accordance with present invention, a material may only be included up to the concentration permitted by one or more widely recognized, valid, organic certification standards. By referencing any particular organic standard, a person of skill in the art may readily ascertain which materials are disallowed in organic products.
[0051] With that restriction, compositions of the present invention may, in general, contain ingredients having any of the functions listed in the International Cosmetic Ingredient Dictionary and Handbook, eleventh edition (2006) herein incorporated by reference, in its entirety. Examples of ingredients that provide one or more benefits to the skin or hair are abrasives, analgesics, antiageing agents, antidandruff agents, anti-inflammatory agents, antioxidants, antiperspirants, astringents, colorants; conditioners, cooling agents, deodorants, depilating agents, dyes, emollients, exfoliants, flavors, fragrances, hair fixatives, hair growth promoters, heating agents, humectants, lip plumping agents, lipids, magnetic agents, occlusives, optically active materials, pigments, protease inhibitors, self-tanners, structured water, sunscreens, thermochromic agents, waterproofing agents, whiteners and vitamins. Examples of ingredients that provide one or more benefits to the composition itself are absorbents, anticaking agents, antifoaming, antistatic agents, binders, buffers, bulking agents, chelating agents, cleansers, corrosion inhibitors, encapsulating agents, emulsion stabilizers, fibers, film-formers, foaming agents, gellants, opacifiers, oxidizing agents, pH adjusters, plasticizers, polymers, propellants, reducing agents, solvents, surfactants, suspending agents, UV absorbers and viscosity controlling agents.
[0052] Furthermore, compositions of the present invention may fall into any product category listed in the International Cosmetic Ingredient Dictionary and Handbook (eleventh edition). Examples of these include aftershave lotions, baby products, basecoats, bath products, beard softeners, blushers, body paints, cleansers, colognes, cuticle softeners, dentifrices, deodorants, depilatories, douches, eyeliners, eye lotions, eye makeups, face and neck preparations, foot powders, foundations, hair bleachers and colorants, hair conditioners, hair rinses, hair curlers, hair straighteners, lip aides, lip sticks, makeup bases, makeup pencils, manicuring preparations, mascara, masks, moisturizers, mouthwashes, mud packs, nail preparations, perfumes, powders, rouges, sachets, shampoos, shaving aides, self tanners, suntan preparations, talcum and tonics.
[0053] The preservation of an all-natural, certifiable-organic cosmetic preparation as disclosed herein, is typically comparable to or superior to conventional cosmetic preservation. That a preservative system of all natural ingredients, in a certifiable organic composition, could perform as well or better than conventional chemical preservatives, is surprising. The invention is further illustrated by the following non-limiting examples, which include compositions that readily meet a 5 log reduction standard within seven days, for molds, yeasts, gram positive, gram negative and enteric bacteria.
EXAMPLE 1
Organic Moisture Lotion
[0054] The oil-in-water compositions 2 and 3 of table 1 were formed by adding a hypoiodite generator at 38° C., after the emulsions were formed. Compositions 2 and 3 are anti-microbial-effective, while composition 1, without a hypoiodite generator, failed micro challenge testing for mold, yeast, Staphylococcus aureus, Pseudomonas aeruginosa, and enteric bacteria. Thus, composition 1 may be certifiable organic, but the combination of aqueous plant extract (rosemary), tocopherol and citric acid are not antimicrobial-effective. In contrast, compositions 2 and 3 are well preserved, meaning the preservative system is antimicrobial-effective. This is unexpected, considering all of the antimicrobial activity lost with the removal of thiocyanate ions from the Biovert substrate and the fact that there is no alcohol in these compositions. Simultaneously, the removal of the thiocyanate ions renders compositions 2 and 3 certifiable organic (as far as the ingredients are concerned).
[0000]
TABLE 1
1 (%)
2 (%)
3 (%)
Oil Phase
organic sesame
20.00
20.00
20.00
seed oil
organic soy lecithin
3.00
3.00
3.00
tocopherol
1.00
1.00
1.00
Water Phase
deionized water
66.30
62.25
65.25
corn starch
2.50
2.50
2.50
citric acid
0.10
0.10
0.10
rosemary extract
0.10
0.10
0.10
glycerine
7.00
7.00
7.00
water/glucose/potassium
0
1.00
1.00
iodide
water/glucose
0
0.05
0.05
oxidase/lactoperoxidase
EXAMPLE 2
Hydrating Body Lotion
[0055] In table 2, compositions 4 and 5, without a hypoiodite generator, failed micro challenge testing for mold, yeast, Staphylococcus aureus, Pseudomonas aeruginosa, and enteric bacteria. Thus, in composition 4, the combination of tocopherol, alcohol and citric acid does not provide effective antimicrobial activity. Furthermore, the addition of an antimicrobial essential oil blend, in composition 5, still does not provide effective antimicrobial activity. In contrast, composition 6 is anti-microbial-effective. The composition meets a seven day, 5 log reduction standard, remains microbially clean to at least 3 weeks and when reinoculated, again satisfied a seven day 5 log reduction. By selecting certified organic versions of the ingredients (where possible), composition 6 may be certifiable organic. That composition 6 is antimicrobially effective is unexpected, considering all of the antimicrobial activity lost with the removal of thiocyanate ions from the Biovert substrate. Simultaneously, the removal of the thiocyanate ions renders composition 6 certifiable organic (as far as the ingredients are concerned). Thus, composition 6 represents a well preserved, aqueous composition that is certifiable organic by one or more widely recognized organic certification standards.
[0000]
TABLE 2
Sequence
4 (%)
5 (%)
6 (%)
1
deionized water
38.40
37.90
37.98
1
waxy maize
2.50
2.50
2.50
2
glycerine
7.00
7.00
7.00
3
deionized water
9.80
9.80
9.80
3
xanthan gum
0.20
0.20
0.20
4
deionized water
9.50
9.50
9.50
4
veegum pure
0.50
0.50
0.50
5
sunflower seed oil
20.00
20.00
9.00
5
coconut oil
6.00
5
organic soy lecithin
3.00
3.00
2.50
5
tocopherol
1.00
1.00
1.00
5
beeswax
2.00
5
palm fruit oil
2.00
6
silica beads
2.00
2.00
3.00
7
deionized water
1.00
1.00
1.00
7
citric acid
0.10
0.10
0.10
8
alcohol denatured
5.00
5.00
5.00
8
essential oil blend
0.50
0.50
9
water/glucose/potassium
0.40
iodide
9
water/glucose
0.02
oxidase/lactoperoxidase
EXAMPLE 3
Nourishing Face Lotion
[0056] The compositions of table 3 are additional examples of an aqueous topical compositions that are certifiable organic by one or more widely recognized organic certification standards and which comprises an antimicrobial-effective preservative system. In the case of compositions 7 and 8, there are no artificial preservatives, alcohol not being used in those compositions. The composition meets a seven day, 5 log reduction standard, remains microbially clean to at least 3 weeks and when reinoculated, again satisfied a seven day 5 log reduction.
[0000]
TABLE 3
7(%)
8(%)
9(%)
1
deionized water
57.83
60.365
63.04
1
corn starch
3.00
3.000
2.50
2
xanthan gum
0.20
2
veegum pure
0.50
2
sunflower oil
14.10
14.100
11.00
2
palm oil
2.00
9.375
2.00
2
coconut oil
2.00
4.00
2
shea butter
3.00
1.00
2
cocoa butter
3.00
1.00
2
soy lecithin
3.00
3.00
2.50
2
tocopherol
1.00
1.00
0.50
2
rosemary leaf oil
0.01
0.01
0.01
2
glycerine
7.00
7.00
7.00
3
olive leaf ext
0.50
3
quillaja saponaria extract
2.00
0.10
0.10
3
alcohol denatured
3.00
3
essential oil blend
0.50
0.45
0.50
4
citric acid
0.01
0.10
5
deionized water
0.50
5
patchouli oil
0.025
5
rose oil
0.025
6
water/glucose/potassium
1.00
1.00
1.00
iodide
7
water/glucose
0.05
0.05
0.05
oxidase/lactoperoxidase
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Well-preserved aqueous topical compositions that satisfy one or more widely recognized organic certification standards. The compositions comprise a preservative system comprising an in situ hypoiodite generator; and a plant extract blend; optionally, an essential oil blend. Such compositions do not require synthetic preservatives, especially parabens. Suitable aqueous compositions may contain an oil phase, such as oil-in-water or water-in-oil emulsions.
| 0
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BACKGROUND OF THE INVENTION
The present invention relates to an electronic switching device, or component, for the switching networks of telephone central offices, the switching device including a switching transistor disposed in the series branch in the signal conduction path and controllable semiconductor devices in a shunt branch which is disposed transversely to the signal conduction path. In the conductive state of the switching transistor, the device has a low series resistance and a high shunt impedance and in the blocking state, the device has a high series resistance and a low shunt impedance.
German Auslegeschrift [Published Patent Application] No. 1,293,214 discloses an electronic switching device with bistable behavior, for the switching of lines in telegraph and particularly telephone central offices of the above-mentioned type, in which the shunt resistance is a voltage-dependent resistor whose impedance can be changed between different values by the control voltage which is applied to the transverse branch and which is dependent on the switching state of the switching device. In this publication it is proposed to connect a variable capacitance diode in parallel with either a resistor, a bipolar transistor or a pn field effect transistor for the controllable transverse branch.
This switching device is limited to using semiconductor devices with bistable behavior in the series branch. In order to keep this switching device in a conductive state after it has been switched on, it is necessary for the direct current flowing therethrough to always be greater than the holding current. Furthermore, interfering pulses in the voice line may cause the switching device to be inadvertently automatically switched off or on.
The magazine Bulletin Technique PTT 2 (1973), describes on pages 79-83 a fully integrated space-multiple switching device which is based on the conventional transistor switching device. It includes a bipolar transistor in the series branch and a fixed ohmic resistor in the transverse branch which serves to switch on and off the series branch transistor by means of a control circuit. In order to produce the switching device in a monolithically integrated form, it is modified so that a npn transistor is used in the series branch as the switching element and instead of the fixed resistor a current source in the form of a pnp lateral transistor and an npn transistor are used as the control in the transverse branch. Both transistors have their collector terminals connected to the base terminal of the series branch transistor. The npn transistor in the transverse branch is controlled by a holding flip-flop. If the npn transistor is switched on, i.e. rendered conductive, the series branch transistor is blocked, if the non transistor is switched off, i.e. placed in its blocking state, the series branch transistor is rendered conductive by the pnp lateral transistor.
The above-described circuit, which is the monolithic equivalent of the conventional circuit, has the drawback that the pnp lateral transistor is always switched on, regardless of whether the series branch transistor is blocking or conductive. Thus there continuously exists a relatively high direct current energy loss in the switching device. The result is that the packing density of the semiconductor switching devices in a switching matrix module produced from these semiconductor switching devices is limited, since with the small space occupied by the switching matrix module the energy consumption is a significant parameter because: (1) the operating dependability of the semiconductor switching devices is a function of the crystal temperature of the semiconductors; and (2) the energy loss per housing is limited to about 200 mW and thus determines the degree of integration per housing.
The above-described matrix module thus contains only 2 × 2 symmetrical semiconductor switching devices including the control circuit on a single semiconductor chip.
A further drawback of the described switching device is that the series branch transistor requires a directional DC collector operating current which limits the freedom of choice for the speech path in the switching network to connections from one side to the other and requires complicated junctor circuits with current sinks and capacitively or inductively coupled switching. A relatively high energy consumption in the junctor circuits is the result. Also, the direct collector current (I C ≈10mA) which flows through one series branch transistor into the junctor circuit is extremely high.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome the above-mentioned drawbacks of the known monolithic circuits.
It is a more specific object of the invention to provide an electronic switching device which has only a slight energy loss, can be easily integrated, and lends itself to high density fabrication, as well as an advantageous arrangement of the switching devices.
This is accomplished in a switching device of the above-mentioned type by constituting the shunt branch by: a control transistor which is controlled at its base, is connected in feedback via its emitter by means of a resistor, and has its collector connected to the base of the switching transistor; and a voltage-dependent resistor which is also connected to the base of the switching transistor and which is operated by the base potential of the switching transistor to be in its high resistance range when the switching transistor is conductive and in its low resistance range when the control transistor is blocking and the switching transistor is blocked by a defined base potential. The conductivity type of the switching transistor is opposite that of the control transistor. The level of a first operating voltage for the emitter of the switching transistor is higher than the level of the base voltage of the conductively connected control transistor, while the level of a second operating voltage at that terminal of the voltage-dependent resistor which is not connected to the base of the switching transistor is higher than the level of the first operating voltage, and a third operating voltage for the collector of the switching transistor is approximately equal to the operating emitter voltage of the control transistor when it is blocking and is fed to the switching transistor via a resistor having a high resistance such that the switching transistor will operate in the saturation region when it is in its conductive state.
With the switching transistor switched on, the control transistor operating in the active region advantageously produces a high impedance and therefore a low shunt attenuation and when the switching device is blocked, the control transistor will also be blocked in an advantageous manner.
The shunt attenuation when the control transistor is blocking is advantageously increased and the blocking effect of the switching transistor is improved by the connection of the voltage-dependent resistor to the base of the switching transistor, with resistor being controlled by the base potential of the switching transistor so that it presents a high resistance when the switching transistor is conductive and a low resistance when the switching transistor is blocking.
The voltage-dependent resistor may simply be a transistor which is connected in feedback with its emitter connected to a resistor and its base-emitter path biased to always be conducting current.
However, the low energy consumption by the current-conducting base-emitter path can be further reduced if, instead of a bipolar transistor, a field effect transistor is used which remains always conductive but which, as is known, does not require a gate current.
It is further advisable, in order to further save energy, to feed the operating voltage for the collector of the switching transistor through a resistor whose resistance is sufficiently high that in the conducting state of the transistor it operates in the saturation region and carries practically no collector current.
The high resistance collector resistor for the switching transistor is preferably a voltage-dependent resistor which has a high resistance when a collector current flows and a low resistance when no collector current is present.
A resistor with such characteristics can be constituted in a very simple manner also by the collector-emitter path of a transistor whose base-emitter path always conducts current, the emitter current being lower than the current for the switched-on switching transistor. Here, too, a field effect transistor can be used in order to eliminate base-emitter current.
In order to improve the cross-talk attenuation it is advisable to provide two sets of electronic switching contacts in a two-wire switching device so that a symmetrical switching device is produced.
Due to the low energy consumption of the switching device according to the present invention, whose energy dissipation in the blocked state advantageously lies below 1 mW, it is advisably utilized in a switching matrix module in a monolithically integrated fashion. About 5 × 4 symmetrical switching devices can then be accommodated on a silicon substrate of the size of 4 × 4 mm 2 without producing undue heating in the switching matrix module.
If the control circuit for the switching device is accommodated on a substrate separate from the switching device substrate and if this is done in a low-energy monolithic type of structure, e.g. using the MOS technique, it will be possible to realize a particularly high component density for the switching devices.
In further accordance with the present invention, a plurality of such switching devices are connected to form a network composed of a plurality of stages with each stage containing a plurality of switching devices arranged in the form of a matrix having a plurality of rows and columns with a respective switching device being located at each intersection of a row and a column, there being an odd number of stages. The network is further composed of a plurality of input means providing signals to be switched, each input means being connected in common to the emitters of the switching transistors of all of the switching devices in a respective row of the first of the stages; a first plurality of connecting lines each connecting the collectors of the switching transistors of all of the devices in a respective column of each odd stage to the collectors of the switching transistors of all the devices in a respective corresponding row of the next succeeding stage, and a second plurality of connecting lines each connecting the emitters of the switching transistors of all of the devices in a respective column of each even stage to the emitters of the switching transistors of all the devices in a respective corresponding row of the next succeeding stage. The network is further arranged to act as a so-called "column short circuit" for the case where all switching devices in the same column are blocked.
In the odd-numbered stages of switching matrices this is accomplished by a single transistor for each column which in this case operates in the saturation region when all switching transistors of that column are blocking and otherwise in the active region. This produces, inter alia, favorable cross-talk conditions in the switching network. When at least one switching device in a column is switched on, the column short circuit is given such a high resistance, by the transistor which operates in the active region to supply the collector voltage of the switching transistor, that its contribution to the insertion loss is negligibly small. This column resistor is here switched automatically in an advantageous manner in dependence on the occupation state of the column to which the link line is connected.
The connection of the individual stages in the manner set forth above makes it possible to establish conference connections in a simple manner, which is of particular significance when the switching network is used in extension systems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of an asymmetrical switching device constituting one preferred embodiment of the present invention.
FIG. 2 is a circuit diagram of a voltage-dependent resistor with bipolar transistor, constituting one embodiment of a component of the circuit of FIG. 1.
FIG. 3 is a circuit diagram of a voltage-dependent resistor with field effect transistor, constituting a second embodiment of such component of the circuit of FIG. 1.
FIG. 4 is a circuit diagram of a symmetrical switching device representing a second embodiment of the invention.
FIG. 5 is a basic circuit diagram of one embodiment of a switching network according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an embodiment of a switching device KU according to the invention which includes a bipolar switching transistor 21 of npn conductivity type whose emitter is connected to receive an operating voltage U 1 through the secondary winding w 21 of an exchange transformer 1 of a telephone set connected to the primary winding w 1 of the transformer.
The collector of the switching transistor is connected to a source of operating voltage U 3 via a high resistance resistor 61.
The shunt resistance is formed, on the one hand, by a pnp control transistor 31 which is controlled by a voltage applied to its base terminal, is connected in feedback via its emitter by means of a resistor 41, and has its collector connected to the base of the switching transistor 21 and, on the other hand, by a voltage-dependent resistor 51 which is also connected to the base of the switching transistor and whose other end is connected to a source of an operating voltage U 2 .
The operating voltage sources supplying U 1 , U 2 and U 3 have a common reference line M to which the emitter resistor 41 of the control transistor 31 is also connected.
The emitter terminal of the switching transistor constitutes input A and the collector terminal of the switching transistor constitutes output a of the asymmetrical switching device KU, which includes the switching transistor 21, the control transistor 31 with resistor 41, and the voltage-dependent resistor 51.
The operating voltages can, according to one example of the present invention, be selected as follows:
U.sub.1 = -7V; U.sub.2 = -10V; U.sub.3 = 0V.
If a positive control voltage is present at control terminal St, the control transistor is rendered nonconductive, or blocking, and its collector current is zero. The base voltage of the switching transistor 21, across the voltage-dependent resistor 51, is equal to the operating voltage U 2 = -10V and the emitter voltage of U 1 = -7V applied to the switching transistor causes that transistor to also be non-conductive.
To achieve a small voltage drop across the voltage-dependent resistor 51 this resistor must have a low resistance so that the base of the switching transistor is connected with the reference line M through a small resistance, relative to a.c., and the switching transistor acquires optimum off-attenuation properties which depend practically only on its parasitic switching capacitance between the emitter and collector terminals.
If a control voltage of about -1.6V is applied to the control terminal St, the pnp control transistor 31 becomes conductive. If, for example, the value of the emitter resistor 41 is selected to be 500 Ω, an emitter current of about 2 mA will flow in the control transistor 31 and will divide between the base terminal of the switching transistor 21 and the voltage-dependent resistor 51. At the collector terminal of the control transistor there then appears a voltage of about -6.3V which results from the operating voltage U 1 , the voltage drop in the secondary winding w 21 of the transformer 1 and the voltage drop across the beam-emitter path of the switching transistor 21 in the on-state. The voltage across the collector-emitter path of the control transistor 31 is then about -5V so that it operates in the active region and thus has a high impedance. The voltage across the voltage-dependent resistor 51 is about 4V. According to the invention, the voltage-dependent resistor 51 should then also have a high resistance and its shunt attenuation is thus low.
A transistor operates in the saturation region when its voltage across the collector-emitter path if about 0V.
The collector terminal of the switching transistor 21 is connected via resistor 61 to voltage source U 3 for direct and alternating current in such a high resistance manner that:
1. the direct collector current I C of the switching transistor flowing through this resistor is negligibly low (I C < 100μA); and
2. the alternating current resistance of this resistor is very high so that no additional shunt attenuation occurs.
If both of the above conditions are satisfied, it will be possible, in a switching network, to establish a subscriber connection directly via a common column wire without the use of a set of connections if all collector terminals of the semiconductor switching devices which lie in the same column are connected to terminals a whenever the semiconductor switching devices of the same column which are required for a connection are switched on.
FIG. 2 shows a circuit for one embodiment of a voltage-dependent resistor which may take the place of resistor 51. In the case where the switching transistor 21 is of the npn type, the voltage-dependent resistor is an npn transistor 511 with an emitter resistor 521 whose free end is connected to the operating voltage source U 2 . The operating voltage U 4 for the base of transistor 511 must be selected to be somewhat higher than the operating voltage U 2 so that the emitter-base path of the transistor always remains conductive. For example, U 4 may be 1V higher than U 2 and resistor 521 may have a resistance of about 1kΩ.
With such operating values the circuit operates with an emitter current of about 0.5 mA and produces an energy loss of less than 0.6 mW.
The collector of transistor 511 must be connected to the base of the switching transistor 21.
Installed into the switching device of FIG. 1, the voltage-dependent resistor of FIG. 2 has a resistance value, when the control transistor 31 is blocking, of about 1.1kΩ, so that the switching transistor 21 receives an off-attenuation which depends practically only on the switching capacitance between its emitter and collector.
When the switching transistor 21 is switched on, there is a drop of approximately 4V across the voltage-dependent resistor. Transistor 511 then operates in the active region and has the desired high impedance, e.g. > 500kΩ.
FIG. 3 corresponds to FIG. 2 with the exception that the bipolar npn transistor 511 is replaced by a field effect transistor 511' having a source S and drain D. For example, an n channel MOSFET of the depletion type or an n channel PNFET can be used. Its gate terminal G may be connected directly to the source of operating voltage U 2 so that in addition to the elimination of a base current, a further electrode terminal is also eliminated.
Furthermore, the collector resistor 61 of the switching transistor 21 of FIG. 1 can also be replaced in an advantageous manner by either of the circuit arrangements shown in FIGS. 2 and 3. The collector of transistor 511 would then be connected to the collector of the switching transistor 21. If instead of the npn transistor 511, a transistor of the opposite conductivity type must be used, voltage source U 2 is replaced by voltage source U 3 and voltage source U 4 is replaced by a voltage source U 5 which is higher by about 1V, so that the base-emitter path of the transistor of the voltage dependent resistor is always maintained conductive.
Such an arrangement is shown in FIG. 5, to be described below, in a circuit including a transistor 611 with an associated emitter resistor 612.
When the transistor 611 and resistor 612 are used as resistor 61 in the circuit of FIG. 1, the emitter current of transistor 61 is advisably set, by selection of base voltage U5 and emitter resistor 612, to be less than 0.1 mA. The emitter current of transistor 611 is thus substantially less than the emitter current of the conductive switching transistor.
When switching transistor 21 is blocking, transistor 611 operates in the saturation region, thus presenting a low resistance (≈ 2kΩ), and therefore practically short-circuits line a which is connected to the collector of the switching transistor 21. When the switching device is used in a switching matrix in which a plurality of switching transistors have their collectors connected to a column line, transistor 611, only one of which then need be provided for each column, acts as a column short circuit when the switching transistors are blocking.
FIG. 4 shows a symmetrical switching device circuit arrangement according to the present invention which is provided in a known manner with a higher cross-talk attenuation, particularly for monolithically integrated embodiments.
The switching device KS of this embodiment includes two switching transistors 21 and 22 each having its emitter-collector path connected serially between the input A or B and output a or b of a respective side of the signal switching path. The base of transistor 21 is connected to a shunt branch composed of control transistor 31, emitter resistor 41, and a voltage-dependent resistance composed of transistor 511 and its associated emitter resistor 521. Similarly, the base of transistor 22 is connected to a shunt branch composed of control transistor 32, emitter resistor 42, and a voltage-dependent resistance composed of transistor 512 and its associated emitter resistor 522.
The input to device KS is provided by a coupling transformer 11 having two secondary windings w 11 and w 22 each connected to a respective one of input terminals A and B. Control signal input terminal St is connected to the bases of both control transistors 31 and 32. At the output side of device KS there are provided two further voltage-dependent resistances 61 and 62 each connected to a respective one of output terminals a and b.
Operating voltage U 1 is applied to the center tap between the secondary windings w 11 and w 22 of transformer 11, while operating voltage U 2 is applied to the other ends of resistors 521 and 522, operating voltage U 3 is applied to the other ends of resistances 61 and 62, operating voltage U 4 is applied to the bases of transistors 511 and 512, and operating voltage U 6 is applied to the other ends of resistors 41 and 42.
With this arrangement, both switching transistors 21 and 22 will always be in the same switching state, i.e. both conductive or both blocking.
All voltages mentioned above relate to 0V
For monolithically integrated embodiments it is advisable to select the following operating voltages:
U.sub.1 = -5V, U.sub.2 = -8V, U.sub.3 = 2V and U.sub.4 = -9V,
in order to adapt the base potential of the control transistor to the output voltages of conventional TTL circuits. For this purpose the emitter operating voltage of the control transistors 31 and 32 must also be raised to U 6 2 = 2V. For U 3 and U 6 the same operating voltage sources can be used.
For a collector current of less than 100μA, a base current of 2 mA, average normal and inverse current amplification factors in common emitter connection of ≈ 70 and ≈ 2, respectively, and a total emitter plus collector bulk resistance of about 5Ω, the impedance of a conductive, monolithically integrated npn switching transistor 21 or 22 ≦ 10Ω.
If the impedance of the collector resistance 61 or 62 is then > 200kΩ, the shunt attenuation additionally produced thereby for the symmetrical switching device is negligibly small (< 1 mN for a transformer ratio w 1 /w 11 or w 22 = 1 and a terminating impedance of 600Ω).
1mN = 0.001N ≈ 0.0087 decibel N=neper
The transmission loss is thus determined only by the resistance of the switching resistor and is < 30 mN for the symmetrical, monolithically integrated semiconductor switching device. The energy loss occurring in the switched-on switching device amounts to about 20mW.
FIG. 5 shows the connection of switching matrix modules, formed of the symmetrical switching devices according to the invention to produce an intermediate line switching arrangement. It is here assumed, for reasons of simplicity, that each switching matrix module forms a stage in a three-stage switching arrangement. To better show the connections between switching devices, only one switching transistor is shown for each such device.
As already mentioned, bipolar transistors 611, which serve as voltage-dependent resistors are connected, to the column lines of the odd-numbered stages 1, 3, etc. The coupling of the stages is effected according to the invention so that, for example, link lines 711 and 712 connect column 1 and column 2, respectively, in the first stage 1 with row 1 and row 2, respectively, in the second stage 2, the collector terminals of the switching transistors being connected to the columns of the first stage 1 and the rows of the second stage 2. The interconnection in the switching network is effected in this way in an advantageous manner because only a very low level current flows through the collector terminals of the switched-on devices and a calling party and called party can be connected together through the column lines of the first stage or of the third stage.
Due to the low collector current of the switching transistors according to the invention it is then possible to connect a plurality of subscribers together via one column line, e.g., for a conference call, because transistors 611 always remain in the active operating region, i.e. they present a high resistance to alternating current, with but a single conductively connected switching transistor and the operating point of the transistors 611 changes only slightly as a result of the interconnection of the subscribers.
If it is noted that a subscriber connection can be made already in the first stage via a common column line, then this can be effected already in this stage by switching on the corresponding switching devices. The subsequent stages are then no longer required to establish the connection.
The interconnection of a plurality of subscribers into a conference connection is appropriate only in columns of the odd-numbered stages. The emitter terminals of the switching transistors are connected to the columns of the even-numbered stages. These emitter terminals are connected to the emitter terminals of the switching transistors of the lines of the next odd-numbered stage via link lines 721, 722, etc. However, the emitter current, which is high compared to the collector current, flows through the emitter terminals of the switching transistors.
Since the emitter current of a switching transistor amounts to about 2 mA, the even-numbered stages must be provided with a device 614 for each column which presents a low resistance to direct current and a high resistance to alternating current to supply the different emitter currents of a column.
This can be accomplished, for example, in that the emitter voltage U 1 of each column is supplied via a choke or a transformer winding of a transformer which is provided, for example, for control purposes.
If no more than two switching transistors are ever switched on in an even-numbered stage, the column current can be made available in a manner similar to that in the columns of the odd-numbered stages by a transistor which is connected in feedback in the emitter by means of a resistor, the conductivity type of the transistor being opposite that of the column transistors 611. In the illustrated embodiment the device 614 may comprise, for example, an npn transistor whose collector is connected to the intermediate line and whose emitter current is set, in the same manner as described in connection with FIG. 2, to twice the value of the emitter current of a switching transistor, i.e. to 4 mA in this example.
This accomplishes in an advantageous manner that even with blocking switching transistors in a column of an even-numbered stage the column is short-circuited by the transistor which then operates in the saturation region.
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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In an electronic switching device for use as the switching component of a switching network in a telephone central office, the device being composed of a switching transistor connected in series in the signal conduction path for switched signals and a controllable impedance connected in a shunt branch, the switching transistor, in its conductive state, having a low series resistance and an associated high shunt resistance, and, in its blocking state, having a high series resistance and an associated low shunt resistance, the shunt branch is composed of a control transistor having a control voltage applied to its base, having its collector connected to the base of the switching transistor, and having its emitter connected to the switching transistor through a resistor to constitute a feedback path for the switching transistor, a voltage-dependent resistor connected to the base of the switching transistor, and suitable sources of operation voltages, the voltages and characteristics of the voltage-dependent resistor being selected to be such that when the switching transistor is conductive, the control transistor operates conductively in its active region and the voltage-dependent resistor presents a high resistance and when the switching transistor is blocking the control transistor is also blocking and the voltage-dependent resistor has a low resistance and supplies to the base of the switching transistor a voltage which maintains the switching transistor blocking.
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PRIORITY
[0001] This application claims priority to and benefit of U.S. Provisional Application No. 61/059,952, filed on Jun. 18, 2008, which is herein incorporated by reference in its entirety.
FIELD
[0002] Embodiments of the present invention relate, in general, to a mat handling assembly and a method for using the same. In particular, embodiments of the invention relate to a system and method for cleaning mats.
BACKGROUND
[0003] Many industries rely upon mats to improve the sanitary conditions of the workplace and to enhance the working environment for workers. For example, floor mats may be used in food service, manufacturing, and health care settings to reduce leg and lower back strain, decrease incidence of injuries due to slipping and fatigue, and limit biological and chemical contamination and pest infestation. Conventional equipment and techniques used to clean mats may require awkward manual manipulation of the mats, which may generate back strain or other injury in workers. In addition, conventional cleaning systems may be wasteful of both time and energy. Due to these limitations, prior art cleaning equipment and techniques may inhibit the efficiency with which mats and screens are properly cleansed, and in some cases, conventional practices may actually degrade the sanitary quality of a work place, public area, or dwelling.
[0004] Thus, it may be advantageous to provide a system and method for cleaning mats that is more energy-efficient by reducing the amount of chemicals, water, and energy used to wash and dry the mats. It may also be advantageous for a mat-cleaning system to improve worker safety by having an ergonomic design and by reducing the number of workers needed to operate the system. Furthermore, it may be advantageous if the mat-cleaning system extends the product life of the mats by reducing wear and providing an opportunity for quality control. Wear and tear on the mats may be reduced by reducing the handling of the mats and/or by lowering the water or fluid pressure when cleaning the mats.
[0005] While several systems and methods have been made and used for cleaning mats, it is believed that no one prior to the inventors has made or used the invention described in the appended claims.
Broad Claim
[0000]
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] While the specification concludes with claims which particularly point out and distinctly claim the invention, it is believed the present disclosure will be better understood from the following description of certain examples taken in conjunction with the accompanying drawings. In the drawings, like numerals represent like elements throughout the several views.
[0007] FIG. 1 depicts an exemplary mat-cleaning system.
[0008] FIG. 2 depicts the loading and vibrating modules of the mat-cleaning system of FIG. 1 .
[0009] FIG. 3 depicts a front view of an air float table.
[0010] FIG. 4 depicts a top view of the air float table of FIG. 3 .
[0011] FIG. 5 depicts a beat roller assembly engaged with a dirty mat.
[0012] FIG. 6 depicts an isometric view of a beat roller assembly.
[0013] FIG. 7 depicts an isometric view of a beat roller.
[0014] FIG. 8 depicts a front view of a beat roller.
[0015] FIG. 9 depicts a side view of a beat roller.
[0016] FIG. 10 depicts a front view of a beat roller assembly.
[0017] FIG. 11 depicts a side view of a beat roller assembly.
[0018] FIG. 12 depicts a front view of a support plate.
[0019] FIG. 13 depicts a side view of a shaft.
[0020] FIG. 14 depicts an isometric view of a bushing.
[0021] FIG. 15 depicts a side view of a bushing.
[0022] FIG. 16 depicts a front view of a bushing.
[0023] FIG. 17 depicts the washing module of the mat-cleaning system of FIG. 1 .
[0024] FIG. 18 depicts an isometric view of an exemplary washing module.
[0025] FIG. 19 depicts the drying module of the mat-cleaning system of FIG. 1 .
[0026] FIG. 20 depicts an isometric view of a vacuum nozzle.
[0027] FIG. 21 depicts a side view of the vacuum nozzle block of FIG. 20 .
[0028] FIG. 22 depicts a cross-sectional view of the vacuum nozzle block of FIG. 20 , along line A-A.
[0029] FIG. 23 depicts an mounting hole in the vacuum nozzle block of FIG. 20 .
[0030] FIG. 24 depicts a groove and a mounting hole in the vacuum nozzle block of FIG. 22 .
[0031] FIG. 25 depicts a corner of the vacuum nozzle block of FIG. 22 .
[0032] FIG. 26 depicts a vacuum nozzle tube seal and two nozzle blocks engaged with a wire belt conveyor.
[0033] FIG. 27 depicts a front view of a belt support.
[0034] FIG. 28 depicts a side view the belt support
[0035] FIG. 29 depicts a hot air dryer according to one embodiment.
[0036] FIG. 30 depicts the discharge module of the mat-cleaning system of FIG. 1 .
[0037] FIG. 31 depicts an exemplary dual action conveyor.
[0038] FIG. 31 depicts an isometric view of the dual action conveyor of FIG. 31 .
[0039] FIG. 32 depicts a discharge apparatus.
[0040] FIG. 33 depicts a mat-cleaning system, according to another embodiment.
[0041] FIG. 34 depicts the loading, vibration, washing, and drying modules of the mat-cleaning system of FIG. 33 .
[0042] FIG. 35 depicts the drying and discharge modules of the mat-cleaning system of FIG. 33 .
[0043] FIG. 36 depicts a mat-cleaning system, according to another embodiment.
[0044] FIG. 37 depicts a flow diagram of a method of cleaning a mat.
DETAILED DESCRIPTION
[0045] The following description of certain examples of the application should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the application will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best methods contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawing and descriptions should be regarded as illustrative in nature and not restrictive.
[0046] Examples described herein relate to the cleaning of rugs or mats, or other similar generally flat objects that require periodic maintenance, and more particularly to systems and methods for industrial mat cleaning. More specifically, the current application discloses a system and method for cleaning and processing mats. As used herein, the term “mat” will refer to any flat object suitable for use in the disclosed cleaning system and by the proposed methodology, including but not limited to industrial floor mats, rugs, or other flat objects. In addition, as used herein, the term “dirt” will refer to any debris present on or in the mat being cleaned by the system ( 100 ), including but not limited to dirt, debris, dust, or any other particles or unwanted matter. A shown in FIG. 1 , one embodiment of a mat cleaning system ( 100 ) comprises one or more modules, including but not limited to a loading module ( 102 ), a vibration module ( 104 ), a washing module ( 106 ), a drying module ( 108 ), and a discharge module ( 110 ). Each mat being cleaned is directed through each module. Although this embodiment discloses the module(s) in a particular order, it should be appreciated that a mat may be directed through the module(s) in any suitable order. For example, vibration module ( 104 ) may come after washing module ( 106 ). The modules comprising mat cleaning system ( 100 ) will be discussed further below.
I. Loading Module
[0047] FIG. 2 shows a loading module ( 102 ) of the system ( 100 ) shown in FIG. 1 . Loading module ( 102 ) may comprise an air-float table ( 112 ) upon which a mat can be placed. As will be apparent to one of ordinary skill in the art, any other suitable table, conveyor, or an equivalent may be used to transport a mat through the system ( 100 ). For example, table ( 112 ) may be a gravity conveyor, which uses gravity to feed the mat through the module. The table ( 112 ) may have a first end ( 114 ) for loading the mats and a second end ( 116 ) that engages with the next module, which in the present embodiment is vibration module ( 104 ). As shown in FIGS. 3-4 , table ( 112 ) may also comprise a number of features to facilitate the loading and cleaning of the mats. For example, table ( 112 ) may comprise one or more load rollers ( 118 ), which may rotate to assist a user in loading a mat into the system ( 100 ). Load rollers ( 118 ) may also help straighten and/or flatten the mat as it is fed onto table ( 112 ). Although load rollers ( 118 ) are positioned near the first end ( 114 ) of table ( 112 ) in the present example, it will be appreciated that a roller ( 118 ) may be located in any other suitable location along table ( 112 ). In addition to the load rollers ( 118 ), table ( 112 ) may comprise one or more edge guides ( 120 ) located along an edge of the table ( 112 ) to help guide the loaded mat along the table ( 112 ).
[0048] Any suitable mat may be loaded into system ( 100 ). The dimensions of the mats that can be cleaned by the system ( 100 ) may depend on the dimensions of system ( 100 ). For example, in the present embodiment, any mat with a width up to five feet may be fed into the system ( 100 ). Larger sized mats may be loaded into other versions of system ( 100 ). A mat may comprise at least two surfaces, an underside and a pile side. The pile side may be the side of the mat generally exposed during use of the mat. The mat may be fed into system ( 100 ), and more particularly into loading module ( 102 ), in any suitable manner as will be apparent to one of ordinary skill in the art. For example, to best clean the pile side of a mat, the mat may be loaded with the pile side positioned down towards table ( 112 ).
[0049] As shown in the present example, air-float table ( 112 ) may further comprise a plurality of apertures ( 122 ) through which air may be blown to easily and ergonomically feed the mat through the module ( 102 ) and into the next module. In another example, at least a portion of the surface of table ( 112 ) may also comprise a grid, screen, or gravity conveyor defining a plurality of open apertures through which dirt may fall. In this way, as a mat is loaded onto table ( 112 ), any dirt shaken from the mat during the loading process may fall through apertures ( 122 ) to be collected by a collection trough ( 124 ) that may be situated beneath table ( 112 ). In addition to collecting any dirt that happen to leave the mat as it is loaded, collection trough ( 124 ) may also collect any dirt that is blown off the loaded mat by way of a blower ( 126 ), which may be situated underneath of table ( 112 ). Blower ( 126 ) may be directed to blow air from the underside of table ( 112 ) and through apertures ( 122 ) to dislodge the dirt on the loaded mat. Blower ( 126 ) may also be used with an air-float table ( 112 ) to assist in feeding the mat to a next module in the system.
[0050] In addition to loading and positioning a mat onto table ( 112 ), loading module ( 102 ) may comprise a quality control inspection, which may be performed prior to or during the loading process. Any suitable quality control inspection may be used. For example, the quality control inspection may include a review of the mat for tears, stains, worn spots, or any other quality-related issues. The inspection may include inspecting both sides of the entire mat. Alternatively, the inspection may only include inspecting either the pile side or the underside of the mat. Even further, the inspection of the pile side of the mat may occur prior to flipping the mat pile side down and feeding the mat onto table ( 112 ). Inspection of the underside portion of the mat may occur after loading the mat onto the air-float table ( 112 ) pile side down. Moreover, a quality control inspection may also include the pretreatment of stains or spots on the mat and/or the removal of damaged mats from the system ( 100 ).
[0051] Of course, the above-described loading module ( 102 ) is merely one example. Any other suitable type of loading module ( 102 ) and associated components may be used. By way of example only, loading module ( 102 ) may also comprise laser sights, which may be used to detect a wavy or rumpled mat that may need to be straightened before further transport through system ( 100 ). Alternatively, loading module ( 102 ) may have any other suitable components, features, configurations, functionalities, operability, etc. Other suitable variations of loading module ( 102 ) and associated components will be apparent to those of ordinary skill in the art in view of the teachings herein.
II. Vibration Module
[0052] In addition to a loading module ( 102 ), the mat cleaning system ( 100 ) of the present example may also comprise a vibration module ( 104 ) as shown in FIG. 2 . For example, after feeding a mat into system ( 100 ) using the loading module ( 102 ), and preferably after a quality control inspection has occurred, the mat may be directed at the second end ( 116 ) of table ( 112 ) to the vibration module ( 104 ). As shown in FIG. 5 , vibration module ( 104 ) may comprise a conveyor ( 128 ) and at least one beat roller ( 130 ). After being fed through the loading module ( 102 ), the mat may be positioned onto the conveyor ( 128 ). Conveyor ( 128 ) may be used to transport the mat through system ( 100 ).
[0053] During operation, as shown in FIG. 5 , the at least one beat roller ( 130 ) and conveyor ( 128 ) engage the mat so as to dislodge any dirt ( 132 ) that is present on or in the mat. For example, a beat roller ( 130 ) may contact the mat simultaneously with or subsequent to the movement of the mat by the conveyor ( 128 ). As shown in FIG. 5 , the beat roller ( 130 ) may contact the mat on its underside or, alternatively, on its pile side. Having the beat roller ( 130 ) contact the mat may loosen as well as dislodge dirt from the mat. Conveyor ( 128 ) may not only be used to transport the mat through system ( 100 ), but may also, through an opening on the conveyor ( 128 ), permit the collection of any dirt that may be loosened or dislodged from the mat during the vibratory action caused by a beat roller ( 130 ). It will be appreciated that any suitable vibration frequency of module ( 104 ) may be used to shake off or dislodge the dirt from the mat. In one embodiment, the vibration frequency is at least 60 Hz and adjustable to 120 Hz. Preferably, the frequency ranges from 70-100 Hz. The optimal vibration frequency of module ( 104 ) may be determined by the number of beat rollers ( 130 ) included in vibration module ( 104 ), as well as the corresponding rotation speed of the module ( 104 ). FIGS. 5-6 disclose an exemplary beat roller assembly ( 134 ), which may comprise at least one beat roller ( 130 ) and various other components.
[0054] One example of a beat roller ( 130 ) is shown in FIGS. 7-9 . Beat roller ( 130 ) may comprise a pair of sealed, high speed bearings ( 160 ) and a generally cylindrical shaft ( 136 ) that defines a central cavity or bore ( 138 ). FIGS. 10-11 depict a beat roller assembly ( 134 ) comprising a plurality of beat rollers ( 130 ). A single beat roller ( 130 ) or an assembly ( 134 ) may be used in vibration module ( 104 ) to loosen and/or dislodge dirt from the mat. In addition to the beat rollers ( 130 ), a beat roller assembly ( 134 ) may further comprise a support plate ( 140 ) and a shaft ( 142 ). Support plate ( 140 ) may be a generally circular plate of suitable thickness having a central cavity ( 144 ) surrounded by one or more periphery holes ( 146 ), as shown in FIG. 12 . Shaft ( 142 ), having a generally cylindrical shape as shown in FIG. 13 , may be positioned through the central cavity ( 144 ) in support plate ( 140 ). A beat roller ( 130 ), having a first end ( 148 ) and a second end ( 150 ) may be placed end to end between two support plates ( 140 ) and secured by the placement of one or more fasteners, such as a dowel, through the one or more periphery holes ( 146 ) in the support plates ( 140 ).
[0055] In addition, a beat roller assembly ( 134 ) may comprise a bushing ( 158 ) like that shown in FIGS. 14-16 . Such a bushing ( 158 ) may be positioned through the central cavity ( 144 ) of support plate ( 140 ) to facilitate the positioning of shaft ( 142 ). A bushing ( 158 ) may be positioned through each support plate ( 140 ) included in assembly ( 134 ).
[0056] In this way, a beat roller assembly ( 134 ) may be assembled having a plurality of beat rollers ( 130 ) positioned between a plurality of support plates ( 140 ) that are secured together by a central shaft ( 142 ) that extends through the cavities ( 144 ) in the support plates ( 140 ). The beat roller assembly ( 134 ) may comprise any number of beat rollers ( 130 ) and support plates ( 140 ). For example, as depicted in FIGS. 10 and 11 , the assembly ( 134 ) comprises four support plates ( 140 ) and a total of twenty-four beat rollers ( 130 ). The twenty-four beat rollers ( 130 ) in the assembly ( 134 ) are divided into three groups ( 152 , 154 , and 156 ) of eight, where eight beat rollers ( 130 ) are positioned around shaft ( 142 ) and between any two support plates ( 140 ). The first group ( 152 ) of eight beat rollers ( 130 ) is shown in FIG. 10 . As will be appreciated by one of ordinary skill in the art, beat roller assembly ( 134 ) may comprise any number of beat rollers ( 130 ) and support plates ( 140 ). By way of example only, FIGS. 10-11 show an assembly ( 134 ) comprising twenty-four beat rollers ( 130 ) and four support plates ( 140 ). In addition, vibrating module ( 104 ) may comprise any number of beat roller assemblies ( 134 ).
[0057] During operation, a beat roller assembly ( 134 ) may pulse and/or rotate along the conveyor ( 128 ) to dislodge or loosen the dirt on a mat. The optimal pulse depth of a beat roller assembly ( 134 ) may be determined by the number of beat rollers ( 130 ) included in the beat roller assembly ( 134 ). A pulse depth may average, for example, 0.100 inches, and the pulse depth may be adjustable depending on the mat being cleaned by the system. A beat roller ( 130 ) and/or a beat roller assembly ( 134 ) may contact the mat on the conveyor ( 128 ). Alternatively, the beat roller ( 130 ) and/or beat roller assembly ( 134 ) may contact the underside of the conveyor ( 128 ).
[0058] Vibration module ( 104 ) may further comprise an apparatus to collect the dirt being shaken or loosened from the mat. Any suitable apparatus may be used and positioned in any suitable manner. For example, a pan may be positioned underneath the conveyor ( 128 ) in alignment with the beat rollers ( 130 ). The pan may collect any dirt dislodged from the mat due to the movement of conveyor ( 128 ) and/or contact with the beat rollers ( 130 ). Even further, a dirt collector may be positioned below and along the length of the vibration module ( 104 ).
[0059] Of course, the above-described vibration module ( 104 ) is merely one example. Any other suitable type of vibration module ( 104 ) and associated components may be used. By way of example only, vibration module ( 104 ) may also comprise a vacuum to transport the dirt away from the system ( 100 ).
[0060] Alternatively, vibration module ( 104 ) may have any other suitable components, features, configurations, functionalities, operability, etc. Other suitable variations of vibration module ( 104 ) and associated components will be apparent to those of ordinary skill in the art in view of the teachings herein.
III. Washing Module
[0061] In the present embodiment, mat cleaning system ( 100 ) may further comprise a washing module ( 106 ) as shown in FIG. 17-18 . For example, after traveling through vibration module ( 104 ) on the conveyor ( 128 ), the mat may next travel to the washing module ( 106 ). Washing module ( 106 ) may comprise a conveyor ( 170 ), which may or may not be the same conveyor ( 128 ) from the vibration module ( 104 ). Furthermore, washing module ( 106 ) may comprise one or more devices for washing and/or rinsing the mat.
[0062] One exemplary process for washing the mat comprises first washing the mat with a chemical-based wash using a high-volume, low-pressure spray nozzle to further clean the mat and dislodge any remaining unwanted matter. Advantageously, because a significant amount of dirt may be removed in the vibration module ( 104 ), a relatively lower amount of chemical wash may be required as compared with prior art cleaning processes. Further, because the mat is already partially cleaned in the loading and vibration modules ( 102 , 104 ), a low-pressure wash may be used, which reduces the amount of wear to the mat being cleaned. The mat preferably may also be rinsed with a high-volume, low-pressure fresh water rinse. Although a low-pressure wash is disclosed, higher pressures could be used within the scope of this disclosure, as will be appreciated by one of ordinary skill in the art. Water may be reused and recycled in the washing module ( 106 ). The reused water may be collected in any suitable manner. The recycled water may be cleaned prior to its future use. In addition, after washing and rinsing the mat, washing module ( 106 ) may comprise a blow off, wherein excess water or chemical agent remaining after the wash and rinse may be blown off the mat with a blower. In addition to water, other agents may be used to clean and/or rinse the mat, including but not limited to detergents, anti-static agents, anti-stain agents, deodorants, perfumes, etc.
[0063] It will be appreciated that the temperature of the washing and rinsing in module ( 106 ) may be varied. For example, because the present system ( 100 ) involves feeding a mat through a vibration module ( 104 ) wherein dirt is dislodged from the mat prior to feeding it through a washing module ( 106 ), a lower temperature wash and/or rinse may be effective to clean the mat. Furthermore, a person of ordinary skill in the art will appreciated that either or both sides of a mat may be washed and/or rinsed in the washing module ( 106 ). In addition, washing module ( 106 ) may comprise an anti-flip roller bar situated at one end of conveyor ( 170 ) to prevent or restrict a mat from flipping over.
[0064] Of course, the above-described washing module ( 106 ) is merely one example. Any other suitable type of washing module ( 106 ) and associated components may be used. By way of example only, washing module ( 106 ) may comprise a high-volume, low-pressure blow off, whereby air is blown around the mat to remove any chemical wash and/or water remaining on the mat. Alternatively, or in addition, the drying module ( 108 ) may comprise this blow off stage. Washing module ( 106 ) may have any other suitable components, features, configurations, functionalities, operability, etc. Other suitable variations of washing module ( 106 ) and associated components will be apparent to those of ordinary skill in the art in view of the teachings herein.
IV. Drying Module
[0065] In addition to a loading module ( 102 ), a vibration module ( 104 ), and a washing module ( 106 ), the present example of a mat cleaning system ( 100 ) may comprise a drying module ( 108 ). For example, after a mat is fed through washing module ( 106 ), it may proceed along to the drying module ( 108 ) to be dried. As shown in FIG. 19 , drying module ( 108 ) may further comprise a conveyor ( 180 ), a vibratory beater ( 182 ), a vacuum ( 184 ), and a dryer ( 186 ). Drying module ( 108 ) may include any one of those features either separately or in any suitable combination. For example, drying module ( 108 ) may consist solely of a vibratory beater ( 182 ) and a vacuum ( 184 ). Conveyor ( 180 ) may be similar or identical to the conveyor ( 128 ) of the vibration module ( 104 ). During drying module ( 108 ), the mat may encounter a vibratory beater ( 182 ), which may contact the mat to shake off any chemical wash and/or water rinse remaining on the mat from the washing module ( 106 ). Vibratory beater ( 182 ) may be identical to the beat roller ( 130 ) or beat roller assembly ( 134 ) described in the vibration module ( 104 ). Vibratory beater ( 182 ) may contact the mat on the conveyor ( 180 ) or it may contact the underside of the conveyor ( 180 ). Module ( 108 ) may vibrate at a given frequency to jostle the mat and shake off any chemical wash and/or water rinse remaining on or in the mat from the washing module ( 106 ). Any suitable vibration frequency may be used. In one embodiment, the vibration frequency is at least 60 Hz and adjustable to 120 Hz. Preferably, the frequency ranges from 70-100 Hz.
[0066] A vacuum ( 184 ), through which a mat may travel, may also be used to dry off a mat after the washing module ( 106 ). Such a vacuum ( 184 ) may be, for example, a two-zone vacuum. In addition, in one embodiment, vacuum ( 184 ) may comprise a nozzle block ( 188 ), a belt support ( 202 ), and a nozzle tube seal ( 190 ). As shown in FIGS. 19 and 29 , vacuum ( 184 ) may also comprise plenum and piping ( 183 ), a wet cyclone separator ( 185 ), and a turbine fan ( 187 ). As shown in FIGS. 20-22 , a nozzle block ( 188 ) may comprise a generally rectangular plate of suitable thickness with grooves ( 192 ) extending along the width of the plate. Nozzle block ( 188 ) may be manufactured out of any suitable material, for example, an ultra high molecular weight plastic. In addition, FIGS. 21 and 23 show that nozzle block ( 188 ) may comprise any number of countersunk and slotted mounting holes ( 194 ) As shown in FIG. 24 , mounting hole ( 194 ) may not have a constant width as it extends through the generally rectangular plate of nozzle block ( 188 ) from a first surface ( 196 ) to a second surface ( 198 ). Moreover, nozzle block ( 188 ) may comprise a rounded edge ( 200 ) at the edge of the plate, as shown in FIG. 25 . FIG. 26 shows that a nozzle tube seal ( 190 ) of vacuum ( 184 ) may be situated between two nozzle blocks ( 188 ), with a wire belt conveyor ( 206 ) positioned in between. Vacuum drying may be achieved when a static vacuum pressure is balanced with the airflow in nozzle block ( 188 ). For example, vacuum drying efficiency may be achieved through nozzle tube seal ( 190 ) when static vacuum pressure is a minimum of 5 inches of Hg and is balanced with a minimum of 20 CFM of airflow per inch of nozzle width.
[0067] Furthermore, a belt support ( 202 ) may be located in between the two nozzle blocks ( 188 ), as shown in FIG. 26 . Belt support ( 202 ) may have a general T-shape as shown in FIG. 27-28 , with a curved cutout ( 204 ) located in a surface of the belt-support ( 202 ), to support the wire belt conveyor ( 206 ). The curved surface ( 204 ) of the belt support ( 202 ) may also provide a curved conveyor belt path under vacuum. This curved path may open up the pile side or underside of a mat to improve the vacuum efficiency in addition to providing support for the conveyor belt ( 206 ) under vacuum.
[0068] The nozzle tube seal ( 190 ) is designed to allow a consistent vacuum pressure seal on any width mat by rotating and sealing above the wire conveyor belt ( 206 ) and nozzle bocks ( 188 ). This rotational sealing may allow a mat or any flat object to be vacuumed with a consistent vacuum draw on mats of any width. Further, the rotating seal may provide long service life due to rotation and negligible wear. The nozzle blocks ( 188 ) also may provide a mating seal surface for the nozzle tube seal ( 190 ). Nozzle blocks ( 188 ) may provide precise control of vacuum air flow and air velocity. As the mat is passing between the wire belt conveyor ( 206 ) and the nozzle tube seal ( 190 ), the vacuum air flow may remove substantial amounts of moisture. This moisture may be pulled through the nozzle plenum and piping ( 183 ) where it may then be separated from the airflow by a wet cyclone separator ( 185 ), as shown in FIG. 19 . The separated moisture may also be collected and discharged or reused and the dry air flow may continue through a turbine fan ( 187 ).
[0069] In addition to a vacuum ( 184 ), drying module ( 108 ) may also comprise one or more other dryers ( 186 ). A typical dryer ( 186 ) may have a number of components, included but not limited to a turbine, a wet separator, a purge tank, and a nozzle. As will be appreciated by one of ordinary skill in the art, an suitable dryer or drying method may be used in the drying module ( 108 ). By way of example, dryer ( 186 ) could comprise one or more of the following: a cool air dryer, a high-volume, low-pressure dryer, a heated low velocity dryer, and a hot air dryer. In a preferred embodiment, a mat would encounter the following dryer mechanisms in a drying module ( 108 ): a cool air blow dryer, a vibrating beater, a vacuum dryer, a hot air dryer, and a cool down blower. An example of a hot air dryer ( 208 ) is shown in FIG. 29 . Hot air dryer ( 208 ) may comprise a number of components including but not limited to a gas train ( 210 ), a thermocouple ( 212 ), and a sliding damper ( 214 ). Hot air dryer ( 208 ) may run at any suitable power, but preferably is run at 1 MMBTU. In addition, a dryer ( 186 ) and/or ( 208 ) may be operated at any suitable temperature. For example, dryer ( 186 ) may be operated up to 427 degrees F.
[0070] As with all other modules described herein, the components and methods described in the drying module ( 108 ) may be used in any suitable order as will be appreciated by one of ordinary skill in the art. By way of example, a mat entering the drying module ( 108 ) may encounter a vibratory beater ( 182 ) before proceeding along the conveyor ( 180 ). In another example, drying module ( 108 ) may comprise a wrinkle remover spreader roll, which may be engaged with a mat prior to a vacuum dry, to flatten the mat to improve drying efficiency. In addition, the components and methods of the drying module ( 108 ), like those of all other modules, may be practiced separately or in conjunction with one or more other components, methods, or modules. Of course, the above-described drying module ( 108 ) is merely one example. Any other suitable type of drying module ( 108 ) and associated components may be used. Drying module ( 108 ) may have any other suitable components, features, configurations, functionalities, operability, etc. Other suitable variations of drying module ( 108 ) and associated components will be apparent to those of ordinary skill in the art in view of the teachings herein.
V. Discharge Module
[0071] After the mat has been dried in drying module ( 108 ), the mat may exit the dryer ( 186 ) and be unloaded from the conveyor ( 180 ). A fifth module that the mat cleaning system ( 100 ) may comprise is the discharge module ( 110 ). For example, as shown in FIG. 30 , after the mat exits the dryer ( 186 ) and is unloaded from the conveyor ( 180 ) in drying module ( 108 ), the mat may be fed onto a table ( 220 ) in the discharge module ( 110 ). Table ( 220 ) may be vibratory and used to hover the mat over the table ( 220 ) for transport and/or alignment of the mat. Alternatively, FIGS. 31-31( a ) shows a dual action conveyor ( 222 ) upon which a mat may be fed in the discharge module ( 110 ). The dual action conveyor ( 222 ) may be driven with free spinning rollers ( 223 ) or vibratory rollers. The dual action aspect of either the free spinning rollers or the vibratory rollers may allow a mat to be discharged from a dryer ( 186 ) at a dryer conveyor speed and then transferred to an discharge module ( 110 ) at a different speed.
[0072] Discharge module ( 110 ) may also include an auto-roll discharge. The auto-roll discharge may be performed by an auto-roll discharge apparatus ( 224 ), as shown in FIG. 32 . Such a discharge apparatus ( 224 ) may sort and roll the mats as they go through the discharge module ( 110 ). Such an automatic rolling system may reduce the number of people needed to operate the system ( 100 ). The discharge apparatus ( 224 ) may also sort according to any suitable factor as will be appreciated by one or ordinary skill in the art. For example, apparatus ( 224 ) may sort the mats according to size, weight, material type, or some other factor. After discharge, the mats may be placed in a mat cart ( 226 ). Alternatively, system ( 100 ) may include a manual sort.
[0073] Such a dual action conveyor ( 222 ) or a vibrating table ( 220 ) may permit a quality control inspection and a manual sort. As with the optional quality control inspection during the loading module ( 102 ), any suitable quality control inspection may be used during the discharge module ( 110 ). For example, the quality control inspection may include a review of the mat for tears, stains, worn spots, or any other quality-related issues. The inspection may include inspecting both sides of the entire mat. Alternatively, the inspection may only include inspecting either the pile side or the underside of the mat. Moreover, a quality control inspection may also include the treatment of stains or spots on the mat and/or the removal of damaged mats from the system ( 100 ).
[0074] Of course, the above-described discharge module ( 110 ) is merely one example. Any other suitable type of discharge module ( 110 ) and associated components may be used. By way of example only, discharge module ( 110 ) may not comprise an auto-roll discharge. As will other module components described herein, discharge apparatus ( 224 ) is merely optional, and may be modified, substituted, supplemented, or omitted as desired. Discharge module ( 110 ) may have any other suitable components, features, configurations, functionalities, operability, etc. Other suitable variations of washing module ( 106 ) and associated components will be apparent to those of ordinary skill in the art in view of the teachings herein.
[0075] Furthermore, the above-described system ( 100 ) is merely one example of a mat cleaning system. Any other suitable type of modules and associated components may be used. By way of example only, the above-mentioned modules may be modified, substituted, supplemented, re-ordered or omitted as desired. For example, system ( 100 ) may include additional safety features such as safety interlocks, guards, and/or e-stops on all moving parts. System ( 100 ) may have any other suitable components, features, configurations, functionalities, operability, etc. Other suitable variations of system ( 100 ) and associated components will be apparent to those of ordinary skill in the art in view of the teachings herein.
[0076] In the above-mentioned embodiments, the figures depict modules wherein the movement of the mat through the module was from left to right in a given figure. For example, the conveyor travel in FIG. 30 is generally from left to right. Such a direction is in no way intended and should not be used to limit the practicing of the invention.
[0077] FIGS. 33-35 depict a particular embodiment of a mat cleaning system ( 300 ). Such a system also comprises a loading module ( 302 ), a vibration module ( 304 ), a washing module ( 306 ), a drying module ( 308 ), and a discharge module ( 310 ). The washing module ( 306 ) may comprise a number of different types of washes. For example, washing module ( 306 ) may include a high-volume, low-pressure wash ( 312 ), a high-volume, low-pressure rinse ( 314 ), a free rinse ( 316 ), and a high-volume, low-pressure blow dry, wherein air is blown around the mat to remove excess water or chemical wash remaining on a mat. The wash of the mat may be conducted with a chemical-based agent, whereas the rinses of the mat may be conducted with water. Drying module ( 308 ) may also comprise a number of sub-components including but not limited to a vibratory dryer ( 320 ), which comprises a vibratory beater that jostles the mat to dislodge an remaining water or chemical wash. A vacuum dryer ( 322 ) and a gas hot air dryer ( 324 ) may be included as part of the drying module ( 308 ). In addition, the discharge module ( 310 ) may comprise a dual action conveyor ( 326 ) and a discharge apparatus ( 328 ) for automatically rolling up the mats as they leave the system ( 300 ).
[0078] In the above-mentioned embodiments, the figures depicted modules wherein the movement of the mat through the module was from right to left in a given figure. For example, the conveyor travel in FIG. 34 is generally from right to left. Such a direction is in no way intended and should not be used to limit the practicing of the invention.
[0079] Of course, the above-described system ( 300 ) is merely one example of a mat cleaning system. Any other suitable type of modules and associated components may be used. By way of example only, the above-mentioned modules may be modified, substituted, supplemented, re-ordered or omitted as desired. System ( 300 ) may have any other suitable components, features, configurations, functionalities, operability, etc. Other suitable variations of system ( 300 ) and associated components will be apparent to those of ordinary skill in the art in view of the teachings herein.
[0080] FIG. 36 depicts another particular embodiment of a system ( 400 ) for cleansing mats. In the embodiment shown in FIG. 36 , the system ( 400 ) comprises loading module ( 402 ), a vibration module ( 404 ), a washing module ( 406 ), a drying module ( 408 ), and a discharge module ( 410 ). A mat may be first loaded onto a gravity roller table ( 412 ), which employs gravity to feed the mat into the system ( 400 ), in the loading module ( 402 ). The mat is loaded pile side down. A quality control inspection may be performed on the mat prior to its traveling by conveyor ( 414 ) to the next module.
[0081] As shown in FIG. 36 , the mat moves to the vibration module ( 404 ), comprising two vibratory rollers ( 416 ), after leaving the loading module. Each vibratory roller ( 416 ) jostles or otherwise rattles the mat to cause dirt to become dislodged from the mat. This dirt falls into the dirt pan ( 418 ) positioned below the vibratory module ( 404 ). In addition to a dirt pan ( 418 ), a blower and a vacuum (not pictured) may be situated beneath vibratory module ( 404 ) to gather and dispose of the unwanted dirt.
[0082] After being subject to the vibratory module ( 404 ), the mat travels to the washing module ( 406 ), which may comprise a number of washes and/or rinses. As shown in FIG. 36 , washing module ( 406 ) comprises two rinse cycles ( 420 ), followed by a first wash ( 422 ) and a second wash ( 424 ), followed by two rinse cycles ( 426 ). The mat may be washed using recycled water. Only during the first washing ( 422 ) is any type of chemical wash used. No chemical wash is used during the second washing ( 424 ). After the washing is complete, the mat is rinsed twice again ( 426 ). During the rinses ( 420 , 426 ) multiple high volume, low pressure air nozzles may spray the mat to blow dirt from it.
[0083] After the washing module ( 406 ), the mat enters the drying module ( 408 ). Drying module ( 408 ) may comprise a blow dryer ( 428 ) and a dry vacuum ( 430 ). The mat may first be exposed to two blow dryers ( 428 ). After drying the mat using blow dryers ( 428 ), the dry vacuum ( 430 ) may be applied to the mat. After leaving the drying module ( 408 ), the mat may travels on the conveyor ( 414 ) to be sorted or otherwise handled as applicable during the discharge module ( 410 ).
[0084] Of course, the above-described system ( 400 ) is merely one example of a mat cleaning system. Any other suitable type of modules and associated components may be used. By way of example only, the above-mentioned modules may be modified, substituted, supplemented, re-ordered or omitted as desired. System ( 400 ) may have any other suitable components, features, configurations, functionalities, operability, etc. Other suitable variations of system ( 400 ) and associated components will be apparent to those of ordinary skill in the art in view of the teachings herein.
Method of Cleaning Mats
[0085] FIG. 37 displays a method ( 500 ) of cleaning mats. The above-mentioned disclosure relating to the various embodiments ( 100 , 300 , 400 ) of a mat cleaning system is incorporated herein by reference as if fully set forth again in full. Method ( 500 ) comprises a number of steps, each of which may be practiced separately or in combination with any of the other steps. As shown in FIG. 37 , one method ( 500 ) of cleaning mats comprises a loading step ( 502 ), a vibration step ( 504 ), a washing step ( 506 ), a drying step ( 508 ), and a discharge step ( 510 ). During the loading step ( 502 ), a user may feed a mat into the system and onto a table, which may be, for example, an air-float table or a gravity roller table. Alternatively, a user may feed the mat onto a conveyor. During the loading step ( 502 ), the mat may be rotated or straightened out by a user or by load rollers or edge guides or the like. A user may also perform a quality control inspection of the mat prior to, during, or subsequent to feeding the mat onto the table or conveyor. Any suitable quality control inspection may be used. For example, the quality control inspection may include a review of the mat for tears, stains, or any other quality-related issues. The inspection may include inspecting both sides of the entire mat. Alternatively, the inspection may only include inspecting either the pile side or the underside of the mat. Even further, the inspection of the pile side of the mat may occur prior to flipping the mat pile side down and feeding the mat onto the table or conveyor. Inspection of the underside portion of the mat may occur after loading the mat onto the table or conveyor pile side down. Moreover, a quality control inspection may also include the pretreatment of stains or spots on the mat and/or the removal of damaged mats from the system.
[0086] After being fed through the loading step ( 502 ), the mat may be fed through the vibration step ( 504 ). For example, a mat may be transported from an air-float table or gravity roller table and positioned onto a conveyor. There, the mat may be shaken or jostled due to the movement of the conveyor. This may cause dirt to be loosened or dislodged from the mat. During the vibration step ( 504 ), the mat may also be fed through contact with at least one beat roller assembly. Contact with the beat roller assembly may also cause any dirt located on or in the mat to be loosened or dislodged. The loosened and/or dislodged dirt may be collected. For example, a dirt collector pan may be placed underneath the conveyor to collect the dirt that falls from the mat during the vibratory step ( 504 ). A vacuum or equivalent device may also be placed near the conveyor to collect the dirt from the mat.
[0087] After the dirt and loosened from the mat and collected during the vibration step ( 504 ), the mat may be fed through the washing step ( 506 ). There, the mat may continue along on a conveyor. During the washing step ( 504 ), the mat may undergo one or more washes and/or rinses. For example, the mat may first be washed with a chemical-based agent using a high volume, low pressure nozzle. After one or more chemical washes, the mat may be rinsed one or more times with water. The water may be reused and recycled in the washing step ( 506 ). The reused water may be collected in any suitable manner. The recycled water may be cleaned prior to its future use. Alternatively, the mat may be rinsed one or more times before it is washed. In addition, after washing and rinsing the mat, washing step ( 506 ) may include blowing air or another gas over and around the mat to remove an water or chemical agent remaining on the mat.
[0088] After the mat is washed and rinsed in the washing step ( 506 ), the mat may be fed through the drying step ( 508 ). This step may comprise a number of sub-steps, including but not limited to vibrating the mat with a conveyor and/or a beater, passing the mat through a vacuum, and passing the mat through one or more dryers. The vacuum may be separate from the dryer or may be part of a dryer, for example a vacuum dryer. Other dryers that may be employed during the drying step ( 508 ) include but should not be limited to: a cool air dryer, a high-volume, low-pressure dryer, a heated low velocity dryer, and a hot air dryer. A mat may be fed through the sub-steps of the drying step ( 508 ) in any suitable order as will be apparent to one of ordinary skill in the art. For example, the mat may be fed through a dryer first and then fed through a vacuum.
[0089] After the mat is fed through the drying step ( 508 ), it may be unloaded from the conveyor. The mat may be placed on a table or a dual action conveyor as part of the discharge step ( 510 ). The discharge step ( 510 ) comprises sub-steps related to discharging, rolling, and sorting mats from the system. For example, the discharge step ( 510 ) may include rolling the mats as they exit the conveyor or table. Discharge step ( 510 ) may also comprise a sorting step, whereby the mat is either manually or automatically sorted according to any suitable factor, such as size, weight, material type, etc. After discharge, the mat may be placed in a mat cart for storage or transport. In addition to rolling and/or sorting, the discharge step ( 510 ) may comprise a quality control inspection. For example, the quality control inspection may include a review of the mat for tears, stains, or any other quality-related issues. The inspection may include inspecting both sides of the entire mat. Alternatively, the inspection may only include inspecting either the pile side or the underside of the mat. Moreover, a quality control inspection may also include the treatment of stains or spots on the mat and/or the removal of damaged mats from the system.
[0090] Of course, the above-described method ( 500 ) is merely one example of a mat cleaning process. The process ( 500 ) may comprise any other suitable steps and modules and associated components. By way of example only, the above-mentioned steps may be modified, substituted, supplemented, re-ordered or omitted as desired. Method ( 500 ) may have any other suitable steps, actions, components, features, configurations, functionalities, operability, etc. Other suitable variations of method ( 500 ) and associated steps will be apparent to those of ordinary skill in the art in view of the teachings herein.
[0091] Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, materials, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should not to be limited to the details of structure and operation shown and described in the specification and drawings.
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An automated system is configured to wash and dry mats. The system includes a number of modules, including a loading module, vibration module, washing module, vacuum module, and a discharge module. The disclosed system provides an opportunity for manual inspection of the mats, too. Because the mats that are fed into the system are jostled or shaken before they are washed, reduced amounts of chemicals, water, water pressure, drying energy, etc. are needed to clean the mats. The system may also optionally include a automatic rolling and sorting apparatus, which rolls a mat and sorts it according to weight, size, etc. after it is discharged from the discharge module. A method of cleaning mats is also disclosed.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to suspended ceiling systems and, in particular, to accessories for mounting ceiling edge trim.
PRIOR ART
[0002] Suspended ceiling islands and soffits are frequently finished at their perimeter or edge with an elongated trim strip to conceal the ends of the suspended grid runners and edges of the tile and to obtain a desired visual effect. Clips or brackets have been devised to connect the ends of the grid runners to the trim strip. U.S. Pat. Nos. 4,744,188; 5,195,289; 5,201,787; and 7,930,864 disclose examples of prior art clips developed for this purpose. The clip shown in the last mentioned '864 patent is an example of a product intended to connect with trim strips having mounting channels on their concealed sides. This prior art clip and other known design which have a set screw to locate the trim in place can create a problem if the screw is over-tightened causing the trim strip to be permanently deformed. Another known type of clip arrangement incorporates a separate metal piece to distribute the screw forces over a large area to minimize distortion of the trim. The types of clips incorporating set screws have the added cost of their separate parts and their assembly. There is a risk that the screw can be cross-threaded, particularly if it is assembled by the ceiling grid installer. Moreover, there is a potential problem that the clip parts can be dropped by the installer who is trying to hold and align several elements together at the same time and trying to tighten a screw. From the foregoing, it can be understood that there is a need for a simplified clip that reduces the number of parts required and avoids the potential for over-tightening of a set screw.
SUMMARY OF THE INVENTION
[0003] The invention provides a one-piece clip for mounting trim strips on the ends of suspended ceiling grid runners. The clip avoids the cost and complications attendant with an assembly of multiple parts. The installer need only handle one element, namely the clip, and the clip can be initially assembled with the trim strip without the use of a tool. Once the parts are aligned, the clip is caused to lock the trim in place by simple lever-like manipulation with a screwdriver or similar tool.
[0004] More particularly, once the trim is located in the lengthwise direction, the clip is forced into a locked position by prying an integral lever and tab into tight engagement with the associated mounting channel. This is simply and quickly accomplished with a screwdriver or a similar tool.
[0005] The disclosed clip, on a leg thereof associated with the grid runner has a tab for locking the clip on the grid runner end without separate fasteners. The tab is insertable in a hole existing in a web of the grid runner. When the clip leg is seated laterally against the grid runner, the tab can be manually bent to fix the clip on the grid runner.
[0006] The disclosed clip, by avoiding the need for separate clip parts and fasteners, facilitates rapid assembly of the trim on the grid runners. Moreover, the clip installation requires minimal dexterity and skill to obtain high quality fit and finish.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a clip constructed in accordance with the invention;
[0008] FIG. 2 is a rear elevational view of the clip;
[0009] FIG. 3 is a side elevational view of the clip;
[0010] FIG. 4 is a top view of the clip;
[0011] FIG. 5 is a side view of the clip in a first stage of assembly with the trim strip;
[0012] FIG. 6 is a side view of the clip showing the assembly of the clip and trim strip after completion of the second stage;
[0013] FIG. 6A is a greatly enlarged cross-sectional view of an area of a lever and overlying port of an associated leg; and
[0014] FIG. 7 is a perspective view of the clip assembled with a grid runner and a trim strip.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] A clip 10 embodying the invention has the general shape of a right angle bracket with perpendicular legs 11 , 12 . The clip 10 is shown, other than in FIG. 4 , in its upright in-use orientation. The clip 10 , preferably, is a rigid, one-piece stamping of sheet metal, for example, of 0.048 in. thick hot dipped galvanized steel. A first one 11 of the legs is adapted to be joined with a grid runner 13 . The leg 11 is generally planar, with a pair of horizontally spaced holes 16 for receiving optional screws or rivets. At a distal end of the leg 11 , there is formed a relatively narrow tab 17 extending horizontally from a horizontal bend line 18 . A hole 19 interrupts the bend line 18 to facilitate manual bending of the tab 17 during installation of the clip 10 .
[0016] The legs 11 , 12 are joined at a vertical corner 21 . The leg 12 is adapted to connect an elongated trim strip 20 of known construction that conceals the ends of laterally spaced parallel grid runners 13 and ceiling tiles at the perimeter of an island ceiling or at a soffit. The leg 12 has a main area 22 with planar portions 23 interrupted by vertical embossments 26 , 27 that serve as stiffening elements. Slots 28 , 29 and slits 31 form and surround a central lever 32 . At its opposite sides, the lever 32 is connected to other parts of the main area 22 by lands or webs 33 which as will be described serve as a combined fulcrum and living hinge.
[0017] A lower end of the lever 32 is offset in the forward direction to form a depending tab 34 forward of the main area 22 . Along an upper edge of the leg 12 is formed an upstanding tab 36 forward of the main area 22 and coplanar with the lever tab 34 . A vertical slot 37 is formed in the leg 12 adjacent the corner 21 .
[0018] The illustrated trim strip 20 is known in the art and is representative of various cross-sectional shapes to be selected by a ceiling designer. The trim strip 20 is an aluminum extrusion, typically 10 foot in length, having on its rear side 38 , which is normally concealed in use, a pair of opposed longitudinally extending channels 39 , 41 facing one another.
[0019] The illustrated grid runner 13 is a cross runner and has a conventional cross-section in the form of an inverted T and is commonly referred to as a grid tee. Other grid runner cross-sectional configurations can be used with the clip 10 . The illustrated grid runner 13 has an upper reinforcing bulb 46 , a vertical web 47 depending from the bulb and a horizontal flange 48 at the bottom of the web. The grid runner 13 includes an end connector 49 of known construction ordinarily used to join with an identical connector of another cross runner usually in a common slot of a main runner. The illustrated cross runner includes an indexing hole 51 rearward of the connector 49 . Cross runners ordinarily will be spaced in parallel alignment on 2 ft. or 4 ft. centers, or industry metric equivalents. A clip 10 is mounted on the end of each cross runner 13 to collectively support a trim strip 20 . In the simplest case, the clip 10 is mounted on a grid runner 13 by inserting its end connector 49 in the vertical slot 37 and the tab 17 through the indexing hole 51 and abutting the leg 11 against a side of the grid runner web 47 . The clip 10 is locked in position on the grid runner 13 by bending the tab 17 upwardly as shown in FIG. 7 . The vertical height of the leg 11 is proportioned to fit closely between the underside of the grid runner bulb 46 and the top of the grid runner flange 48 so that the clip is properly positioned or indexed to the grid runner 13 .
[0020] The trim strip 20 can be mounted on the clips 10 in a two step process. The trim strip 20 is first hung on the clips 10 by lowering the upper mounting channel 39 onto the upper clip tabs or grips 36 . During this initial step, the central lever 32 is in a position illustrated in FIG. 5 where an upper end 53 is displaced rearward of the main area 22 of the leg 12 . The lower end of the lever 32 represented by the depending tab or grip 34 is forward and upward from a final position where it lies in the same vertical plane as the upper tab 36 and is vertically farthest from the upper tab. The clip 10 may be supplied from the manufacturer with the displaced position of the lever 32 illustrated in FIG. 5 .
[0021] With the upper tab 36 seated in the upper trim strip channel 39 , the lever 32 can be manually pushed, for example, with a screwdriver in contact with the depression in the center of the lever above the lands 33 until the upper end 53 contacts a part of the leg 12 overlying the slits 31 . This motion of the lever 32 swings the lower tab 34 into the lower trim strip channel 41 to provisionally capture the trim strip 20 on the clip 10 . Lengthwise adjustment of the strip 20 can be made at this time. When the longitudinal position of the strip 20 is correct, the lever 32 is forced back into the plane of the main area 22 of the leg 12 causing the lower tab 34 to move vertically downwardly away from the upper tab 36 and thereby frictionally lock the tabs to the respective channels 41 , 39 with an interference fit. FIG. 6A is a greatly enlarged cross-sectional view of the geometry of the slits 31 . Preferably, as shown in FIG. 6A with some exaggeration, the slits 31 are inclined upwardly from the rear to the front of the clip leg 12 . The lever 32 pivots on the lands 33 with the lands acting as a living hinge. The undercut or inclined geometry of the slits 31 along with an interference fit created by proportioning the clip to be oversized to the channel to channel dimension prevent the lever from unintentionally moving back to its initial position where the lever is out of the plane of the main area 22 . A flat blade screwdriver (not illustrated) can be used to toggle or pry the lever from its initial out of plane condition into the final position where it is coplanar with the remainder of the main area 22 . The blade of the screwdriver is inserted in the central slot 29 to permit this prying action. The lands 33 , in addition to working as a living hinge, operate as a fulcrum and cause the lower part of the lever represented by the depending tab 34 to swing into the lower trim strip channel 41 . When the upper end 53 of the lever 32 is forced over center of the slit surface of the main or planar portion of the leg 12 , interference caused by the slit geometry strongly resists a reverse or unlocking movement of the lever
[0022] The clip 10 can be used with main runners or with cross runners that are less than full length and do not have the end detail described above. In this case, the tab 17 can be bent back into the plane of the remainder of the leg 11 and the holes 16 can accept self-tapping screws or rivets to secure the leg 11 to the web of the grid runner in question. Small projections 54 can be stamped in the tabs 34 , 36 to improve the retention force of the clip 10 on the trim strip 20 .
[0023] It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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A clip for mounting an elongated trim strip on ends of ceiling grid runners, having a right angle configuration with two intersecting legs, one leg adapted to laterally abut an end of a grid runner and the other being adapted to engage the trim strip, said other leg having oppositely extending upper and lower grips for reception into upper and lower opposing channels of the trim strip, the grips being relatively moveable, and a toggle arrangement for moving said grips away from one another, when retracted, the grips being capable of passing between the opposed channels, the toggle arrangement selectively maintaining said grips in an extended position to frictionally lock onto the opposed channels of the trim strip.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for improving the production rate from an existing producing well.
THE PRIOR ART
Wells with high inflow performance ability that are equipped with pumping units and are completed with 31/2" or 41/2" casing strings are limited in daily production volumes by pumping equipment capacity, rather than the reservoir capability. These wells can only be completed with 23/8" tubing, which limits the maximum rod diameter that can be used to 7/8". The 7/8" rods are the weak link in a production chain. Production rates of 400 BFPD are the maximum rates that can be achieved without exceeding acceptable stress loads on such rods. If a well's inflow is greater than the production equipment outflow, oil is left in the wellbore rather than being produced to the stock tank each day of operation. The solution to this problem requires a rod string which is capable of handling the high stresses that such high production volumes place on the production equipment.
SUMMARY OF THE INVENTION
The present invention achieves an increase in the production rate of a producing well by revising what has heretofore been the accepted order of rods in a string. High tensile strength small diameter rods are placed at the top of the string with progressively larger diameter lower tensile strength rods forming lower sections of the rod string.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings in which the single figure illustrates the present invention in a schematic vertical section through a producing well.
DETAILED DESCRIPTION OF THE INVENTION
In a typical production well produced by a rod string, an API steel rod string is assembled with the stronger (larger diameter) rods installed at the top of the string and the weaker (smaller diameter) rods at the bottom of the string in order to sustain the loads imposed by the weight of the rods, produced fluid, and pumping acceleration. This means that the largest diameter rod has been placed at the top while the smallest diameter rod has been placed at the bottom when using prior art rod string assembly techniques.
The present invention improves the production rate by assembling a rod string with smaller diameter, high tensile strength rods at the top of the string and larger diameter, lower tensile strength rods at the bottom of the string. The present invention is schematically shown in the single figure. The producing well 10 has a pumping assembly 12 and rod string 14 descending into the well. The rod string is made up of a plurality of sections 16, 18, and 20. In order to practice the present invention it is necessary that the smaller diameter rods have a much higher tensile strength than a typical prior art steel rod. Such a rod exists and is known as an EL® rod (A registered trademark of National Oilwell of Houston, Texas). EL® rods are able to withstand the high stress levels this configuration imposes on the rod system. Typical steel rods would be unable to produce a well using this configuration for a significant period of time because of the high stress loads imposed on the top rods.
It has been found, through computer simulation, that this rod string configuration results in an increase in the downhole net stroke, similar to that achieved by a fiberglass rod string. The result is a higher production rate than is possible with the typical prior art steel rod string.
The present invention was put into an actual production well application. The parameters for this producing well, prior to the installation of the rod string according to the present invention, were as follows: the well had a 41/2" casing which allowed only 23/8" tubing to be installed. 23/8" tubing has an inner diameter of 1.995" which limited the largest diameter rod, in a typical API rod string, to 7/8". The well had sufficient reservoir pressure to be capable of producing 700 BFPD, but actual production was limited to 500 BFPD by the pumping equipment. This difference resulted in the well building up fluid within the wellbore and meant that oil, which could have been produced by reducing the fluid level, was actually stacking up within the wellbore. Attempts to increase the well's production were made in the form of speeding up the pumping unit to the maximum that the rod string would allow.
A rod string according to the present invention was installed in this well and consisted of 2,500 feet of 3/4" diameter EL rods on top of 2,500 ft. of 7/8" grade D rods. This rod string was capable of achieving 645 BFPD. This was a production increase of 29% over the previous rod string. The significance of the rod string configuration of the present invention is in the newly found ability to produce wells at a higher rate, in spite of the constraints that the smaller diameter tubulars had imposed in previous designs.
The present invention may be subject to many modifications and changes without departing from the spirit or essential characteristics thereof. The present embodiment should therefore be considered in all respects as illustrative and not restrictive of the scope of the invention as defined by the appended claims.
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Production from a producing oil well is increased by forming a pumping string with pipe sections of small diameter and high tensile strength at the top and large diameter low tensile strength at the bottom of the well.
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This is a division, of application Ser. No. 525,205, filed 11/19/74.
BACKGROUND OF THE INVENTION
2. Field of the Invention
This invention relates to a novel composition of matter useful as a catalyst and/or catalyst base in hydrocarbon conversion reactions. More particularly, this invention relates to synthetic halloysite, its preparation and its use in hydrocarbon conversion reactions such as cracking, hydrocracking, hydrofining, desulfurization, and demetallization.
2. Description of the Prior Art
Halloysite is a well-known kaolin clay mineral having the empirical formula Al 2 O 3 :2SiO 2 :2H 2 O. A complete chemical analysis for halloysite is given in the "Encyclopedia of Chemical Technology", 2nd Edition, Vol. 5, page 545 (Interscience Publishers). Further description concerning the properties and characteristics of naturally-occurring halloysite may be found in the literature such as, for example, Thomas F. Bates et al. (1950), Morphology and Structure of Endellite and Halloysite, The American Mineralogist, Vol. 35, pages 463-484; Thomas F. Bates et al, Further Observations on the Morphology of Chrysotile and Halloysite, Proceedings National Conference on Clays and Clay Minerals, VI, Berkeley, 1957 pages 237-248; and G. Brown, The X-Ray Identification and Crystal Structures of Clay Minerals, Mineralogical Society (Clay Minerals Group), London, 1961, pages 68-77.
Natural halloysite has been used heretofore in the petroleum art as a catalyst cracking catalyst. Unfortunately, naturally-occurring halloysite contains various metals, such as iron, which are detrimental to its effectiveness as a hydrocarbon conversion catalyst. It has been found, therefore, necessary to subject the naturally occurring halloysite to acid treatment in order to reduce the iron content and thereby increase its effectiveness as a hydrocarbon conversion catalyst. Unfortunately, acid treatment often does substantial damage to the crystalline structure of the halloysite which drastically limits its use as a catalyst in hydrocarbon conversion processes.
SUMMARY OF THE INVENTION
In accordance with the present invention, a synthetic halloysite which is substantially iron-free is obtained by crystallization from a reaction mixture containing hydrous alumina gel and aqueous silica sol. In a further embodiment of the invention, metal substituted synthetic halloysites are prepared by coprecipitation of metal hydroxides with the alumina gel.
In general, the halloysite of the invention is prepared by crystallization from an aqueous mixture containing a mixture of alumina gel and a silica source maintained at a pH of 4 to 10 for at least about 16 hours at a temperature in excess of 200° C. A preferred reaction scheme is given by the following equations:
AlCl.sub.3 (aqueous solution) + NH.sub.4 OH→Al(OH).sub.3.50 H.sub.2 O (gel) + NH.sub.4 Cl (solution)
2 Al(OH).sub.3.50 H.sub.2 O (washed gel) + 2 SiO.sub.2.8 H.sub.2 O (sol) → Al.sub.2 (OH).sub.4 Si.sub.2 O.sub.5 (synthetic halloysite) + 117 H.sub.2 O
metal substituted synthetic halloysites can be prepared in accordance with the invention by coprecipitation of a hydroxide of the metal with the alumina gel. The empirical formula for such metal substituted synthetic halloysites, which may have an SiO 2 /Al 2 O 3 ratio greater than the stoichiometric amount, can be expressed by the following formula:
[x Al + 3/n (1-x)M].sub.2 O.sub.3.(2+y) SiO.sub.2.2H.sub.2 O
where M is a metal selected from Groups IIA, IIIB, VIB and VIII of the Periodic Table
n is valence of M
x = 0 to 1, preferably 0.8 to 1.0
y = 0 to 1.
Preparation of the synthetic halloysite of the invention involves the reaction of hydrous alumina gel, i.e., Al(OH) 3 , and a source of silica. The hydrous alumina gel is prepared in accordance with known techniques such as by the reaction of aqueous mixtures of aluminum chloride or aluminum sulfate and an inorganic base such as NH 4 OH, NaOH or NaAlO 2 , and the like. Preparation of alumina gel by use of ammonium hydroxide is preferable to the use of sodium hydroxide since it is desirable to maintain the soda (Na 2 O) content to a low level and because the more alkaline gels tend to form crystalline boehmite.
The silica source may include those sources which are conventionally used for the preparation of crystalline aluminosilicate zeolites. These include silicic acid, silica sol, silica gel, sodium silicate, etc. Silica sols are particularly useful. These are colloidal dispersions of discrete spherical particles of surface-hydroxylated silica such as is sold by E. I. du Pont de Nemours & Company, Inc. under the trademark "Ludox".
The proportions of the reactants employed in the initial reaction mixture are determined from the following molar ratio of reactants.
______________________________________ Reactant Molar Ratio Particularly General Preferred Preferred______________________________________Al(OH).sub.3 /SiO.sub.2 0.5-1.2 0.8-1.0 0.9-1.0H.sub.2 O/SiO.sub.2 20-60 30-50 40-50______________________________________
The pH of the reaction mixture should be adjusted to a range of about 4 to 10, preferably 6 to 8. The temperature of the reaction mixture should preferably be maintained at between about 230° and 270° C., more preferably 240° to 250° C., for a period from about 2 hours to 100 hours or more. The time necessary for crystallization will depend, of course, upon the temperature of the reaction mixture. By way of example, the crystallization of the synthetic halloysite occurs in about 24 hours at a temperature of about 250° C.
The catalytic activity of the synthetic halloysites of the invention can be improved by incorporating therein metals selected from Groups IIA, IIIB, VIB, and VIII of the Periodic Table as given in "Websters Seventh New Collegiate Dictionary", (1963) published by G. C. Merriam Company. Specific examples of such metals include, among others, magnesium, lanthanum, molybdenum, cobalt, nickel, palladium, platinum and rare earths. Particularly preferred metals include magnesium, nickel, cobalt and lanthanum. The metals are incorporated into the synthetic halloysite structure by adding soluble salts of the metal to the reaction mixture or by coprecipitation of the metal hydroxide with Al(OH) 3 . The metals are most conveniently added to the reaction mixture in the form of their hydroxides. The synthetic halloysite of the invention, particularly when substituted with the afore-described metals, is useful for catalytic cracking, hydrocracking, desulfurization, demetallization and other hydrocarbon conversion processes. For example, substituted halloysites of the invention containing metals such as magnesium, lanthanum and rare earths such as cerium, praseodymium, neodymium, gadolinium, etc. are useful in catalytic cracking of petroleum feedstocks. Synthetic halloysite containing nickel, cobalt, palladium, platinum, and the like are particularly useful for hydrocracking petroleum feedstocks.
The feedstocks suitable for conversion in accordance with the invention include any of the well-known feeds conventionally employed in hydrocarbon conversion processes. Usually they will be petroleum derived, although other sources such as shale oil are not to be excluded. Typical of such feeds are heavy and light virgin gas oils, heavy and light virgin naphthas, solvent extracted gas oils, coker gas oils, steam-cracked gas oils, middle distillates, steam-cracked naphthas, coker naphthas, cycle oils, deasphalted residua, etc.
The operating conditions to be employed in the practice of the present invention are well-known and will, of course, vary with the particular conversion reaction desired. The following table summarizes typical reaction conditions effective in the present invention.
__________________________________________________________________________ Reaction ConditionsPrincipal Pressure, Feed Rate Hydrogen RateConversion Desired Temperature, ° F. p.s.i.g. V/V/Hr. s.c.f./bbl.__________________________________________________________________________Hydrofining 500-800 50-2,000 0.1-10.0 500-10,000Hydrocracking 450-850 200-2,000 0.1-10.0 500-10,000Catalytic Cracking 700-1,000 0-50 0.1-20.0 0Catalytic Reforming 850-1,000 50-1,000 0.1-20.0 500-10,000__________________________________________________________________________
The halloysite structure of the composition of this invention has been confirmed by X-ray diffraction and electron microscopy. However, there are a number of significant differences between naturally occurring halloysite and the synthetic halloysite of this invention. For example, the synthetic halloysites of the invention have surface areas ranging from about 85 sq. meters/gram to about 200 sq. meters/gram (BET Method as used, for example, in U.S. Pat. No. 3,804,741) as compared to naturally occurring halloysite which has a surface area generally within the range of 40-85 sq. meters/gram (BET Method). Further, the synthetic halloysite of the invention will be substantially iron-free, i.e., less than 0.05% iron, as compared to naturally occurring halloysite which contains significant amounts of iron. The synthetic and naturally occurring halloysites also differ in that the physical form of the synthetic halloysite is flakes, while the physical form of the natural halloysite has a tube-like configuration. Furthermore, it has been discovered that the synthetic halloysite has considerably better catalytic activity than natural halloysite under analogous hydrocarbon conversion conditions. Although the synthetic halloysite has the same empirical formula as naturally occurring halloysite, the higher surface area, the elimination of iron and the presence of selective metals makes the synthetic halloysite a more effective hydrocarbon conversion catalyst.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples further illustrate the present invention. Unless otherwise specified, all percentages and parts are by weight.
EXAMPLE 1
This example illustrates a general procedure for the preparation of the synthetic halloysite of the invention.
A solution consisting of 962 grams of AlCl 3 .6H 2 O in 3,200 cubic centimeters (cc) of water were added to a 1 gallon stainless steel vessel. The solution was stirred at ambient conditions and neutralized with about 740 cc. of a 28% ammonia solution, thereby producing a pH greater than 8. The Al(OH) 3 gel produced was washed with water until it was substantially chloride-free. The washed Al(OH) 3 gel was then blended with 790 grams of silica sol sold under the trade name "LS-30 Ludox" by E. I. du Pont de Nemours & Company. The blend of silica sol and alumina gel was then transferred to a 200 cc. Monel autoclave where it was heated at 246° C. for 48 hours to produce synthetic halloysite.
EXAMPLE 2
Using the general procedure of Example 1, a number of synthetic halloysites were prepared to determine the surface area of synthetic halloysite prepared in accordance with the invention. The results given below in Table I show that the surface area expressed in square meters per gram is higher than naturally occurring halloysite.
TABLE I__________________________________________________________________________SURFACE AREA OF SYNTHETIC HALLOYSITEGel Composition CrystallizationSilica Source Al Source Al/Si H.sub.2 O/Al.sub.2 O.sub.3 Conditions Surface Area.sup.(1) (m..sup.2 /g, BET Method)__________________________________________________________________________LS-30 Ludox.sup.(2) Al(OH).sub.3.sup.(3) 1.0 72 20 Hr. at 250° C. 114LS-30 Ludox Al(OH).sub.3 1.0 89 20 Hr. at 246° C. 88LS-30 Ludox Al(OH).sub.3 +MgCl.sub.2 0.9 100 20 Hr. at 246° C. 103LS-30 Ludox Al(OH).sub.3 +NiCl.sub.2 0.9 100 20 Hr. at 246° C. 118LS-30 Ludox Al(OH).sub.3 +FeCl.sub.2 0.9 100 20 Hr. at 246° C. 91LS-30 Ludox Al(OH).sub.3 +CoCl.sub.2 0.9 100 20 Hr. at 246° C. 93LS-30 Ludox Al(OH).sub.3 1.0 86 48 Hr. at 246° C. 99LS-30 Ludox Al(OH).sub.3 +Mg(OH).sub.2 1.0 67 48 Hr. at 255° C. 193LS-30 Ludox Al(OH).sub.3 +Mg(OH).sub.2 1.0 67 48 Hr. at 246° C. 143__________________________________________________________________________ .sup. (1) Naturally occurring halloysite typically has a surface area in the range of 45-85 m..sup.2 /g. .sup.(2) Colloid silica sol (150 A.) particle size sold by E. I. du Pont de Nemours & Company. .sup.(3) AlCl.sub.3 naturalized with NaOH and washed.
EXAMPLE 3
Using the general preparation procedure given in Example 1, a number of metal-substituted synthetic halloysites were prepared by precipitating insoluble hydroxides of various metals with aluminum hydroxide and blending the resultant washed gel with the silica sol. The reaction conditions and the amount of substituted metal in the synthetic halloysite product are given in Table II.
TABLE II__________________________________________________________________________ H.sub.2 O/Al.sub.2 O.sub.3 Product Amount of SubstitutedExperiment* Synthesis Gel, Molar Proportions Mole Ratio Yield** Metal in Product, Wt.__________________________________________________________________________ %A SiO.sub.2 Sol + Al(OH).sub.3 + 0.15 Mg(OH).sub.2 72 81 1.23% MgB SiO.sub.2 Sol + Al(OH).sub.3 + 0.15 Ni(OH).sub.2 66 71 2.6% NiC SiO.sub.2 Sol + Al(OH).sub.3 + 0.15 Fe(OH).sub.2 77 94 4.6% FeD SiO.sub.2 Sol + Al(OH).sub.3 + 0.15 Co(OH).sub.2 84 82 5.6% Co__________________________________________________________________________ *In all experiments, the Al/Si mole ratio in reaction mixture was 0.94 an crystallization conditions were 24 hours at 246° C. **Wt. % of theoretical yield calculated as Al.sub.2 O.sub.3 . 2SiO.sub.2 2H.sub.2 O.
EXAMPLE 4
The catalysts prepared in the previous example were pressed on a hydraulic ram, the compacted forms of the catalyst then crushed to 14-35 mesh (Tyler series), and then calcined at 540° C. for 16 hours. Portions of this granular catalyst were charged to reactors and the temperature adjusted to 280° C. A stream of helium was passed through a saturator filled with cumene at 18° C. and passed into the reactor and contacted with the catalyst. The effluent from the reactor was analyzed by gas chromatography to determine the amount of conversion of the cumene to benzene and propylene. The results obtained were compared with natural halloysite (API Standard No. 13). The results obtained are given below in Table III.
TABLE III______________________________________CUMENE CRACKING ACTIVITY Cumene Conver- W/Hr./W sion, % (G. of (At Cumene/ 525° F. Hr./G. After 30 K*Catalyst Description of Cat.) Minutes (Hr..sup.-1)______________________________________Natural Halloysite (API #13) 0.08 8 0.006Syn. Halloysite of Example 1 0.08 16 0.013Mg-Substituted Syn. Halloysite 0.075 60 0.068Product A of Example 3Ni-Substituted Syn. Halloysite 0.081 37 0.038Product B of Example 3Fe-Substituted Syn. Halloysite 0.22 0 0Product C of Example 3Syn. Halloysite of Example 1 0.22 5 0.012Co-Substituted Syn. Halloysite 0.22 10 0.023Product D of Example 3Mg-Substituted Syn. Halloysite 0.22 43 0.124Product A of Example 3Ni-Substituted Syn. Halloysite 0.22 25 0.062Product B of Example 3Mg-Substituted Syn. Halloysite 0.26 18 0.052Product A of Example 3______________________________________ *First order rate constant for cumene cracking reaction.
The above data show the effectiveness of the synthetic halloysites of the invention as cracking catalyst. Synthetic halloysite is more active than natural halloysite and the activity of synthetic halloysite is significantly improved by substituting such metals as magnesium and nickel in the structure. Conversely, the incorporation of iron in synthetic halloysites acts as a catalyst poison, just as it does in natural halloysites.
EXAMPLE 5
This example compares in Table VI the X-ray powder diffraction pattern of a typical synthetic halloysite of the invention with the published patterns for naturally occurring halloysite (ASTM 13-375) and the closely related mineral kaolinite (ASTM 14-164).
In obtaining the X-ray powder diffraction pattern, standard procedures were employed. The radiation source was the K-alpha doublet for copper. A Geiger counter spectrometer with a strip chart pen recorder was used in recording the data. The peak heights I, and the positions as a function of 2θ, where θ is the Bragg angle, were read from the spectrometer chart. From these, the relative intensities I were observed. Also, the interplanar spacing, d, in Angstrom units, corresponding to the recorded lines, were determined by reference to standard tables. The more significant interplanar spacings, i.e., d values, for a typical synthetic halloysite of the invention, natural halloysite and kaolinite are shown below in Table IV. As regards the synthetic halloysite of the invention, the relative intensities of the lines are expressed as s. (strong), m. (medium) and w. (weak).
TABLE IV______________________________________X-RAY DIFFRACTION PATTERNSFOR HALLOYSITES AND KAOLINITESyntheticHalloysite* Natural Halloysite** Kaolinite*** I/ I/d(A) I hkl d(A) I.sub.1 hkl d(A) I.sub.1 hkl______________________________________7.3 m. 001 7.4 95 001 7.17 100 0014.43 s. 11.sub.-,02.sub.- 4.41 100 11.sub.-,02.sub.- 4.48 35 0203.56 m. 002 3.62 65 002 4.37 60 1102.55 m. 20.sub.-,13.sub.- 2.58 30 20.sub.-,13.sub.- 3.58 80 0022.34 m. 003 2.39, 2.32 35 003 2.385 25 0031.68 m 24.sub.-,31.sub.- 1.70, 1.67 20 26.sub.14 ,31.sub.- 1.94 35 1321.49 m. 33.sub.-,06.sub.-______________________________________ *First-listed product of Table I **ASTM 13-375 ***ASTM 14-164
As regards synthetic halloysite and the related kaolinite mineral, the d line at 4.43 A is significant. Kaolinite has d lines at 4.48 A and 4.37 A, but no strong intensity d line at 4.43 A as in the case of the synthetic halloysite of the invention. The synthetic halloysite of the invention can also be distinguished on the basis that the d line at 4.43 A is of stronger intensity than either the 001 line (d = 7.3) or the 002 (d = 3.56). Accordingly, the significant X-ray diffraction characteristics of the synthetic halloysite of the invention are as follows:
______________________________________d(A) I______________________________________7.3±0.2 m4.42±0.02 s3.56±0.04 m______________________________________
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A synthetic halloysite which is substantially iron-free is obtained by crystallization from a reaction mixture containing hydrous alumina gel and aqueous silica sol. Metal substituted synthetic halloysites can be prepared by coprecipitation of metal hydroxides with the alumina gel. Hydrocarbons are converted over cracking catalysts derived from these halloysites.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a multiple speed step-ratio automatic transmission for a motor vehicle and, in particular, to the control of a coasting downshift performed by the transmission.
2. Description of the Prior Art
During a coasting downshift of an automatic transmission in which shifts occur between individual gear ratios, a lash transition can occur when torque converter turbine speed and engine speed (or torque converter impeller speed) cross at too high of a rate. This lash transition excites components in the transmission and driveline system, which can result in an audible clunk disturbance to the vehicle operator and passengers. Under certain conditions, the lash can cross and cross back, and the customer may experience both an excessively long gear shift and a double clunk.
The technical reason for the clunk during the coasting downshift sequence is the rate at which the on-coming synchronous element, such as a brake comprising a band and drum, gains torque capacity relative to the off-going synchronous element losing torque capacity. The relative element capacities are determined by estimated engine torque, engine inertia, and vehicle deceleration rate, which are translated into hydraulic control pressures and apply forces acting on the elements. This translation is further impacted by a rise in the interface temperature of the on-coming band and drum, which increases the likelihood of a torque reversal and subsequent lash transition during the gear shift.
The apply force on the band is proportional to torque for both an on-coming friction control element and an off-going control element. The torque reversal causes a crossing of driveline lash, which creates a torque disturbance and the audible clunk.
A need exists in the automotive industry for a technique to adjust the relative pressures of the on-coming and off-going control elements during a coasting downshift to reduce lash and therefore minimize the rate at which that lash is crossed based on system level inputs.
SUMMARY OF THE INVENTION
A method for controlling a coast down downshift that is produced in an automatic transmission by disengaging an off-going control element and engaging an on-coming control element, including the steps of determining a first desired pressure magnitude of the off-going control element and a first desired pressure magnitude of the on-coming control element, executing the current downshift using said first desired pressure magnitudes, determining during execution of the current downshift corrections of said first desired pressure magnitudes that occur during the current downshift, determining a second desired pressure magnitude of the off-going control element and a second desired pressure magnitude of the on-coming control element, using said corrections and the second desired pressure magnitude to determine a subsequent desired pressure magnitude of the off-going control element and a subsequent desired pressure magnitude of the on-coming control element, and executing a downshift using said subsequent desired pressure magnitudes.
In order to reduce the likelihood of a torque reversal a “controlled tie-up” of the coasting synchronous downshift is produced. Due to low operating torques and pressure variability, the pressures are adapted as a function of temperature and vehicle deceleration rate. The controlled tie-up creates a controlled torque reversal rate between the off-going and on-coming friction elements during the synchronous coasting downshift.
The controlled tie-up is accomplished by raising the starting off-going element pressure to a value higher than that required based on system level inputs, thereby allowing the synchronous shift hand-off from off-going element to on-coming element to occur in a torque and pressure region where the rate of the hand-off of the shift can be managed.
The two starting servo pressure magnitudes of the on-coming element and off-going element are further adjusted until the desired hand off rate is obtained.
In addition to producing a “controlled tie-up”, and in order to provide for the range of operating conditions and unit-to-unit variability, the servo pressures of the on-coming element 74 and off-going element 70 ( FIG. 1 ) are adapted for changing conditions. To accomplish this adaptation, an algorithm of prioritized shift performance metrics determines the magnitudes of various desired corrective metrics, stores the metric values in memory, iteratively revises the stored metric values, and recalls them for use in controlling subsequent coasting downshifts.
The algorithm learns and stores in memory corrective adjustments of the synchronous pressures to avoid large levels of lash based on system level inputs.
The scope of applicability of the preferred embodiment will become apparent from the following detailed description, claims and drawings. It should be understood, that the description and specific examples, although indicating preferred embodiments of the invention, are given by way of illustration only. Various changes and modifications to the described embodiments and examples will become apparent to those skilled in the art.
DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood by reference to the following description, taken with the accompanying drawings, in which:
FIG. 1 is a schematic diagram showing the kinematic arrangement of an automatic transmission operating in a forward gear;
FIG. 2 is a schematic diagram showing the showing the kinematic arrangement of the transmission of FIG. 1 operating in a lower forward gear; and
FIG. 3 is a logic flow diagram representing an algorithm for controlling successive coasting downshifts.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is illustrated in FIG. 1 the kinematic arrangement of an automatic transmission 10 . A torque converter includes a bladed impeller wheel 12 connected to the crankshaft 14 of an internal combustion engine, a bladed turbine wheel 16 , and a bladed stator wheel 18 . The impeller, stator and turbine wheels define a toroidal fluid flow circuit, whereby the impeller 12 is hydrokinetically connected to the turbine 16 . The stator 18 is supported rotatably on a stationary stator sleeve shaft 20 , and an overrunning brake 22 anchors the stator to the shaft 20 to prevent rotation of the stator in a direction opposite the direction of rotation of the impeller, although free-wheeling motion in the opposite direction is permitted.
The torque converter includes a bypass clutch 24 located within the torque converter 26 . When clutch 24 is engaged, the turbine and impeller are mechanically connected to a transmission input shaft 28 ; when clutch 24 is disengaged, the turbine and impeller are hydrokinetically connected and mechanically disconnected. Fluid contained in the torque converter is supplied to the torque converter from the output of an oil pump assembly and is returned to an oil sump, to which an inlet of the pump is connected hydraulically.
A planetary gear system includes first, second, and third gear units 30 , 32 , 34 . Gear unit 30 includes a first sun gear 31 , a ring gear 35 , a carrier 36 secured to input 28 , and planet pinions 38 supported on carrier 36 and meshing with sun gear 32 and ring gear 34 . An overrunning coupling 40 includes an inner race 42 connect to input 28 and carrier 36 , an outer race 44 connected to ring gear 34 , and a set of sprags for alternately driveably connecting and releasing the races 42 , 44 .
Gear unit 32 includes a sun gear 44 , a ring gear 46 , a carrier 48 secured to an output shaft 50 , and planet pinions 52 supported on carrier 48 and meshing with sun gear 44 and ring gear 46 .
Gear unit 34 includes a sun gear 54 secure to sun gear 44 , a ring gear 56 , a carrier 58 secured to output shaft 50 , and planet pinions 60 supported on carrier 58 and meshing with sun gear 54 and ring gear 56 . An overrunning coupling 62 includes an inner race 64 held against rotation of the transmission case 66 , an outer race 68 connected to carrier 58 , and a set of sprags for alternately driveably connecting and releasing the races 64 , 68 .
A high clutch 70 , a hydraulically-actuated friction control element, alternately connects an intermediate shaft 72 to sun gears 44 , 54 when clutch 70 is engaged, and releases that connection when clutch 70 is disengaged. An intermediate brake band 74 , a second hydraulically-actuated friction control element, alternately connects sun gears 44 , 54 and case 66 when brake band 74 frictionally engages a brake drum 76 , and releases that connection when brake band 74 is disengaged. A reverse brake band 77 , a third hydraulically-actuated friction control element, alternately connects carrier 58 and outer race 68 when brake band 77 frictionally engages a brake drum 78 , and releases that connection when brake band 77 is disengaged. A forward high clutch 80 , another hydraulically-actuated friction control element, alternately connects intermediate shaft 72 to ring gear 46 when clutch 80 is engaged, and releases that connection when clutch 80 is disengaged.
Transmission 10 operates in fourth gear when clutches 70 and 80 are engaged and the other control elements are disengaged. With the transmission so disposed, sun gears 44 and 54 are driven through clutch 80 at the speed of shaft 72 , ring gear 46 is driven through clutch 70 at the speed of shaft 72 , and carrier 48 and output shaft 50 rotate at the speed of intermediate shaft 72 .
A coasting downshift to third gear from fourth gear occurs when high clutch 70 is disengaged synchronously with engagement of intermediate brake 74 , forward clutch remains engaged, and the other friction elements remain disengaged. With the transmission so disposed, ring gear 46 is driven through clutch 80 at the speed of shaft 72 , sun gear 44 is held against rotation on case 66 due to the engagement of brake 74 with brake drum 76 , and carrier 48 and output shaft 50 are underdriven relative to the speed of intermediate shaft 72 .
Each of control elements 70 , 74 , 77 and 80 are actuated to engage and disengage in response to a variable magnitude of pressure present within a hydraulic cylinder of the respective servo associated with each of the control elements. In order to reduce the likelihood of a torque reversal that could produce a clunk during a power-off or coasting downshift, a need exists for a “controlled tie-up” of the coasting synchronous downshift. Due to the low operating torque capacities of the control elements and the variability of the servo pressures, a need exists also to adapt the actuating servo pressures as a function of temperature and vehicle deceleration rate.
Delivering a “controlled tie-up” creates a controlled torque reversal rate between the off-going friction element 70 and on-coming friction element 74 during the synchronous coasting downshift. The “controlled tie-up” is accomplished by raising the starting servo pressure of off-going element 70 to a value higher than that required based on system level inputs, thereby allowing the synchronous shift to occur in a torque and pressure region where the rate of the torque transfer from the off-going element 70 to the on-coming element 74 during the downshift can be managed.
Referring to FIG. 3 , the algorithm, initialized and started at step 100 , identifies at step 102 that a synchronous coasting downshift of transmission 10 is required. Generally the need for the downshift is determined by a transmission controller from electronic signals representing the vehicle speed and the updated position of an accelerator pedal, i.e., the extent to which the pedal is depressed by the vehicle operator. These vehicle parameters together determine the desired gear in which the transmission should be operating according to a function stored in electronic memory, accessible to the microprocessor, and indexed by current vehicle speed and current accelerator pedal position. When these parameters indicate that a downshift is required to produce the desired gear, the algorithm detects at step 102 that the downshift is required and about to occur.
The vehicle deceleration rate and the temperature of the automatic transmission fluid (ATF) in the transmission oil sump are determined at step 104 .
At step 106 , a desired pressure in the servo of the on-coming friction element and a desired pressure in the servo of the off-going friction element are determined as a function of engine combustion torque, engine inertia torque, transmission oil temperature and vehicle speed.
At step 108 , corrective values acquired during previous coasting downshifts between the subject gears and stored in electronic memory, preferably keep alive memory (KAM), are used to change the values determined from step 106 to produce the desired pressure in the servo of the on-coming friction element and the desired pressure in the servo of the off-going friction element for the current downshift.
At step 110 , the coasting downshift is executed, and variables such as delay, duration, and lash during the current downshift are determined and stored in electronic memory.
Delay is the length of a period that begins at a reference event, such as the start of the downshift, and ends at a reference percentage of completion of the current downshift, such as five percent completion. The algorithm compares the length of delay during the current downshift to a reference range of delay. Duration is the length of a period that begins at a reference percentage of completion of the current downshift event, such five percent completion, and ends at a second reference percentage of completion of the current downshift, such as eighty-five percent completion. The algorithm compares duration of the current downshift to a reference duration.
Lash, the difference between the speed of turbine 16 and the speed of the engine crankshaft 14 , is a measured parameter determined from signals representing these speeds that are produced by speed sensors. The algorithm determines the magnitude of the maximum lash that occurs after turbine speed begins to exceed engine speed and compares it to a reference lash range.
At step 112 , a check is made to determine whether the current delay is within the reference delay range. If the result of step 112 is logically true, control passes to step 114 . If the result of step 112 is logically false, control passes to step 116 where a correction of the off-going friction element pressure is determined from a schedule of off-going friction element pressure corrections that varies inversely with the magnitude of the current delay. For example, if the current delay is short relative to the reference range of delay, the off-going friction element pressure correction is increased and control passes to step 118 . If the current delay is long relative to the reference range of delay, the off-going friction element pressure correction is decreased and control passes to step 118 .
At step 118 , a check is made to determine whether the current lash relative to the measured delay is within the reference lash range. If the result of step 118 is logically true, indicating that the current lash is within the lash range, control passes to step 120 where the off-going friction element pressure correction due to delay alone with acceptable lash is recorded in KAM.
If the result of step 118 is logically false, control passes to step 122 where a correction of the off-going friction element pressure, determined on the basis of delay, is further adjusted on the basis of lash. If the current magnitude of lash is high relative to the reference lash range and delay is short relative to the reference range, the off-going friction element pressure correction due to lash may be increased further. If the current magnitude of lash is high relative to the reference lash range and delay is long relative to the reference range, the off-going friction element pressure due to lash may be decreased further. If the current magnitude of lash is low relative to the reference lash range and delay is long relative to the reference range, the off-going friction element pressure due to lash may be decreased further. If the current magnitude of lash is low relative to the reference lash range and delay is short relative to the reference range, the off-going friction element pressure due to lash may be decreased further. Then control passes to step 120 , where the off-going friction element pressure corrections due to delay and lash are recorded in KAM for use during execution of a subsequent coasting downshifts between the subject gears.
If the result of step 114 is logically true, indicating that duration is within the reference duration range, control passes to step 124 where no correction of the on-coming pressure element pressure is made and execution of the algorithm for the current downshift ends.
If the result of step 114 is logically false, control passes to step 126 , where a correction of the on-coming friction element pressure is determined from a schedule of such pressure corrections that varies inversely with the magnitude of the current duration. For example, if the difference between the current duration and the reference duration range is zero, the on-coming friction element pressure correction may be −1.5 psi. If the difference between the current duration and the reference duration range is greater than zero, the oncoming friction element pressure correction may be −0.50 psi.
Then control passes to step 128 a check is made to determine whether the current delay is within the reference delay range. If the result of step 128 is logically true, indicating that the current delay is within the reference delay range, control passes to step 130 where the on-coming friction element pressure correction due to duration alone is recorded in KAM.
If the result of step 128 is logically false, indicating that the current delay is without the reference delay range, control passes to step 132 where a correction of the on-coming friction element pressure due to delay is determined as described with reference to step 116 . Then, at step 130 , the on-coming friction element pressure corrections due to duration and delay are recorded in KAM for use during execution of a subsequent coasting downshifts 132 between the subject gears.
In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that the alternate embodiments can be practiced otherwise than as specifically illustrated and described.
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A method for controlling a coast down downshift that is produced in an automatic transmission by disengaging an off-going control element and engaging an oncoming control element, including the steps of determining a first desired pressure magnitude of the off-going control element and a first desired pressure magnitude of the oncoming control element, executing the current downshift using said first desired pressure magnitudes, determining during execution of the current downshift corrections of said first desired pressure magnitudes that occur during the current downshift, determining a second desired pressure magnitude of the off-going control element and a second desired pressure magnitude of the oncoming control element, using said corrections and the second desired pressure magnitude to determine a subsequent desired pressure magnitude of the off-going control element and a subsequent desired pressure magnitude of the oncoming control element, and executing a downshift using said subsequent desired pressure magnitudes.
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RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application 08/628,320 filed Apr. 4, 1996 now U.S. Pat. No. 5,845,844.
FIELD OF THE INVENTION
The present invention relates to a wireless temperature monitoring system useful in reducing the risk of scalding to the user of a faucet. The system includes a temperature sensor/transmitter attached to the end of a faucet which communicates via a wireless link to a controller. The wireless link is utilized to facilitate installation on a faucet. One embodiment of the system includes a user detector for touchless control of the flow of water to a faucet. The invention may also provide a digital display with audio and/or visual alarms to indicate if a pre-set maximum temperature has been exceeded and a shut-off valve to interrupt flow of water to the faucet.
BACKGROUND OF THE INVENTION
The risk of scalding through the use of hot water faucets by certain groups of people, particularly disabled, elderly or young children, is present in many homes or institutions. Often, these people mistake the hot and cold water taps on a faucet or have difficulty operating a faucet which leads to exposure to dangerously hot water from the faucet. Typically, water temperatures in excess of 42° C. can cause injury to unprotected skin. While in various hot water heaters it is possible to set the thermostat to a lower temperature, many hot water tanks have their thermostats set in excess of 60° C. in order to ensure adequate hot water supply to the system for tasks such as laundry or running a dishwasher where a higher water temperature is desired.
Accordingly, there has been a need for products which effectively control the flow of hot water from a faucet to ensure that potentially scalding temperatures are not exceeded by individual faucets in a hot water system.
Past temperature monitoring and shut-off systems exist for controlling the flow of water or a fluid through conduits. Systems also exist with respect to faucets which regulate and control the flow of water to a faucet. These systems often include mechanisms for electronically monitoring the water temperature and adjusting the flow of hot and cold water to control a selected temperature. One disadvantage of these systems is that they are often highly complex requiring complete replacement of an entire faucet to enable their installation. The complexity often leads to an increased cost to the consumer.
Furthermore, these past systems may detract from the aesthetic look of a particular faucet by requiring unsightly attachments to the faucet or, alternatively, requiring the complete replacement of a faucet with a design which does not complement the overall style or look to a bathroom or kitchen. For example, in those systems which do not require replacement of the existing faucet, the installation often detracts from the aesthetic appearance of the faucet either through visible wires, valves and/or complex control panels.
Accordingly, there has been a need for an anti-scald device which may be installed on existing faucets without detracting from the aesthetic look of the faucet, specifically without the use of unsightly wires or valve mechanisms. Furthermore, there has been a need for an anti-scald device which can be readily installed by either a plumber or a lay person with minimal plumbing experience.
Specifically, there has been a need for a device which monitors the temperature of water flowing from a faucet and communicates the temperature information to a controller for processing through a wireless communication link. Information received from the controller may be used for providing a digital display of temperature and/or for controlling a shut-off valve in the event that the water temperature exceeds a pre-set value.
Still further, with respect to the wireless transmission of temperature data, there has been a need to improve the efficiency of power consumption relating to the transmission of temperature and, specifically, a need for a system which transmits temperature data only if a user is present.
Furthermore, while systems exist which allow for touchless control of a faucet, few systems allow a user to control of the temperature the water. In addition, some of these systems pressurize a faucet at the aerator causing stress in the spout and faucet outside of its engineered specifications which may lead to premature failure of the faucet.
Accordingly, there has been a need for an anti-scald device having increased power consumption efficiency through the provision of a user detector enabling non-continuous temperature data transmission. Additionally, there has been a need for an anti-scald device that has the feature of touchless flow control which also eliminates pressurizing the spout and faucet.
A review of the prior art indicates that systems exist which provide water temperature monitoring, control and shut-off in the event of excess temperatures. These include devices disclosed in U.S. Pat. Nos. 4,256,258, 5,184,642, 4,756,030, 4,886,207 and 5,226,629. However, none of these patents disclose a device which addresses and solves the above problems, specifically providing a device which can be readily retrofitted to existing faucets without significantly detracting from the aesthetic look of the faucet.
SUMMARY OF THE INVENTION
In view of the above needs, the invention seeks to provide an anti-scald device which may be readily configured to existing faucets and which does not significantly detract from the aesthetic look of the faucet.
Accordingly, the invention provides a temperature sensing device and transmitter, preferably for attachment to the end of a faucet with a screw ring having a standard thread. Temperature information from the faucet is transmitted to a controller where it may be used to actuate a hot-water shut-off valve and optionally provide a digital display of actual temperature or both. In the case of a hot-water shut-off valve, it is preferable that the shut-off valve is battery operated.
The system may also be provided with a user detector for automatic activation of the faucet thereby improving operational efficiency. The user detector is able to serve as an on/off switch for the system enabling the system to automatically turn on when a user is present and/or off when a user is no longer present.
Thus, in accordance with the invention, a faucet control system to monitor the temperature of a fluid flowing from a faucet is provided, the faucet control system comprising:
a temperature sensor and transmitter for attachment to the faucet, the temperature sensor and transmitter for obtaining temperature data relating to the temperature of a fluid flowing from the faucet and for wireless transmission of the temperature data;
a user detector operatively connected to the temperature sensor and transmitter, said user detector including means for activating the temperature sensor and transmitter in the presence of a user; and
a controller for receiving and processing the temperature data wherein the controller includes means for initiating fluid flow from the faucet and/or means for interrupting fluid flow from the faucet if the temperature of the fluid flowing from the faucet exceeds a pre-set value or the user detector no longer detects the presence of a user.
In a further embodiment, the invention also provides a faucet control system which controls the flow of a fluid through a faucet comprising:
a user detector for detecting the presence of a user at the faucet and generating an ON signal in the presence of a user and an OFF signal in the absence of a user;
a transmitter operatively connected to the user detector for attachment to the faucet, the transmitter for wireless transmission of the ON signal and OFF signal;
a controller for receiving and processing the ON signal and OFF signal wherein the controller includes means for initiating fluid flow from the faucet upon receipt of the ON signal and means for interrupting fluid flow from the faucet upon receipt of the OFF signal.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will be more apparent from the following description in which reference is made to the appended drawings of the valve unit in accordance with the invention;
FIG. 1 is a front sectional view of one embodiment of the invention showing a user sensor with a combined controller and shut-off valve;
FIG. 2 is a front sectional view of one embodiment of the invention showing an existing faucet retrofitted to function as a touchless, constant water temperature faucet;
FIG. 3 is a front sectional view of one embodiment of the invention showing a faucet containing an integrated user sensor;
FIG. 4a is a top sectional view of a temperature sensor/transmitter according to one embodiment of the invention;
FIG. 4b is a side view of a typical aerator module;
FIG. 4c is a top view of a typical aerator module;
FIG. 5 is a flow chart showing a preferred control scheme for the operation of a hands-free spout attachment in accordance with the invention;
FIG. 6 is a flow chart showing a preferred control scheme for the operation of a valve unit when in the presence of a user detector in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
Three embodiments of a touchless, wireless, temperature monitoring device 320 are shown in FIGS. 1, 2 and 3.
With reference to FIGS. 1, 2, and 3, an anti-scald device 320 is shown in combination with a user detector 302. In each of these figures, the temperature monitoring device 320 includes a temperature sensor/transmitter 16, an integrated controller 18/shut-off valve 20, and a user detector 302.
Detection of a user by the user detector 302 activates the temperature sensor/transmitter 16 to generate temperature data. The temperature data is transmitted to the controller 18 where the temperature data is received and processed. The controller 18 activates the shut-off valve 20 initiate the flow of water and/or stop water flow should the temperature exceed a pre-set maximum temperature or the user moves away from the faucet. The temperature sensor/transmitter 16, the controller 18 and the valve 20 are preferably battery operated.
FIG. 1 illustrates an embodiment in which an existing faucet 12 is retrofitted with a wireless temperature monitoring system resulting in a touchless faucet which provides the user with direct temperature control of water flowing from the faucet. In this embodiment, the user detector 302 is integrated with the temperature sensor/transmitter 16 to form an aerator module 312. An integrated controller 18/shut-off valve 20 is configured to each of the hot water 21 and cold water 310 pipes. In this embodiment, both the hot and cold water controller 18/shut-off valve units 18,20 will simultaneously receive temperature data from the aerator module 312. The simultaneous receipt of temperature data allows the valves 20 on both the hot water 21 and cold water 310 pipes to open concurrently to initiate water flow and/or close concurrently thereby stopping all water flow to the faucet 12 in the event that the pre-set maximum temperature is exceeded or the user moves away from the faucet.
In operation, a user approaches the faucet 12 and operates the knobs 314 in the normal manner for starting and stopping water flow from the faucet. The user detector 302, detecting the presence of a user, causes temperature data to be transmitted from the temperature sensor/transmitter 16 whereby it is simultaneously received by the controllers 18 on the hot and cold water supply lines 21,310. The receipt of temperature data causes the shut-off valves 20 to simultaneously open allowing water to flow from the faucet. In the event that the water temperature flowing from the faucet exceeds a pre-set maximum, the controllers 18 cause valves 20 to close. Alternatively, if the user moves away from the faucet, temperature data will cease being transmitted and the valves 20 will simultaneously close.
The location of the integrated controller 18/shut-off valve 20 beneath the faucet 12 ensures high pressure water is upstream of the faucet 12.
FIG. 2 shows an embodiment in which an existing faucet 12 is retrofitted on an existing faucet to function as a touchless, constant water temperature faucet. In this embodiment, the existing faucet control knobs are opened to allow water to flow through the faucet 20. Decorative caps 300 may be provided to cover the existing faucet knobs in order to prevent a user from attempting to operate the existing faucet knobs. Hot water 21 and cold water 310 pipes are joined upstream of the integrated controller 18/shut-off valve 20 in order to provide hot and cold water mixing at the shut-off valve 20. Downstream of shut-off valve 20, pipes 22 are separated for connection to the existing faucet 12. The temperature of the water to the faucet 12 is fixed by the position of the compression stops 304 on each of the hot water 21 and cold water 310 pipes. The controller is linked via a wireless link to an aerator module 312 as described above.
In this embodiment, a user merely approaches the faucet and places their hands beneath the aerator module 312. The user detector 302, upon sensing the user initiates the transmission of temperature data from the aerator module 312. The integrated controller 18/shut-off valve 20, upon receiving temperature data, opens the shut-off valve to allow mixed hot and cold water to flow through the faucet. In the event that the temperature of the water flowing from the faucet exceeds a preset value, the shut-off valve will close thus stopping water flow from the faucet 12. Similarly, if a user removes their hands from the faucet, the transmission of temperature data ceases and the controller 18 causes the shut-off valve 20 to close, thus stopping the flow of water from the faucet.
FIG. 3 shows an embodiment of the invention incorporating touchless and anti-scald properties into a faucet having a tepid water supply. In this embodiment, the temperature sensor/transmitter 16 is preferably packaged in the base of the faucet 12 and communicates through a wireless link with the integrated controller 18/shut-off valve 20. This embodiment would be typically used in an institutional installation where a warm water supply would be available. Accordingly, in this embodiment, a warm or tepid water supply requires only a single pipe and hence, only a single controller 18/shut-off valve 20 to provide full anti-scald protection in the event of a change in water supply temperature.
FIGS. 4a, 4b, 4c show an aerator module 312 containing a temperature sensor/transmitter 16, a temperature sensor 26, a controller/transmitter 28, a user detector 302, a battery 316 and an optional bypass button 24. The user detector 302 can be any touchless detection switch known in the art that is suitable for a faucet application. For example, the user detector 302 could be an infrared switch. The user detector 302 acts to detect the presence of a user, generally a user's hands approaching the faucet 12. The aerator module 312 is provided with a bore 32 to permit the passage of water there through and standard faucet threads 34 to permit attachment of the aerator module 312 to the outflow end of faucet. The temperature sensor 26 extends into the bore 32 to obtain temperature data from the fluid flowing through the bore 32. The bypass button 24 may be implemented to enable a user to access hotter water than would otherwise be allowed to flow from the faucet. Essentially, in the event that a user wishes to access hotter water, pressing the by-pass button will prevent the controller 18/shut-off valve from closing in the event that the maximum temperature is exceeded during a particular user session. The controller/transmitter 28 receives and processes signals from the user detector 302 and temperature sensor 26 and transmits temperature data and/or an ON or OFF signal to the controller 18/shut-off valve 20.
A flow chart of the operation of the hands-free, touchless, spout attachment (aerator module) 312 is shown in FIG. 5. When the faucet 12 is not in use, the temperature sensor/transmitter 16 circuit is in a stand-by mode (box 400) wherein no temperature data is generated or transmitted. During the standby mode (box 400) the power to the temperature sensor/transmitter circuit 16 is off.
Detection of a user by the user detector 302 (box 402) will start a 10 second timer (box 404). Power to the temperature sensor/transmitter 16 will be turned on in response to the detection of a user. Measurement of water temperature (box 406) is then performed and this data is transmitted to the controller 18.
At the expiry of the timer (box 408) the state of the temperature sensor/transmitter 16 circuit is sent back to standby mode 400 where the continued presence of a user will cause the timer to be reset and temperature data transmission to continue. If a user is no longer present the transmission of temperature data stops and the power to the temperature sensor/transmitter 16 is turned off, further enhancing battery life and ensuring that water flow is stopped in the absence of a user.
A flow chart of the operation of the valve unit 18, 20 in the presence of a touchless aerator module 312 is shown in FIG. 6. The valve unit 18,20 has three binary variables, namely, safety mode, "S", valve, "V", and buzzer, "B". The power to the valve unit 18,20 will be turned on (box 420) from standby mode 444 when it starts to receive temperature data (box 422). This causes variable B to be set to 0 and V to be set to 1 (valve open). The battery level is checked (box 426) and if it is not OK, V is set to 0 (valve closed) and a low battery level indicator (i.e. a buzzer) is activated (box 428). If the battery level is OK, the unit checks to ensure temperature data is still being received (box 430). Continued receipt of temperature data causes the data to be read (box 432) and compared to a pre-set maximum allowable temperature (box 434). In the event that the water temperature is over the maximum, V is set to 0, B is set to 1 and a 3 second timer is started (box 438). When the timer reaches 0, V is set to 1 and B is set to 0 (box 442) and the unit checks to ensure temperature data is still being received 430 before reading the temperature again.
If the temperature is under the allowable maximum, the battery level is checked. In the case that the battery level is not OK, V is set to 0 and a low battery indicator is activated (box 440). If the battery level is OK the unit checks to ensure it is still receiving temperature data 430 before reading the temperature again.
In some circumstances it may be desirable to provide a base unit beside the faucet to display the water temperature, using for example an LCD, and/or sound an alarm. Preferably, the base unit and the controller 18/shut-off valve 20 will receive data independently.
Preferably, the valve unit is also provided with a rotary switch which allows the user to set the value of the shut-off temperature at discreet levels. It is also preferable that the valve is a solenoid valve.
Similarly, in order to facilitate installation in an environment where multiple units may be installed in close proximity to one another, the temperature sensor/transmitter 16 and valve unit 20 are preferably provided with a frequency selector in order to enable operation of adjacent units at distinct frequencies so as to minimize the risk of interference.
In certain installations, such as in residential care facilities, old age homes, day care facilities and schools, full time anti-scald protection may be desired. Accordingly, units may be built which do not allow for de-activation of the anti-scald device.
While the above described embodiments contemplate a radio frequency link between the sensor/transmitter 16, controller 18 and valve unit 20, other wireless links such as an LED, infrared or sound links may be utilized.
The system may also contemplates an embodiment in which an ON signal is generated by the user detector in the presence of a user and an OFF signal is generated by the user detector in the absence of a user and these signals are transmitted to a controller/valve system to initiate or interrupt the flow of fluid from the faucet, respectively. Accordingly, this embodiment does not provide anti-scald protection but merely automates the flow of water from a faucet wherein a wireless link is used between a user detector/transmitter and controller/valve system.
The terms and expressions which have been employed in this specification are used as terms of description and not of limitations, and there is no intention in the use of such terms and expressions to exclude any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the claims.
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The present invention relates to a wireless temperature monitoring system useful in reducing the risk of scalding to the users of a faucet. The system includes a temperature sensor/transmitter attached to the end of a faucet which communicates via a wireless link to a controller. The wireless link is particularly advantageous in the installation of the system on a faucet. One embodiment of the system includes a user detector for touchless control of the flow of water from a faucet. The invention may also provide a digital display with audio and/or visual alarms to indicate if a pre-set maximum temperature has been exceeded and a shut-off valve to interrupt flow of water to the faucet.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to improved endoscopes and endoscopic methods employing phase conjugate imaging techniques.
2. Discussion of the Prior Art
Endoscopic or least invasive surgery has many advantages over conventional "open" surgery. Patients who have undergone endoscopic surgery rather than open surgery experience vastly less trauma and much faster recovery, leading to improvement in quality and reduction in cost of health care. These advantages have spurred extensive development of endoscopes.
The term "endoscope" as used herein refers to an elongated optical probe capable of presenting a visible image of the interior of a body cavity, joint, organ or the like to a surgeon by way of an eyepiece or on a video screen. The endoscope is typically introduced into the body cavity through a bore in another device also typically referred to in the art as an endoscope (or as an endoscope sheath) including a light source as well other bores for introducing surgical instruments, water, air, suction and the like. Endoscopes as optimized for various surgical procedures are referred to as arthroscopes, colonoscopes, bronchoscopes, hysteroscopes, cystoscopes, sigmoidoscopes, laparoscopes and ureterscopes.
Endoscopes typically consist of a distal objective for forming an optical image of the interior of the body cavity, bone, joint or organ, a transfer module (sometimes termed a "relay section") for transmitting the image from the distal end of the probe to its proximal end, and an ocular at the proximal end of the transfer module for presenting the image to an eyepiece, a video camera or the like. Typically the ocular contains the movable focusing components of the endoscope.
The art has for some years sought to develop a suitable disposable endoscope. The surgical requirement of absolute sterility is difficult to satisfy with conventional endoscopes as these complex instruments are not readily amenable to conventional sterilization techniques. The spread of infectious disease is of particular concern and requires that care and caution be employed during the sterilization process. Accordingly there is a strong need for a suitable disposable endoscope, that is, one made sufficiently inexpensively as to be cost effective for disposal after single-patient use.
One of the difficult tasks in designing a satisfactory endoscope is that of designing the transfer module. The transfer module must be capable of transmitting the image formed by the objective to the ocular without significant loss of brightness or sharpness. Early designs included numerous glass refractive elements, each requiring extensive polishing and costly anti-reflection coatings. The high cost of manufacture precludes use of these designs for disposable endoscopes.
Accordingly, it is an object of the invention to provide an endoscope which can be manufactured inexpensively so as to be cost-effective for disposability after single-patient use, while not suffering optical performance losses when compared to conventional endoscopes employing complex designs too costly for disposable, single-patient use.
The angular width of the field of view of an endoscope is equivalent to the solid angle from which light rays are gathered by the objective. Typically it is desired that the field of view be centered about a viewing axis forming an angle to the axis of the elongation of the probe. In this way a greater effective field of view is provided; that is, by rotating the probe about its axis of elongation, the surgeon can scan over a larger effective field of view within a body cavity or the like. In order that the axis of the field of view forms an angle with the axis of the probe, a prism may be disposed at the distal tip of the endoscope. Such prisms typically comprise several internally reflecting surfaces to direct light rays received along the axis of the field of view along the axis of the probe. The manufacture of such prisms has in general involved exacting assembly of several costly glass elements, rendering probes incorporating prisms relatively complex and expensive. It will be apparent that an endoscope with a wide field of view is more useful than one with a narrow field of view. Accordingly, it is an object of the invention to provide an endoscope having a relatively wide field of view without requiring a prism at the distal tip of the endoscope probe and eliminating any necessity of rotating the endoscope.
As examples of prior art endoscope probes illustrating one or more of the deficiencies of the prior art mentioned above, reference may be made to the following patents.
U.S. Pat. No. 3,257,902 to Hopkins shows an optical system for an endoscope employing a number of cylindrical rod-like glass lenses in the transfer module of the probe. This design has the deficiency that the rod-like lenses are costly to form, as many individual glass surfaces must be separately polished.
U.S. Pat. No. 4,025,155 to Imai shows an improvement on the Hopkins transfer module employing field and relay lenses. The Imai transfer module is also relatively complicated and difficult to construct.
U.S. Pat. No. 4,138,192 to Yamasita shows a forward viewing optical system for an endoscope including a prism as generally discussed above. The Yamasita prism is relatively complex and expensive to manufacture.
U.S. Pat. No. 4,165,917 to Yamasita et al shows objective assemblies for endoscopes which are relatively complex and costly to manufacture.
U.S. Pat. No. 4,168,882 to Hopkins shows an improvement on the original Hopkins transfer module design of U.S. Pat. No. 3,257,902 referred to above. The improved Hopkins design is also unduly complex and expensive.
U.S. Pat. No. 4,195,904 to Yamasita shows a complicated prism structure for providing a retrograde viewing system for endoscopes.
U.S. Pat. No. 4,755,029 to Okabe shows an objective lens for an endoscope including an element formed of a gradient refractive index (GRIN) material. This design reduces the number of elements in the endoscope at the expense of increasing their complexity of manufacture by use of the GRIN material.
Finally, U.S. Pat. No. 4,964,710 to Leiner shows a transfer module for an endoscope using plano-ended glass rods and molded plastic lenses intermediate the glass rods.
More recently, there has been filed commonly-assigned U.S. patent application Ser. No. 07/833,416 in the name of Broome for a disposable endoscope. The disclosure in that patent application is incorporated herein by reference and relates to an endoscope design wherein substantially all elements of the elongated probe having curved surfaces are molded of plastic such that substantially all the glass elements are plano-ended. This design substantially simplifies manufacture of the endoscope and is cost-effective for single-patient disposable use. The Broome design further features a molded plastic prism for increasing the effective field of view of the endoscope without involving a costly multiple-element glass prism. The disposable probe of the Broome endoscope is designed to be used in conjunction with a non-disposable focusing ocular comprising several glass elements. Despite the substantial improvement provided by the Broome design, there remains as always a desire for further simplification and reduction in cost of the endoscope.
The present invention seeks to further simplify the endoscope design disclosed in the aforesaid patent application and other prior art endoscope designs by utilizing phase conjugate imaging techniques. In essence, a phase conjugate optical filter is a device capable of receiving a number of rays at random angles of incidence and redirecting those rays along paths essentially inverse to the paths of the incident rays. A reflective phase conjugate filter reflects the incident rays precisely back along their incident paths, while a transmissive phase conjugate filter retransmits the incoming rays along ray paths making angles of transmission, with respect to a plane of symmetry of the phase conjugate transmissive element, equal to the angles of incidence at which the corresponding incoming rays meet the plane of symmetry.
An example will assist in understanding the operation of a phase conjugate optical filter.
Reflection takes place at an ordinary plane mirror such that the angle of reflection of the exit ray is precisely equal to the angle of incidence of the incident ray. Thus, if one looks in a plane mirror, one's eye detects rays of light from objects having been incident on the mirror at precisely the angle from which the rays were reflected by the mirror. Accordingly, one sees one's own eye in a plane mirror only when directly looking at the mirror; that is, only then is the incident ray at precisely 90° to the surface of the mirror, so that the angles of incidence and reflection are both 90° . Objects off the perpendicular are seen when a ray from the object is incident on the mirror at precisely the same angle as the ray reflected from the mirror meeting one's eye. For this reason it is possible to see objects imaged in a mirror; that is, because there is a precise one-to-one correspondence between the rays incident on the mirror and the rays received by the mirror from one's eye, an image can be formed. When such a one-to-one relation does not exist, an image cannot be formed. For example, when rays from an object are received by the eye from a variety of directions, a diffuse image is formed, such as from frosted glass or a similar diffusive surface.
By comparison, a phase conjugate reflector has the property of reflecting an incident light ray received from substantially any incident angle back precisely along the incident ray path. A bicycle reflector is a simple example of a phase conjugate reflector. Light incident on the bicycle reflector from any direction is reflected back toward the source. Thus, if one is driving a car at night with the headlights illuminated, hence providing a directional beam, one can see the light reflected from a bicycle reflector even though the headlight beam is not perpendicular to the surface of the reflector. It will be intuitively apparent that if the bicycle reflector were replaced by a plane mirror, one would only see reflection of light from one's headlights under very limited circumstances, that is, when the light beam from the headlights happened to be incident on the mirror substantially perpendicular to its surface, so that the reflected light would return essentially along the path of the incident beam.
A bicycle reflector exhibits the phase conjugate property by provision of multiple-faceted reflector structures, wherein three reflecting planes meet at perpendicular angles to one another, forming "internal corners". Such internal corners have the phase conjugate property, i.e., a light ray incident at any angle on an internal corner formed of three reflectors meeting one another at right angles will reflect back along the direction of the incident ray. The same principle is used in radar reflectors commonly mounted on wires or like structures of small cross-section to ensure that a radar receiver "sees" the structure, and in other applications.
The phase conjugate property is also exhibited by certain photorefractive solids and gases under appropriate circumstances. These instances of the phase conjugate property do not involve internal reflection, but involve stimulated periodic spatial variation in the optical characteristics of the medium. For example, phase conjugation can be performed by "stimulated Brillouin scattering" and by "optical 4-wave mixing in non-linear media". See generally Yeh, "Photorefractive Phase Conjugators", Proceedings of the IEEE, vol. 80, no. 3, March 1992. This paper fully discusses the theoretical basis of phase conjugation and gives useful examples of materials which can be employed or stimulated to exhibit this property.
The properties of phase conjugators are also discussed in Shkunov et al, "Optical Phase Conjugation", Scientific American December 1985, p. 54-59. Shkunov et al provides an example of the property of phase conjugate optical elements. A coherent light beam passed through a diffusive medium such as frosted glass, if reflected from a phase conjugate reflector and passed back through the same medium, regains its original properties.
The only publication known to the present inventor specifically discussing the application of phase conjugate techniques to endoscopes is U.S. Pat. No. 4,928,695 to Goldman et al. Goldman et al disclose a system for treating diseased tissue within the body. An imaging portion of this device involves passing light distally through an endoscope along a first fiber optic. The light is reflected from the body tissue of interest to pass proximally through the endoscope along a second fiber optic, is reflected by a phase conjugate reflector, passes distally back through the second fiber optic, is reflected a second time from the body tissue, and returns proximally through the first fiber optic to be imaged on a viewing screen. The Goldman et al patent is not clear on the precise reasons for this sequence. The presence of the phase conjugate reflector in the image path between the proximal and distal traversals of the second fiber optic by the reflected light serves merely to return any image of the object to the vicinity of the object. No means is shown for forming an image of the object, or for transmitting such an image to an eyepiece or video imaging chip. Accordingly, the disclosure in Goldman et al does not teach a device capable of satisfying the aforementioned objects of the present invention.
As mentioned above, in one form of optical phase conjugation a so-called four-wave mixing technique is employed. This technique requires a coherent light source, i.e., a laser or the equivalent. It would obviously be desired to provide an endoscope not requiring such a complication. Other phase conjugate techniques employ holographic techniques also requiring a coherent light source such as a laser. For example, U.S. Pat. No. 4,921,333 to Brody et al discusses phase contrast image microscopy using optical phase conjugation. Brody employs holographic phase techniques, thus requiring a coherent light source, and relates to imaging of "transparent phase objects". It would seem that such a microscope would not be amenable to endoscopic use.
Other patents directed to the use of phase conjugation for various purposes include U.S. Pat. No. 4,500,855 to Feinberg, U.S. Pat. No. 4,750,818 to Cochran, U.S. Pat. No. 4,927,251 to Schoen, U.S. Pat. No. 4,938,596 to Gauthier et al, U.S. Pat. No. 5,018,852 to Cheng et al and U.S. Pat. No. 5,059,917 to Stevens. None of these patents relate directly to endoscopic imaging, nor appear amenable to satisfaction of the objects of the invention. Finally, U.S. Pat. No. 4,945,239 to Wist et al teaches a transilluminating system for detecting breast cancers and the like employing a phase conjugate technique, apparently to improve the image. The Wist et al device does not appear suitable for endoscopic image formation.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an improved method and apparatus wherein the unique properties of phase conjugative optical elements are employed to yield an endoscope of simplicity and low cost, so as to be cost-effective for single-patient disposable use, being readily manufacturable and suffering no performance disadvantage compared to prior optical endoscopes.
It is a further object of the invention to provide a method and apparatus employing phase conjugative optical techniques as above and furthermore providing a relatively wide effective field of view, eliminating any need for complex prisms or the like in endoscopes.
These and other objects of the invention and needs of the art are satisfied by the endoscope of the present invention. An elongated probe includes a first optically transmissive element extending from the distal tip of the endoscope to an intermediate location. A phase conjugative optical filter element is located at the intermediate location, and a second optically transmissive element extends from the intermediate location to the proximal end of the endoscope. The first and second optically transmissive elements are optically identical and are spaced by the phase conjugative element. Therefore, rays exiting the first transmissive element and incident on the phase conjugate filter are retransmitted by the phase conjugate filter along paths inverse to the incident paths. Any distortion or internal reflection experienced by light transmitted along the first transmissive element is effectively reversed during its transmission along the second element. Accordingly, light rays exit the proximal tip of the endoscope probe bearing the precise relationship to one another as that obtained upon their entry at the distal tip. Conventional image formation techniques can be employed to form an image on an eyepiece or video chip juxtaposed to the proximal end of the endoscope, that is, essentially as if the image were being formed at the distal tip of the endoscope.
An endoscope including a phase conjugate element according to the invention may include objective and ocular lenses of identical optical properties at the proximal and distal tips of the probe, respectively. Such lenses would typically serve to increase the light gathering power of the probe. Intermediate lenses may be disposed on either side of the phase conjugate element and must be optically identical. The first and second transmissive elements may each include a single optical fiber having a core and a cladding meeting at a distinct interface; a bundle of optical fibers; or a plurality of glass rods interspersed with molded glass lenses as, for example, described in the aforementioned Broome patent application. However, in each case the first and second transmissive elements must be optically identical in order that the phase conjugate element can in effect optically invert light rays entering the distal tip of the probe and retransmit the rays to the proximal end of the probe. Identical transmissive paths are thus provided so that light traverses the transmissive paths in a manner optically equivalent to passing the light beams twice through the same optical medium, e.g., as in the example from the Shkunov article, supra.
Other objects and advantages of the present invention will become apparent from the following description of the preferred embodiments taken in conjunction with the accompanying drawings wherein like parts in each of the several figures are identified by the same reference characters.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in longitudinal section of an endoscope according to the invention extending from a portal in a patient's body to a surface of an interior organ or the like to be imaged, together with associated equipment for forming a visible image.
FIG. 2 is an enlarged broken view in longitudinal section of the endoscope probe of FIG. 1 illustrating paths of the optical rays therein.
FIG. 3 is a broken view in longitudinal section of a further embodiment of the invention employing a reflective phase conjugate element.
FIG. 4 is a broken view in longitudinal section of a further embodiment of the invention employing "binary optic" phase conjugate elements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of an endoscope 10 employing phase conjugate imaging techniques according to the invention is shown in FIG. 1. Endoscope 10 comprises an elongated tube extending into a body cavity indicated generally at 12 through a portal 14, so that the distal tip of the endoscope is juxtaposed to an internal body part, organ, bone or the like to be examined, as indicated generally at 16. A light source 18 may be integrated with the endoscope probe 10 as shown, or may be provided separately. As indicated above, the endoscope of the invention may slide within a bore in a larger instrument, possibly also including bores for surgical instruments, irrigation, suction, or the like. In the embodiment shown, power for light source 18 is provided by power supply 20. The light emitted by source 18 is incoherent; that is, light source 18 need not comprise a laser or similar source of coherent radiation. Accordingly, light from source 18 is emitted over a wide angle of illumination and is reflected in numerous different directions from the object, i.e., from body part 16. It is the function of the endoscope to collect these dispersed light rays such that a visible image can be formed.
An objective lens 22 may be provided at the distal tip of the endoscope to gather light rays from the object. However, contrary to conventional teachings of the art, objective lens 22 is not required to form an image of the object at or near the distal tip of the endoscope. The image may be formed directly on a charge-coupled diode (CCD) chip 34 for generating a video signal for display. If an objective lens 22 is provided, an optically identical ocular lens 46 must be provided, so that the light transmissive paths are optically identical. Optionally, light exiting the proximal tip of the endoscope is transferred to a second ocular lens 32 at the ocular or proximal end of the endoscope. Optional ocular lens 32 forms an image by focusing light rays onto an eyepiece (not shown) for direct viewing, or onto CCD chip 34. Ocular lens 32 may also be employed to scale the image to the active surface of chip 34, or to collimate the rays so as to appear at infinity for convenience in direct viewing.
Thus, according to the present invention, light reflected from the body part 16 need not be imaged at the distal tip of the endoscope probe as in the prior art. That is, in the prior art, an objective lens forms an image at the distal tip of the endoscope; a transfer module transfers the image from the distal tip to the proximal end, typically forming intermediate images at several points along the length of the probe; and an ocular presents the image to an eyepiece, video imaging chip or the like. According to the present invention, while a lens 22 as shown may be provided at the distal tip of the endoscope 10 to improve the light gathering properties of the endoscope, an image per se is not necessarily formed at the tip of the endoscope.
According to the invention, light rays enter the distal tip of the endoscope 10 from all directions within a wide solid angle, such that a prism is not required to provide a wide field of view. Rays entering the endoscope at its distal tip traverse first transmissive element 24 and are redirected along an inverse path by phase conjugate filter 26. Rays transmitted through filter 26 pass along a second transmissive member 28 to the proximal tip 30 of the endoscope 10. The rays of light exiting the proximal tip 30 will form an identical image of the object without an ocular lens. As mentioned, an ocular lens 32 at proximal tip 30 may be used to focus the rays to form an appropriately sized image on CCD chip 34. CCD chip 34 provides an output signal to a video driver 36, providing a conventional video signal to a video display 38. Ocular lens 32 may also collimate the light rays exiting the proximal tip 30 of the endoscope, so as to provide an image appearing at infinity when directly viewed by means of an eyepiece.
As noted, the first and second transmissive members 24 and 28 must be identical, and may each comprise a single fiber optic having a core 40 and a cladding 42 as shown. Alternatively members 24 and 28 may each comprise a bundle of relatively smaller fiber optics (as discussed in connection with FIG. 4), or a series of rods and lenses as exemplified generally by the prior art referred to above and preferably as disclosed in the Broome patent application Ser. No. 07/833,416. The basic function of the transmissive members 24 and 28 is simply to carry the light rays entering the distal tip of the endoscope to the intermediate phase conjugate filter 26 and thence to the proximal tip 30 with minimum loss in brightness and definition while providing substantially identical optical properties. As mentioned above, if an objective lens 22 is provided, an optically identical lens 46 must be provided to ensure the light transmissive paths on either side of the phase conjugate element are optically identical.
As mentioned, light rays reaching the intermediate phase conjugate filter 26 do not necessarily define an intermediate image but travel in numerous directions determined by the angles of the rays entering the distal tip of the endoscope and the optical characteristics of the transmissive member 24. See FIG. 2, showing in essentially schematic form the random directions of rays entering first transmissive member 24. Such essentially unfocused, random rays traverse transmissive member 24 and enter a transmissive phase conjugate filter 26. As discussed above, a phase conjugate filter has the unique property of emitting rays precisely optically inverse to the incident rays. In the case of a reflective phase conjugate filter (such as a bicycle reflector), the rays are emitted precisely along the path of the corresponding incident rays; in the case of the phase conjugate transmissive filter 26, the angle of exit of the transmitted rays with respect to a plane of symmetry 44 (FIG. 2) is precisely the same as the angle of incidence of the incident rays on plane 44. Therefore, rays exiting the phase conjugate transmissive filter 26 are the "inverse" of those incident on phase conjugate transmissive filter 26.
Accordingly, when the rays exiting filter 26 then traverse a second transmissive member 28 optically identical to the first transmissive member 24, the rays exit the proximal end 30 of the endoscope bearing precisely the same relation to one another as had obtained upon their incidence on the distal tip of the endoscope. Therefore, ocular lens 32 (if employed) may be effectively optically identical to an objective lens for disposition at the distal tip of the endoscope; that is, lens 32 may be designed as if the ocular lens 32 and CCD chip 34 were disposed at the distal tip of the endoscope. Ocular lens 32 may be provided with axial positioning adjustment means (not shown) for focusing the image on chip 34. Ocular lens 32 and chip 34 may also be provided with angular positioning adjustment means (not shown), to scan the entire hemisphere of the object field 16.
As noted, an endoscope employing a phase conjugate transmissive member according to the invention thus requires that the optical paths between the distal tip of the endoscope and the phase conjugate filter 26 and between filter 26 and the ocular lens 32 be identical. Accordingly, if an objective lens 22 is used to gather additional light (or to form an image), an optically identical lens 46 must be disposed at the proximal tip of the endoscope. Likewise, if it is found convenient to employ a lens 48 between the first transmissive member 24 and the phase conjugate filter 26, an optically identical lens 50 must be disposed between the phase conjugate filter 44 and the second transmissive member 28. Lenses 48 and 50 may be useful, for example, to match the effective apertures of the transmissive members 24 and 28 to the aperture of the phase conjugate transmissive member 44.
FIG. 2 shows optical rays entering the endoscope 10 through an objective lens 22 and passing through a first transmissive member 24, again configured as a single fiber optic member having a core 40 and a cladding 42. Rays reflect at various points along the interface between the core and the cladding as shown. The rays then enter phase conjugate transmissive filter 26 and are effectively optically inverted. Rays exiting filter 26 then enter a second transmissive member 28, optically identical to the first transmissive member 24, along ray paths making precisely the same exit angle with respect to the plane of symmetry 44 of filter 26 as made by the incident rays from transmissive member 24. Accordingly, if a lens 46 optically identical to the objective lens 22 is placed at the proximal tip 30 of the endoscope 10, rays exiting the endoscope will have precisely the same relation to one another as the rays entering the endoscope and accordingly can be imaged on the surface of CCD chip 34 to provide a suitable video signal. CCD chip 34 could be replaced by a conventional eyepiece, as is conventional in the art. Again, it will be appreciated that the object 16 viewed by objective lens 22 will be imaged exactly by lens 46 at the proximal tip of the endoscope, without the necessity of optional ocular lens 32.
FIG. 3 shows a further embodiment of the invention wherein the endoscope 10' includes a reflective phase conjugate element 50, a one-way mirror 51 and a plane mirror 52. In this embodiment of the invention, the first transmissive element 24 is off-axis with respect to the second transmissive element 28, while the reflective phase conjugate filter 50, one-way mirror 51 and plane mirror 52 are disposed such that rays are directed correctly from the first transmissive element 24 to the second 28. That is, light rays exiting transmissive member 24 pass through one-way mirror 51, are incident on and are redirected by reflective phase conjugate element 50, reflect from one-way mirror 51 and plane mirror 52, and enter second transmissive member 28. The transmissive elements 24 and 28 must again be optically identical; if an objective lens 22 is used an optically identical lens 46 must be provided at the ocular. In order that the optical path lengths between transmissive elements 24 and 28 and reflective phase conjugate element 50 are identical, element 24 is spaced axially from phase conjugate element 50, as shown. Similarly, if lenses are disposed between the transmissive elements 24 and 28 and the phase conjugate reflective filter and mirror 52 respectively, these too must be optically identical. As indicated above, the transmissive elements 24 and 28 may be solid fiber optic members having a core 40 and a cladding 42 as shown, may comprise a bundle of optical fibers, or may be a sequence of rods and intermediate lenses preferably as discussed in the aforementioned Broome patent application.
As discussed above, the prior art shows a number of different types of phase conjugate optical elements, many of which may be adapted for employment in the several embodiments of the endoscope of the invention. As also indicated above, the preferred embodiment of the invention includes a passive phase conjugate optical filter element, that is, a filter not requiring excitation by a laser beam or the like, as found in certain four-wave mixing phase conjugate elements, or in phase conjugate elements employing Brillouin scattering. Accordingly, solid crystals of phase conjugate materials are in general to be preferred for the phase conjugate filter, whether disposed in a transmissive or reflective configuration.
A further phase conjugate filter suitable for practice of the invention employs so-called "binary optic" technology. See Veldkamp et al, "Binary Optics", Scientific American, May 1992, p. 92-97. As discussed by Veldkamp et al, binary optic elements are thin film optical elements employing diffraction rather than refraction for appropriately bending light beams. Binary optic fabrication technology uses the same sequence of masking, reacting, and etching of planar members used to form electronic circuit elements, and many of the same semi-conductor materials. See U.S. Pat. No. 4,895,790 to Swanson et al. Preliminary design studies indicate that binary optic elements can be fabricated to perform the functions of phase conjugate filters. Moreover, the binary optic elements can be fabricated directly on the ends of a bundle of fiber optic elements making up the first and second transmissive members. Alternatively, the binary optic phase conjugate filters can be assembled to a bundle of such fiber optic elements. An exemplary design of an endoscope probe employing such a binary optic phase conjugate filter is shown in FIG. 4.
Referring to FIG. 4, in a further embodiment of endoscope 10", phase conjugate imaging is performed by a plurality of binary optic elements 56 formed on either or both opposed ends of pairs of fiber optic elements 58 formed into bundles so as to collectively constitute the first and second transmissive elements 24 and 28. As indicated by Veldkamp et al, supra, it is possible to form such binary optic elements 56 directly on the ends of fiber optics 58 and then bundle the fiber optics together to form the transmissive members. The binary optic elements may be fabricated on a planar member with the planar member disposed between the opposed ends of the bundles of fiber optics. The binary optic elements may also be fabricated as reflective rather than transmissive phase conjugate members. Diffractive binary optic lenses can also be employed in place of refractive lenses 22, 48, 50, 46 and 32. See Veldkamp U.S. Pat. No. 4,994,664.
The transmissive elements can also comprise solid rods with binary optic members between adjacent rods, that is, in lieu of the intermediate lenses between rods as disclosed in the Broome patent application incorporated by reference above. It is also within the scope of the invention to employ plural phase conjugate filters at spaced locations along the endoscope probe, for example, to limit distortion along a lengthy bundle of fiber optics.
Each of these alternatives is considered to be within the scope of the invention where technically feasible and where not excluded by the scope of the appended claims. Therefore, inasmuch as the present invention is subject to many variations, modifications and changes in detail, it is intended that all subject matter discussed above or shown in the accompanying drawings be interpreted as illustrative only and not be taken in a limiting sense.
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An improved endoscope employing phase conjugate imaging principles includes a first transmissive member for transmitting light rays received at a distal tip of the endoscope to an intermediate filter location. A phase conjugate filter at the intermediate filter location redirects the rays, according to the precise inverse of their incoming direction, along a second transmissive member optically identical to the first. Rays exiting the endoscope bear the exact relation to one another as when entering the tip of the endoscope and may be imaged or displayed on an eyepiece or video screen.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a steering assembly for use in a bicycle, tricycle or similar vehicle. The invention has particular application to steering assemblies incorporating threadless steerer tubes.
2. Description of the Related Art
Prior art bicycle steering assemblies commonly include a front wheel mounted in a fork assembly. The fork assembly has a steerer tube which extends upwardly through a head tube mounted to the bicycle frame. The upper end of the steerer tube projects past the top of the head tube. The steerer tube is pivotally mounted to the head tube by bearing assemblies at either end of the head tube. During normal use the bearing assemblies may be exposed to very large forces. The bearing assemblies typically each comprise upper and lower races separated by a plurality of ball bearings which roll on bearing surfaces of the upper and lower races.
Applying the correct amount of pre-load force to the bearing assemblies is important to the proper functioning of such prior art steering assemblies. If there is too little pre-load then the bearings will be loose and incapable of transmitting forces from the steerer tube to the head tube without suffering damage. If the bearings are very loose then steering control may be adversely affected. Too much pre-load force can damage the bearings, cause the bearings to bind and make the steering action rough.
In so-called "threaded" prior art steering assemblies the steerer tube is secured by a nut threaded on an externally threaded section of the steerer tube. The lower surface of the nut bears on the upper race of the upper bearing assembly. The lower race of the lower bearing assembly is mounted to the steerer tube. In these steering assemblies, bearing pre-load is adjusted by altering the tightness of the nut. A separate lock-nut is generally provided to lock the nut in position after the bearing pre-load has been set. Such assemblies have the disadvantage that it is difficult to properly set bearing pre-load because tightening the lock-nut generally turns the nut sufficiently to alter the bearing pre-load. With this design it is also difficult to prevent the nut from coming loose during use. Furthermore, providing external threads on the steerer tube is an expensive manufacturing step.
U.S. Pat. No. 5,095,770, Rader III shows a bicycle steering assembly in which the steerer tube is "threadless", that is, it has a smooth outer surface with no external threads. The top end of the steerer tube is threaded internally. An adjustment screw is threaded into the top end of the steerer tube. The adjustment screw applies pressure to the top race of the upper bearing assembly via a mounting sleeve and a tapered compression ring. In a bicycle, handlebars are mounted at one end of a stem attached to the mounting sleeve. Steering assemblies according to the Rader III design have recently become very popular, especially in high quality all terrain bicycles.
In the Rader III assembly, the mounting sleeve is clamped externally to the steerer tube. The mounting sleeve must be fixed relative to the steerer tube because the bicycle handlebar stem is mounted to the mounting sleeve. It is not possible to affix the mounting sleeve by clamping it inside the bore of the steerer tube because of the adjustment screw which threads into the upper end of the steerer tube.
The need to clamp the sleeve externally to the steerer tube causes the Rader III design to have some disadvantages. Fixing the sleeve to the steerer tube generally requires either protruding clamping bolts, which can injure a rider in a fall, or alternative clamping arrangements which are either structurally weak or can cause damage to the steerer tube if over-tightened.
A further disadvantage of the Rader III design is that it is somewhat difficult to properly set the bearing pre-load. This is because there is friction between the sleeve and the steerer tube. To set bearing pre-load, the sleeve must be loosened and slid upward and then the adjustment screw must be tightened just enough to provide the correct bearing pre-load. If the adjustment screw is over-tightened then the adjustment screw must be loosened, the sleeve must be slid upward and the process repeated. Bearing pre-load cannot be reliably reduced by simply loosening the adjustment nut because the sleeve might not slide freely up the steerer tube when the adjustment nut is loosened.
U.S. Pat. No. 5,303,611 Chi discloses an upper steering assembly for a bicycle in which an externally threaded member is clamped to the outside surface of a steerer tube. A locking nut is threaded on the externally threaded member. Bearing pre-load can be set by turning the locking nut relative to the externally threaded member. This design has several parts which are expensive to machine.
U.S. Pat. No. 5,201,242, Chi and U.S. Pat. No. 5,319,993 disclose designs for a bicycle steering assemblies which are similar to the Rader III design but do not require internal threads on the bicycle steerer tube. Like the Rader III design, these designs use stem assemblies which clamp to the outside of the steerer tube. These designs suffer from disadvantages similar to those of the Rader III design.
U.S. Pat. No. 5,303,611, Chi discloses a mechanism for adjusting pre-load on steering bearings in a bicycle equipped with a threadless steerer tube. Chi provides a compression socket which clamps to the steerer tube. The compression socket has external threads around its lower periphery. A rotational socket is threaded to the compression socket. Pre-load on a bearing assembly mounted beneath the rotational socket may be adjusted by turning the rotational socket with respect to the compression socket. The Chi design includes several relatively complicated parts and requires handlebars to be mounted to the steerer tube with separate components.
SUMMARY OF THE INVENTION
An object of this invention is to provide a handlebar stem which is useful with a threadless steerer tube and yet overcomes some of the above-noted disadvantages of the prior art.
This invention provides an improved steering assembly for a vehicle. The steering assembly comprises: a head tube connected to a frame of the vehicle; a steerer tube having a wheel mounted at one end thereof and a second end extending through the head tube and projecting past an upper end of the head tube; a bearing assembly at the upper end of the head tube; and, a stem assembly connected to the steerer tube. The improvement is that the stem assembly comprises: a member (or plug) slidably engaged in a bore of said steerer tube; mounting means on the member to affix the member within the bore; a sleeve connected to the member and extending over an outer surface of the steerer tube; and extension means on the sleeve for applying longitudinal pre-load force to the bearing assembly.
Another aspect of the invention provides a stem assembly for use in a bicycle having a threadless steerer tube. The stem assembly comprises: a cap member; a rod slidably engageable in a bore of a steerer tube and affixed to the cap member; mounting means on the rod for affixing a first end of the rod within the bore of the steerer tube; a cylindrical sleeve mounted to the cap member concentric with the rod, the sleeve slidably engageable around an exterior surface of the steerer tube, the sleeve and the rod defining a deep annular channel therebetween for receiving an end of the steerer tube; attachment means on the sleeve for attaching handlebars to the stem assembly; and extension means at an end of the sleeve away from the cap member for applying a longitudinal force to a surface adjacent the end of the sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the invention will now be described with reference to the following drawings in which:
FIG. 1 is a section through a steering assembly according to the invention; and
FIG. 2 is an exploded view of the steering assembly of FIG. 1; and,
FIG. 3A is a plan view of a locking nut for use in the invention and FIG. 3B is a plan view of a compression ring for use with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show a steering assembly 10 according to the invention. Steering assembly 10 comprises a head tube 12 attached to the frame 14 of a bicycle. A steerer tube 16 is attached to the crown of front fork 18 and extends upwardly through head tube 12. Lower and upper bearing assemblies 20, 23 maintain the axis of steerer tube 16 fixed relative to head tube 12 but permit steerer tube 16 to pivot within head tube 12. A wheel 17 is mounted to front fork 18. The wheel may be steered by pivoting steerer tube 16 in head tube 12.
Although steerer tube 16 could have external threads and still be used with the invention, steerer tube 16 preferably has a smooth cylindrical outer surface. Lower bearing assembly 20 comprises first and second races 20A, 20B and a plurality of ball bearings 21 between races 20A and 20B. First race 20A is mounted to steerer tube 16 and second race 20B is on the lower end of head tube 12. Upper bearing assembly 23 similarly comprises first and second races 23A and 23B with ball bearings 21 disposed between the first and second races. First race 23A is on the upper end of head tube 12. Second race 23B sits on top of first race 23A and is compressed toward lower race 23B by a stem assembly 40. Bearing assemblies 20, 23 may use roller, cartridge, thrust or needle bearings instead of ball bearings 21 without departing from the scope of the invention.
Preferably upper bearing assembly 23 is constructed in the manner of the upper bearing assembly described in U.S. Pat. No. 5,095,770 which is incorporated herein by reference. Such bearing assemblies are available from Dia-compe U.S.A. Inc. of 355 Cane Creek Road, Fletcher N.C., U.S.A. 28732 as part of that company's AHEADSET™ bicycle head sets. Second race 23B has a central aperture 24 having an inner diameter somewhat greater than the outer diameter of steerer tube 16. An angled annular contact surface 25 is provided around the upper periphery of aperture 24. An annular split compression ring 27 is provided between stem assembly 40 and second race 23B. Compression ring 27 has a top surface 29, an inner surface 30, and a tapered contact surface 31.
Stem assembly 40 is mounted to the upper end of steerer tube 16. Stem assembly 40 has a plug (or rod) 42 which projects downwardly from a top cap 43 into the bore of steerer tube 16. Rod 42 is preferably cylindrical and is preferably slightly smaller in diameter than the interior diameter of steerer tube 16 so that rod 42 can be slid into the bore of steerer tube 16 without binding. Rod 42 may be solid or may be a section of tubing attached to top cap 43.
Stem assembly 40 is affixed to steerer tube 16 by a wedge clamp 44 mounted at the lower end of rod 42. Wedge clamp 44 comprises a wedge 46 which abuts an inclined engagement surface 47 on the lower end of rod 42 and a bolt 48. Bolt 48 passes through a clearance hole in top cap 43 and rod 42 and threads into wedge 46. Preferably the head of bolt 48 is recessed below the upper surface of top cap 43 so that it does not present a projection which could injure a rider in a fall.
Tightening bolt 48 causes wedge 46 to slide along inclined engagement surface 47. In so moving, the outer surface 49 of wedge 46 is forced radially outward against the inner wall of steerer tube 16 thereby firmly fastening rod 42 within the bore of steerer tube 16. Alternative secure mounting means for firmly fastening rod 42 in place inside the bore of steerer tube 16 such as other known types of expansion bolt may be used in place of wedge clamp 44. Preferably the mounting means are internal to the bore of steerer tube 16.
Stem assembly 40 further comprises an outer sleeve 50 which extends downward from top cap 43 over the outer surface of steerer tube 16. Sleeve 50 and rod 42 together define a channel 52 which receives the upper end of steerer tube 16. Preferably sleeve 50 extends to a point approximately even with wedge clamp 44. Sleeve 50 then reinforces the outside of steerer tube 16 in the vicinity of wedge clamp 44. Preferably, steerer tube 16 is a slip fit inside sleeve 50 so that sleeve 50 can be slid over steerer tube 16 until the upper end of steerer tube 16 is in contact with top cap 43. It can be appreciated that it is unnecessary to clamp sleeve 50 to the exterior surface of steerer tube 16 because sleeve 50 is rigidly mounted to steerer tube 16 by wedge clamp 44 which attaches inside the bore of steerer tube 16.
Handlebars 55 are at the end of a stem 58 which is mounted to sleeve 50, for example by welding. Top cap 43, rod 42, sleeve 50, and stem 58 are all parts of a single unitary component which may be fabricated, for example, by welding, casting, brazing, adhesive bonding, pinning, or any other known process compatable with the materials being used.
Sleeve 50 has external threads 60 in a region near its lower edge. A locking nut 62 is threaded on threads 60. A lower engagement surface 64 of locking nut 62 bears against top surface 29 of compression ring 27. Locking nut 62 preferably has an inwardly projecting flange 68 and engagement surface 64 extends onto flange 68 to contact fully the top surface of compression ring 29. Flange 68 also serves to prevent locking nut 62 from being screwed too far up collar 50. Threads 60 preferably have a fine pitch to allow accurate adjustment of bearing pre-load.
Pre-load on bearing assemblies 20 and 23 may be adjusted by turning locking nut 62. Locking nut 62 is preferably provided with locking means. Suitable locking means may be provided by making a gap 66 in locking nut 62 and providing a set screw 65 which passes through a clearance hole on one side of gap 66 and is threaded into lock nut 62 on the other side of gap 66. Locking nut 62 can then be locked in place by tightening set screw 65 to clamp locking nut 62 around threaded region 60. Alternative locking means such as one or more radially aligned set screws, or a vertically oriented set screw for clamping together the edges of a horizontal slit in locking nut 62, may be provided in substitution for gap 66 and screw 65.
If an upper bearing assembly is used which does not require a compression ring 27 then lower engagement surface 64 may bear directly on second race 23B of upper bearing assembly 23.
Steering assembly 10 can be assembled by: inserting steerer tube 16 through head tube 12; placing stem assembly 40 on top of steerer tube 16 with rod 42 fully inserted into the bore of steerer tube 16; tightening bolt 48 to fix stem assembly 40 in place; adjusting bearing pre-load by means of locking nut 62; and locking nut 62 in place with screw 65. It can readily be appreciated that, if locking nut 62 is accidentally over-tightened, bearing pre-load can be properly set by loosening locking nut 62. Locking nut 62 is in direct contact with upper bearing assembly 23. After screw 65 has been loosened, locking nut 62 may be adjusted by hand to set bearing pre-load force to an acceptable value.
While the means for applying pre-load force to bearing assemblies 20 and 23 preferably comprise a locking nut 62 threadedly engaged with threads 60, as described above, other extension means on sleeve 50 which fulfill this purpose also come within the scope of the invention. For example, a sliding member may be provided which slidably engages the lower end of sleeve 50 and means may be provided to lock the sliding member in place. The sliding member may have internal pins grooves or splines which engage external grooves pins or splines on sleeve 50.
Sleeve 50 could be clamped to the exterior surface of steerer tube 16 in addition to or in substitution for the mounting means disclosed above, which are internal to the bore of steerer tube 16. This is not preferable because providing exterior clamping means eliminates some of the advantages of the invention. However, the inventor considers that the invention, in a broad context, includes a steering assembly having a sleeve surrounding a steerer tube, a stem affixed to the sleeve, means for affixing the sleeve to a steerer tube, and extension means as described above for adjusting the pre-load on bearings in the steering assembly.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
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A bicycle steering assembly is disclosed. The assembly has a threadless steerer tube passing through a head tube. Bearing assemblies are mounted at either end of the steerer tube. A stem assembly is fastened to the upper end of the steerer tube with an expansion bolt, which is preferably a wedge clamp, inside the bore of the steerer tube. The stem has an integral sleeve which extends over the upper end of the exterior surface of the steerer tube. The sleeve reinforces the steerer tube. The lower end of the sleeve is threaded to accept a threaded locking collar. Pre-load on the bearings can be adjusted by turning the locking collar. The stem assembly has few parts, fastens securely to the steerer tube, is robust and does not have projecting bolts which could harm a rider.
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This application incorporates by reference in their entireties U.S. patent application Ser. No. 13/490,414, filed Jun. 6, 2012 and U.S. provisional application 61/512,555, filed Jul. 28, 2011.
BACKGROUND
Field of the Invention
The present invention relates to methods and apparatus for lithography and/or metrology usable, for example, in the manufacture of devices by lithographic techniques and in particular to their illumination sources.
Background Art
A lithographic apparatus is a machine that applies a desired pattern onto a substrate, usually onto a target portion of the substrate. A lithographic apparatus can be used, for example, in the manufacture of integrated circuits (ICs). In that instance, a patterning device, which is alternatively referred to as a mask or a reticle, may be used to generate a circuit pattern to be formed on an individual layer of the IC. This pattern can be transferred onto a target portion (e.g., including part of, one, or several dies) on a substrate (e.g., a silicon wafer). Transfer of the pattern is typically via imaging onto a layer of radiation-sensitive material (resist) provided on the substrate. In general, a single substrate will contain a network of adjacent target portions that are successively patterned. Known lithographic apparatus include so-called steppers, in which each target portion is irradiated by exposing an entire pattern onto the target portion at one time, and so-called scanners, in which each target portion is irradiated by scanning the pattern through a radiation beam in a given direction (the “scanning”-direction) while synchronously scanning the substrate parallel or anti parallel to this direction. It is also possible to transfer the pattern from the patterning device to the substrate by imprinting the pattern onto the substrate.
In lithographic processes, it is desirable frequently to make measurements of the structures created, e.g., for process control and verification. Various tools for making such measurements are known, including scanning electron microscopes, which are often used to measure critical dimension (CD), and specialized tools to measure overlay, the accuracy of alignment of two layers in a device. Recently, various forms of scatterometers have been developed for use in the lithographic field. These devices direct a beam of radiation onto a target and measure one or more properties of the scattered radiation—e.g., intensity at a single angle of reflection as a function of wavelength; intensity at one or more wavelengths as a function of reflected angle; or polarization as a function of reflected angle—to obtain a “spectrum” from which a property of interest of the target can be determined. Determination of the property of interest may be performed by various techniques: e.g., reconstruction of the target structure by iterative approaches such as rigorous coupled wave analysis or finite element methods; library searches; and principal component analysis.
Both lithography and scatterometry require an illumination source. In particular, scatterometry often requires a number of different illumination modes. The required illumination profiles for these illumination modes are usually obtained by the placing of a suitable aperture plate between the source and the target being measured. However, there can be many different illumination modes needed each requiring a different aperture plate. This ultimately puts a practical limit on the number of modes available. Additional flexibility can be obtained by using a Spatial Light Modulator (SLM). However, both aperture plates and SLMs reduce the amount of light available by ultimately blocking a portion of the light from the source.
SUMMARY
It is desirable to provide an illumination source that provides increased illumination control, while avoiding or at least mitigating one or more of the associated problems, mentioned above.
According to an embodiment of the present invention, there is provided an illumination system for a lithographic or inspection apparatus comprising an illumination source, plurality of optical waveguides for transmitting radiation from the illumination source to an output, and a switching system enabling selective control of one or more subsets of the plurality of optical waveguides.
For the avoidance of doubt, a “subset” may comprise an individual waveguide, or may be a non-contiguous group of waveguides.
Another embodiment of the present invention provides an inspection apparatus and a lithographic apparatus comprising, for its primary illumination source, an illumination system as described above.
Another embodiment of the present invention provides an inspection method comprising directing a beam of radiation onto a target, the beam of radiation being obtained from an illumination system comprising: an illumination source, a plurality of optical waveguides for transmitting radiation from the illumination source to an output, and a switching system enabling selective control of one or more subsets of the plurality of optical waveguides, measuring one or more properties of the scattered radiation, and determining one or more properties of the target from the one or more measured properties of the scattered radiation.
According to a further embodiment of the present invention, there is provided an illumination system for a lithographic or inspection apparatus comprising an illumination source and an optical bandpass filter. The optical bandpass filter comprises a plurality of parallel optical bandpass filter elements. The optical bandpass filter elements each being operable to only transmit a predetermined wavelength or a band of wavelengths of radiation emitted by the illumination source. At least two of the parallel optical bandpass filter elements being operable to transmit different wavelengths or band of wavelengths.
According to a yet further embodiment of the present invention, there is provided an inspection method comprising obtaining a filtered beam of radiation by passing radiation through an optical bandpass filter, the optical bandpass filter comprising a plurality of different parallel optical bandpass filter elements, such that each optical bandpass filter element only transmits a different predetermined wavelength or band of wavelengths of radiation, directing the filtered beam of radiation onto a target, measuring one or more properties of the scattered radiation, and determining one or more properties of the target from the one or more measured properties of the scattered radiation.
Further features and advantages of the invention, as well as the structure and operation of various embodiments of the invention, are described in detail below with reference to the accompanying drawings. It is noted that the invention is not limited to the specific embodiments described herein. Such embodiments are presented herein for illustrative purposes only. Additional embodiments will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 depicts a lithographic apparatus according to an embodiment of the invention;
FIG. 2 depicts a lithographic cell or cluster according to an embodiment of the invention;
FIG. 3 comprises (a) a schematic diagram of a dark field scatterometer for use in measuring targets according to embodiments of the invention, and (b) a detail of diffraction spectrum of a target grating for a given direction of illumination.
FIG. 4 shows a number of different illumination profiles useful for providing different illumination modes when using a scatterometer for diffraction based overlay measurements;
FIG. 5 shows a an illumination system according to an embodiment of the invention;
FIGS. 6( a ) to 6( c ) depicts three example illumination profiles possible using the apparatus of FIG. 5 .
FIG. 7 shows an example illumination profiles possible using the apparatus of FIG. 5 with a custom polarizer.
FIG. 8 shows an example illumination profiles possible using the apparatus of FIG. 5 with a custom polarizer.
FIG. 9 shows an example illumination profiles possible using the apparatus of FIG. 5 with a custom polarizer.
The features and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings, in which like reference characters identify corresponding elements throughout. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. The drawing in which an element first appears is indicated by the leftmost digit(s) in the corresponding reference number.
DETAILED DESCRIPTION
This specification discloses one or more embodiments that incorporate the features of this invention. The disclosed embodiment(s) merely exemplify the invention. The scope of the invention is not limited to the disclosed embodiment(s). The invention is defined by the claims appended hereto.
The embodiment(s) described, and references in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment(s) described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is understood that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
Embodiments of the invention may be implemented in hardware, firmware, software, or any combination thereof. Embodiments of the invention may also be implemented as instructions stored on a machine-readable medium, which may be read and executed by one or more processors. A machine-readable medium may include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computing device). For example, a machine-readable medium may include read only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; electrical, optical, acoustical or other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.), and others. Further, firmware, software, routines, instructions may be described herein as performing certain actions. However, it should be appreciated that such descriptions are merely for convenience and that such actions in fact result from computing devices, processors, controllers, or other devices executing the firmware, software, routines, instructions, etc.
Before describing embodiments of the invention in detail, it is instructive to present an example environment in which embodiments of the present invention may be implemented.
FIG. 1 schematically depicts a lithographic apparatus LA. The apparatus includes an illumination system (illuminator) IL configured to condition a radiation beam B (e.g., UV radiation or DUV radiation), a patterning device support or support structure (e.g., a mask table) MT constructed to support a patterning device (e.g., a mask) MA and connected to a first positioner PM configured to accurately position the patterning device in accordance with certain parameters; a substrate table (e.g., a wafer table) WT constructed to hold a substrate (e.g., a resist coated wafer) W and connected to a second positioner PW configured to accurately position the substrate in accordance with certain parameters; and a projection system (e.g., a refractive projection lens system) PS configured to project a pattern imparted to the radiation beam B by patterning device MA onto a target portion C (e.g., including one or more dies) of the substrate W.
The illumination system may include various types of optical components, such as refractive, reflective, magnetic, electromagnetic, electrostatic or other types of optical components, or any combination thereof, for directing, shaping, or controlling radiation.
The patterning device support holds the patterning device in a manner that depends on the orientation of the patterning device, the design of the lithographic apparatus, and other conditions, such as for example whether or not the patterning device is held in a vacuum environment. The patterning device support can use mechanical, vacuum, electrostatic or other clamping techniques to hold the patterning device. The patterning device support may be a frame or a table, for example, which may be fixed or movable as required. The patterning device support may ensure that the patterning device is at a desired position, for example with respect to the projection system. Any use of the terms “reticle” or “mask” herein may be considered synonymous with the more general term “patterning device.”
The term “patterning device” used herein should be broadly interpreted as referring to any device that can be used to impart a radiation beam with a pattern in its cross-section such as to create a pattern in a target portion of the substrate. It should be noted that the pattern imparted to the radiation beam may not exactly correspond to the desired pattern in the target portion of the substrate, for example if the pattern includes phase-shifting features or so called assist features. Generally, the pattern imparted to the radiation beam will correspond to a particular functional layer in a device being created in the target portion, such as an integrated circuit.
The patterning device may be transmissive or reflective. Examples of patterning devices include masks, programmable mirror arrays, and programmable LCD panels. Masks are well known in lithography, and include mask types such as binary, alternating phase-shift, and attenuated phase-shift, as well as various hybrid mask types. An example of a programmable mirror array employs a matrix arrangement of small mirrors, each of which can be individually tilted so as to reflect an incoming radiation beam in different directions. The tilted mirrors impart a pattern in a radiation beam, which is reflected by the mirror matrix.
The term “projection system” used herein should be broadly interpreted as encompassing any type of projection system, including refractive, reflective, catadioptric, magnetic, electromagnetic and electrostatic optical systems, or any combination thereof, as appropriate for the exposure radiation being used, or for other factors such as the use of an immersion liquid or the use of a vacuum. Any use of the term “projection lens” herein may be considered as synonymous with the more general term “projection system”.
As here depicted, the apparatus is of a transmissive type (e.g., employing a transmissive mask). Alternatively, the apparatus may be of a reflective type (e.g., employing a programmable mirror array of a type as referred to above, or employing a reflective mask).
The lithographic apparatus may be of a type having two (dual stage) or more substrate tables (and/or two or more mask tables). In such “multiple stage” machines the additional tables may be used in parallel, or preparatory steps may be carried out on one or more tables while one or more other tables are being used for exposure.
The lithographic apparatus may also be of a type wherein at least a portion of the substrate may be covered by a liquid having a relatively high refractive index, e.g., water, so as to fill a space between the projection system and the substrate. An immersion liquid may also be applied to other spaces in the lithographic apparatus, for example, between the mask and the projection system. Immersion techniques are well known in the art for increasing the numerical aperture of projection systems. The term “immersion” as used herein does not mean that a structure, such as a substrate, must be submerged in liquid, but rather only means that liquid is located between the projection system and the substrate during exposure.
Referring to FIG. 1 , the illuminator IL receives a radiation beam from a radiation source SO. The source and the lithographic apparatus may be separate entities, for example when the source is an excimer laser. In such cases, the source is not considered to form part of the lithographic apparatus and the radiation beam is passed from the source SO to the illuminator IL with the aid of a beam delivery system BD including, for example, suitable directing mirrors and/or a beam expander. In other cases the source may be an integral part of the lithographic apparatus, for example when the source is a mercury lamp. The source SO and the illuminator IL, together with the beam delivery system BD if required, may be referred to as a radiation system.
The illuminator IL may include an adjuster AD for adjusting the angular intensity distribution of the radiation beam. Generally, at least the outer and/or inner radial extent (commonly referred to as σ-outer and σ-inner, respectively) of the intensity distribution in a pupil plane of the illuminator can be adjusted. In addition, the illuminator IL may include various other components, such as an integrator IN and a condenser CO. The illuminator may be used to condition the radiation beam, to have a desired uniformity and intensity distribution in its cross section.
The radiation beam B is incident on the patterning device (e.g., mask) MA, which is held on the patterning device support (e.g., mask table MT), and is patterned by the patterning device. Having traversed the patterning device (e.g., mask) MA, the radiation beam B passes through the projection system PS, which focuses the beam onto a target portion C of the substrate W. With the aid of the second positioner PW and position sensor IF (e.g., an interferometric device, linear encoder, 2-D encoder or capacitive sensor), the substrate table WT can be moved accurately, e.g., so as to position different target portions C in the path of the radiation beam B. Similarly, the first positioner PM and another position sensor (which is not explicitly depicted in FIG. 1 ) can be used to accurately position the patterning device (e.g., mask) MA with respect to the path of the radiation beam B, e.g., after mechanical retrieval from a mask library, or during a scan. In general, movement of the patterning device support (e.g., mask table) MT may be realized with the aid of a long-stroke module (coarse positioning) and a short-stroke module (fine positioning), which form part of the first positioner PM. Similarly, movement of the substrate table WT may be realized using a long-stroke module and a short-stroke module, which form part of the second positioner PW. In the case of a stepper (as opposed to a scanner) the patterning device support (e.g., mask table) MT may be connected to a short-stroke actuator only, or may be fixed.
Patterning device (e.g., mask) MA and substrate W may be aligned using mask alignment marks M1, M2 and substrate alignment marks P1, P2. Although the substrate alignment marks as illustrated occupy dedicated target portions, they may be located in spaces between target portions (these are known as scribe-lane alignment marks). Similarly, in situations in which more than one die is provided on the patterning device (e.g., mask) MA, the mask alignment marks may be located between the dies. Small alignment markers may also be included within dies, in amongst the device features, in which case it is desirable that the markers be as small as possible and not require any different imaging or process conditions than adjacent features. The alignment system, which detects the alignment markers is described further below.
The depicted apparatus could be used in at least one of the following modes:
1. In step mode, the patterning device support (e.g., mask table) MT and the substrate table WT are kept essentially stationary, while an entire pattern imparted to the radiation beam is projected onto a target portion C at one time (i.e., a single static exposure). The substrate table WT is then shifted in the X and/or Y direction so that a different target portion C can be exposed. In step mode, the maximum size of the exposure field limits the size of the target portion C imaged in a single static exposure.
2. In scan mode, the patterning device support (e.g., mask table) MT and the substrate table WT are scanned synchronously while a pattern imparted to the radiation beam is projected onto a target portion C (i.e., a single dynamic exposure). The velocity and direction of the substrate table WT relative to the patterning device support (e.g., mask table) MT may be determined by the (de-)magnification and image reversal characteristics of the projection system PS. In scan mode, the maximum size of the exposure field limits the width (in the non-scanning direction) of the target portion in a single dynamic exposure, whereas the length of the scanning motion determines the height (in the scanning direction) of the target portion.
3. In another mode, the patterning device support (e.g., mask table) MT is kept essentially stationary holding a programmable patterning device, and the substrate table WT is moved or scanned while a pattern imparted to the radiation beam is projected onto a target portion C. In this mode, generally a pulsed radiation source is employed and the programmable patterning device is updated as required after each movement of the substrate table WT or in between successive radiation pulses during a scan. This mode of operation can be readily applied to maskless lithography that utilizes programmable patterning device, such as a programmable mirror array of a type as referred to above.
Combinations and/or variations on the above described modes of use or entirely different modes of use may also be employed.
Lithographic apparatus LA is of a so-called dual stage type which has two substrate tables WTa, WTb and two stations—an exposure station and a measurement station—between which the substrate tables can be exchanged. While one substrate on one substrate table is being exposed at the exposure station, another substrate can be loaded onto the other substrate table at the measurement station and various preparatory steps carried out. The preparatory steps may include mapping the surface control of the substrate using a level sensor LS and measuring the position of alignment markers on the substrate using an alignment sensor AS. This enables a substantial increase in the throughput of the apparatus. If the position sensor IF is not capable of measuring the position of the substrate table while it is at the measurement station as well as at the exposure station, a second position sensor may be provided to enable the positions of the substrate table to be tracked at both stations.
As shown in FIG. 2 , the lithographic apparatus LA forms part of a lithographic cell LC, also sometimes referred to a lithocell or cluster, which also includes apparatus to perform pre- and post-exposure processes on a substrate. Conventionally these include spin coaters SC to deposit resist layers, developers DE to develop exposed resist, chill plates CH and bake plates BK. A substrate handler, or robot, RO picks up substrates from input/output ports I/O1, I/O2, moves them between the different process apparatus and delivers then to the loading bay LB of the lithographic apparatus. These devices, which are often collectively referred to as the track, are under the control of a track control unit TCU which is itself controlled by the supervisory control system SCS, which also controls the lithographic apparatus via lithography control unit LACU. Thus, the different apparatus can be operated to maximize throughput and processing efficiency.
A metrology apparatus according to an embodiment of the invention is shown in FIG. 3( a ) . The apparatus shown is capable of performing so-called dark field metrology, where the zeroeth order is blocked. However, the invention may be used for other types of metrology apparatuses and techniques, as well as for lithographic apparatuses. A target grating T and diffracted rays are illustrated in more detail in FIG. 3( b ) .
The metrology apparatus may be a stand-alone device or incorporated in either the lithographic apparatus LA, e.g., at the measurement station, or the lithographic cell LC. An optical axis, which has several branches throughout the apparatus, is represented by a dotted line O. In this apparatus, light emitted by source 11 (e.g., a xenon lamp) is directed onto substrate W via a beam splitter 15 by an optical system comprising lenses 12 , 14 and objective lens 16 . These lenses are arranged in a double sequence of a 4F arrangement. Therefore, the angular range at which the radiation is incident on the substrate can be selected by defining a spatial intensity distribution in a plane that presents the spatial spectrum of the substrate plane, here referred to as a (conjugate) pupil plane. In particular, this can be done conventionally by inserting an aperture plate 13 of suitable form between lenses 12 and 14 , in a plane which is a back-projected image of the objective lens pupil plane. Using, for example, an annular illumination profile, centered on the optical axis of the illumination system formed by lenses 12 , 14 and 16 , the measurement beam will be incident on substrate W in a cone of angles not encompassing the normal to the substrate. The illumination system thereby forms an off-axis illumination mode. Other modes of illumination are possible by using different apertures. The rest of the pupil plane is desirably dark as any unnecessary light outside the desired illumination mode will interfere with the desired measurement signals.
As shown in FIG. 3( b ) , target grating T is placed with substrate W normal to the optical axis O of objective lens 16 . A ray of illumination I impinging on grating T from an angle off the axis O gives rise to a zeroeth order ray (solid line 0) and two first order rays (dot-chain line +1 and double dot-chain line −1). It should be remembered that with an overfilled small target grating, these rays are just one of many parallel rays covering the area of the substrate including metrology target grating T and other features. Since the annular aperture in plate 13 has a finite width (necessary to admit a useful quantity of light, the incident rays I will in fact occupy a range of angles, and the diffracted rays 0 and +1/−1 will be spread out somewhat. According to the point spread function of a small target, each order +1 and −1 will be further spread over a range of angles, not a single ideal ray as shown.
At least the 0 and +1 orders diffracted by the target on substrate W are collected by objective lens 16 and directed back through beam splitter 15 . Remembering that, when using the illustrated annular aperture plate 13 , incident rays I impinge on the target from a cone of directions rotationally symmetric about axis O, first order rays −1 from the opposite side of the cone will also enter the objective lens 16 , even if the ray −1 shown in FIG. 3( b ) would be outside the aperture of objective lens 16 . Returning to FIG. 3( a ) , this is illustrated by designating diametrically opposite portions of the annular aperture as north (N) and south (S). The +1 diffracted rays from the north portion of the cone of illumination, which are labeled +1(N), enter the objective lens 16 , and so do the −1 diffracted rays from the south portion of the cone (labeled −1(S)).
A second beam splitter 17 divides the diffracted beams into two measurement branches. In a first measurement branch, optical system 18 forms a diffraction spectrum (pupil plane image) of the target on first sensor using the zeroeth and first order diffractive beams. The sensor is preferably a two-dimensional sensor so that a two-dimensional angular scatter spectrum of a substrate target 30 can be measured. The sensor 19 may be, for example, an array of CCD or CMOS sensors, and may use an integration time of, for example, 40 milliseconds per frame. It is possible, in other embodiments, that this measurement branch images the structure itself, rather than the pupil plane.
Each diffraction order hits a different point on the sensor, so that image processing can compare and contrast orders. The sensor 19 may measure the intensity of scattered light at a single wavelength (or narrow wavelength range), the intensity separately at multiple wavelengths or integrated over a wavelength range. Furthermore, the detector may separately measure the intensity of transverse magnetic- and transverse electric-polarized light and/or the phase difference between the transverse magnetic- and transverse electric-polarized light.
The pupil plane image captured by sensor 19 can be used for focusing the metrology apparatus and/or normalizing intensity measurements of the first order beam. The pupil plane image can also be used for many measurement purposes such as reconstruction, where the structure or profile giving rise to the detected spectrum is reconstructed by processing unit PU, e.g. by Rigorous Coupled Wave Analysis and non-linear regression or by comparison with a library of simulated spectra. In general, for the reconstruction the general form of the structure is known and some parameters are assumed from knowledge of the process by which the structure was made, leaving only a few parameters of the structure to be determined from the scatterometry data. Such a scatterometer may be configured as a normal-incidence scatterometer or an oblique-incidence scatterometer.
In the second measurement branch, optical system 20 , 22 forms an image of the target on the substrate W on sensor 23 (e.g. a CCD or CMOS sensor). An aperture stop 21 is provided in a plane that is conjugate to the pupil-plane. Aperture stop 21 functions to block the zeroeth order diffracted beam so that the image of the target formed on sensor 23 is formed only from the first order beam. This is the so-called dark field image, equivalent to dark field microscopy. The images captured by sensors 19 and 23 are output to image processor and controller PU, the function of which will depend on the particular type of measurements being performed.
The target T on substrate W may be a 1-D grating, which is printed such that after development, the bars are formed of solid resist lines. The target 30 may be a 2-D grating, which is printed such that after development, the grating is formed of solid resist pillars or vias in the resist. The bars, pillars or vias may alternatively be etched into the substrate. This pattern is sensitive to chromatic aberrations in the lithographic projection apparatus, particularly the projection system PL, and illumination symmetry and the presence of such aberrations will manifest themselves in a variation in the printed grating. Accordingly, the scatterometry data of the printed gratings is used to reconstruct the gratings. The parameters of the 1-D grating, such as line widths and shapes, or parameters of the 2-D grating, such as pillar or via widths or lengths or shapes, may be input to the reconstruction process, performed by processing unit PU, from knowledge of the printing step and/or other scatterometry processes.
Using a broadband light source (i.e. one with a wide range of light frequencies or wavelengths—and therefore of colors) is possible, which gives a large etendue, allowing the mixing of multiple wavelengths. The plurality of wavelengths in the broadband preferably each has a bandwidth of Δλ and a spacing of at least 2 Δλ (i.e. twice the bandwidth). Several “sources” of radiation can be different portions of an extended radiation source which have been split using fiber bundles. In this way, angle resolved scatter spectra can be measured at multiple wavelengths in parallel. A 3-D spectrum (wavelength and two different angles) can be measured, which contains more information than a 2-D spectrum. This allows more information to be measured which increases metrology process robustness. This is described in more detail in EP1,628,164A, which is incorporated by reference herein in its entirety.
While off-axis illumination is shown, on-axis illumination of the targets may instead be used and an aperture stop with an off-axis aperture is used to pass substantially only one first order of diffracted light to the sensor. 2nd, 3rd and higher order beams (not shown in FIG. 3 ) can be used in measurements, instead of or in addition to the first order beams.
Illumination profiles can be varied greatly and the use of custom illumination is becoming more and more important in both lithography and optical metrology. The customization of the illumination enables improvement of the measurement quality (TMU, cross-correlation and sensitivity). Examples of some more commonly used illumination profiles are shown in FIG. 4 . This shows annular illumination (a), unipolar illumination, which can admits light at certain angles around the optical axis only (b)-(e), bipolar illumination (f)-(g), opposite quadrant illumination (h) and half-field illumination (i). Unipolar illumination can be used to make asymmetry measurements of small target gratings, for the dark field overlay measurement method disclosed in international patent application PCT/EP2010/060894, incorporated herein by reference in its entirety. Illumination profiles (h) and (i), which allow separation of the zeroeth and first orders in the resultant image, are described in US patent publication 2010/0201963, incorporated herein by reference in its entirety.
All the optical systems used to control the illumination essentially customize the intensity (or the phase) across the pupil field. In the examples described thus far, specific apertures have been placed in the conjugate back focal plane (CBFP or illumination pupil plane) of the optical system. The use aperture plates provide customization at the expense of the amount of light transmitted, and are not always easy to implement for a general application. Some specific illuminations are for instance used for μDBO (micro-diffraction based overlay), but the aperture used in the CBFP is very specific while the number of different apertures must be limited, since the filter wheel has a finite number of slots. A Spatial Light Modulator (SLM) can be used as this provides more flexibility. However, this flexibility is at the expense of switch time, while the problem of the amount of light transmitted remains. Other specific systems for particular applications such as light homogenization have also been developed. However these systems are expensive and do not offer the flexibility needed in metrology.
FIG. 5 shows a system which addresses the above issues. It shows a light source comprising a fiber bundle 500 placed in the CBFP. Fiber switches 510 are provided, to turn on and off (or partially off) each single fiber, thereby providing required flexibility in customizing the illumination. Multiples 520 of these fibers, grouped according to wavelength carried, are coupled via couplings 530 to a larger core (say 1 mm) fiber 540 at the source 550 .
The source 550 used for the fiber bundle 500 can be a broadband lamp provided with a spectral filtering system, fiber coupled LEDs or fiber coupled Lasers. The design of the switching system 510 will depend on the number of fibers, the complexity of the main fiber bundle pattern and the source 550 .
The number of fibers used in the fiber bundle 500 will essentially depend on the size of the fiber core chosen and the physical size of the CBFP of the instrument. Other factors which may influence the number of fibers in a bundle 500 are: the number of “angle of incidence” wanted, the output power of the fiber as a function of the core diameter and the feasibility of making an otherwise desirable fiber bundle 500 . The fiber diameter also defines the angular resolution of the incident wave. It cannot be too small, otherwise diffraction effects will become paramount. In an illustrative example, if 200 μm core fibers are used and the CBFP diameter is 5 mm, the fiber bundle may be approximately made of 500 single fibers.
This illumination system makes it possible to set up different wavelengths for each fiber or set of fibers. Consequently it provides the capability to perform simultaneous measurements at different angles and wavelengths, and therefore spectroscopic and angle resolved measurement simultaneously in the pupil plane. This will improve the acquisition time of the experimental data. It will also improve the decorrelation of the parameters used in the reconstruction process, e.g. CD, n&k, thicknesses.
For example, measurement of the optical properties of a stack can be improved by using different wavelengths and angles to decorrelate the thickness of the layer from the optical properties of the layer. This can be done today using conventional scatterometry illumination sources. However, this requires a large number of measurements (one for each wavelength) to be taken. The illumination system described herein enables this to be done in a single measurement. In one particular example, where the structure studied has symmetry properties (e.g. a layered material or a zeroeth order grating), all four quadrants of the pupil plane will be identical for a single wavelength. Consequently, four wavelengths can be used in each quadrant simultaneously to extract more information of the target.
FIGS. 6( a ) to 6( c ) show some examples of possible wavelength and angle customization of the CBFP using an illumination system as described herein. Each figure shows an illumination profile 600 , 600 ′, 600 ″ made up from individual fibers 610 . Fibers carrying light of different wavelengths are differentiated by their hatching pattern. FIG. 6( a ) shows an illumination profile 600 in which each quadrant has light of different wavelength. In FIG. 6( b ) , illumination profile 600 ′ has light distributed such that regions of fibers having the same wavelength form concentric squares. In FIG. 6( c ) , illumination profile 600 ″ has three quadrants with light of the same wavelength while the other quadrant has light of different wavelengths distributed such that regions of fibers having the same wavelength form nestled L-shapes. Of course, these examples are purely illustrative, and the number of different profiles is virtually limitless, and includes all those of FIG. 4 .
It is also possible to customize the polarization of the CBFP by adding a custom polarizer. Such a custom polarizer may polarize each fiber or group of fibers differently. This means that it is possible to measure simultaneously two polarization states and two wavelengths for different angles of incidence. This reduces the acquisition time of the measurements (theoretically by a factor of four).
FIG. 7 shows an example illumination profile 700 using a custom polarizer. Quadrants 1 and 2 are polarized in X (fibers 610 drawn with normal lines) and quadrants 3 and 4 are polarized in Y (fibers 610 drawn with bold lines). Also, quadrants 1 and 3 have a different wavelength to quadrants 2 and 4.
It is also possible to use polarization maintaining fibers and arrange them in a polar coordinate system to obtain a (p,s) polarization illumination, which will simplify the calibration and the simulation part of the inverse problem (the modeling of structures from the measured pupil spectra). Other arrangements are possible, so as to obtain the desired global polarization of the illumination. However, in these cases the fiber arrangement may be fixed. To change it will therefore require switching between fiber bundles.
It should also be noted that the illumination systems described above provide a good homogeneous (if the intensity of each fiber is the same) and incoherent source with a high radiance. Of course, as it is possible to customize the input intensity of each fiber, it is not only possible to make it homogenous but to provide for any other kind of intensity distribution.
One of the main advantages of the above illumination systems is that it allows the possibility of performing simultaneous measurements at different angles and wavelengths. However, it is sometimes desirable to keep any changes to the rest of the optical apparatus to a minimum. Consequently an embodiment has been devised, which replaces the fiber bundle arrangement with a optical bandpass filter arrangement.
FIG. 8 illustrates such an embodiment. Shown is an illumination profile 800 in which each of the four quadrants has a different wavelength (represented by different shading). FIG. 9 shows an alternative illumination profile 900 comprising two halves each having a different wavelength.
The illumination profile in this embodiment may be achieved by creating a custom optical band pass filter 802 / 902 that passes light of only certain wavelength(s), in each quarter (or other segment) of the pupil. The source of the tool should either be broadband, or have the desired multiple wavelengths. The wavelength filtering is performed in the CBFP using the custom bandpass filter.
Optical bandpass filters are usually square, rectangular or circular shaped. it is proposed that filter components 804 / 904 which make up the custom filter of this embodiment will be quarter-circle, half-circle or smaller circular shaped. These filter components may be mounted in a special mount 806 / 906 , which will hold (for example) two or four of the filter components, depending on their shape and the desired illumination profile. Once fixed onto their mount, the custom filter can be placed on a rotating wheel in the pupil plane of the tool.
While specific embodiments of the invention have been described above, it will be appreciated that the invention may be practiced otherwise than as described. In association with the physical grating structures of the novel targets as realized on substrates and patterning devices, an embodiment may include a computer program containing one or more sequences of machine-readable instructions describing a methods of producing targets on a substrate, measuring targets on a substrate and/or analyzing measurements to obtain information about a lithographic process. This computer program may be executed for example within unit PU in the apparatus of FIG. 3 and/or the control unit LACU of FIG. 2 . There may also be provided a data storage medium (e.g., semiconductor memory, magnetic or optical disk) having such a computer program stored therein.
Although specific reference may have been made above to the use of embodiments of the invention in the context of optical lithography, it will be appreciated that the invention may be used in other applications, for example imprint lithography, and where the context allows, is not limited to optical lithography. In imprint lithography a topography in a patterning device defines the pattern created on a substrate. The topography of the patterning device may be pressed into a layer of resist supplied to the substrate whereupon the resist is cured by applying electromagnetic radiation, heat, pressure or a combination thereof. The patterning device is moved out of the resist leaving a pattern in it after the resist is cured.
The terms “radiation” and “beam” used herein encompass all types of electromagnetic radiation, including ultraviolet (UV) radiation (e.g., having a wavelength of or about 365, 355, 248, 193, 157 or 126 nm) and extreme ultraviolet (EUV) radiation (e.g., having a wavelength in the range of 5-20 nm), as well as particle beams, such as ion beams or electron beams.
The term “lens”, where the context allows, may refer to any one or combination of various types of optical components, including refractive, reflective, magnetic, electromagnetic and electrostatic optical components.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description by example, and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
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 and their equivalents.
It is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and thus, are not intended to limit the present invention and the appended claims in any way.
The present invention has been described above with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
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 and their equivalents.
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An illumination system for a lithographic or inspection apparatus. A plurality of optical waveguides transmit radiation from the illumination source to an output. A switching system enables selective control of one or more subsets of the optical waveguides. An inspection method uses an illumination system and inspection and lithographic apparatuses comprise an illumination system. In one example, the optical waveguides and switching system are replaced by a plurality of parallel optical bandpass filter elements. The optical bandpass filter elements each only transmit a predetermined wavelength or a band of wavelengths of radiation. At least two of the parallel optical bandpass filter elements each being operable to transmit a different wavelength or band of wavelengths.
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FIELD OF THE INVENTION
This invention relates to the processing of workpieces that are to be sewn by an automatic sewing machine. In particular, this invention relates to the manner in which stitch patterns are assigned to these workpieces.
BACKGROUND OF THE INVENTION
U.S. application Ser. No. 266,298, filed on May 22, 1981, now U.S. Pat. No. 4,479,446 and entitled, "Sewing Machine System Having Automatic Identification and Processing of Mounted Work" discloses an automatic sewing machine system wherein workpieces prearranged within pallets are automatically sewn. The system allows each workpiece prearranged within a particular pallet to be automatically identified. This is accomplished by sensing a code present on the pallet. This automatic identification is used to assign a stitch pattern to the workpiece that is to be automatically sewn each time the particular pallet is presented to the automatic sewing machine system. The stitch pattern assignment is made by a separate interactive communication between the operator and the machine following the automatic identification of the pallet containing the workpiece. The stitch pattern thus assigned is automatically sewn each time the particular pallet is presented to the sewing machine system.
The above system furthermore allows for the automatic processing of a number of pallets so as to thereby allow a number of different individual workpieces to each have a particular stitch pattern automatically sewn thereon. This automatic processing of a number of different workpieces continues until either a workpiece is not timely presented, or a workpiece is presented that does not have a stitch pattern previously assigned thereto.
The above described system does not allow for either the assigning or subsequent sewing of a multiple number of stitch patterns on the same or similar workpiece prearranged within the same pallet. In this regard, the same stitch pattern will always be sewn on the workpiece prearranged within the given pallet each time the workpiece is presented for sewing.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a process or system within an automatic sewing machine which allows more than one stitch pattern to be assigned to a workpiece prearranged within a pallet and presented to the automatic sewing machine;
It is another object of the invention to provide a process or system within an automatic sewing machine which allows a sequence of stitch patterns to be assigned to a workpiece prearranged within a pallet; and
It is still another object of the invention to provide a process or system within an automatic sewing machine which allows for an assignment of a number of stitch patterns to a number of different workpieces prearranged within pallets so as to thereby allow for the sequential sewing of the patterns on the respective workpieces.
SUMMARY OF THE INVENTION
The above and other objects are achieved according to the present invention by an automatic sewing machine which allows the operator of the machine to arbitrarily assign a number of stitch patterns to a workpiece prearranged within a pallet. The pallet is presented to the automatic sewing machine in such a manner that a code present on the pallet is automatically sensed by a sensor. A computer system associated with the sensor awaits communications from the operator relative to the assignment of stitch patterns to the sensed code. The operator enters in successive fashion, via a keyboard, the numerical identifications of the stitch patterns that are to be assigned to the sensed code. Each keyboard entry is analyzed by the computer system prior to acceptance as a valid stitch pattern assignment. The computer system is operative to thereafter store an accepted stitch pattern assignment in a recallable table of valid stitch pattern assignments. In the event that the keyboard entry is unacceptable, the computer system is operative to advise the operator to make another numerical entry.
In accordance with the invention, the operator may separately enter a sequence of stitch patterns to each of a number of differently coded pallets. The computer system stores the entered sequence of stitch pattern assignments in a manner which allows one of the stitch patterns from the particular sequence to be recalled each time the particular coded pallet is presented.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the invention will now be particularly described with reference to the accompanying drawings, in which:
FIG. 1 is an overall perspective view of an automatic sewing machine system having an automatic pallet handling apparatus in association with an automatic positioning system;
FIG. 2 is a perspective view of the pallet handling apparatus in association with the sewing machine head of the automatic sewing system;
FIG. 3 illustrates the pallet sensor associated with the automatic pallet handling apparatus;
FIG. 4 is a perspective view of a portion of the automatic pallet handling apparatus;
FIG. 5 illustrates the transfer of a pallet within the automatic pallet handling apparatus;
FIG. 6 illustrates the locking of the transferred pallet to a carriage within the automatic positioning system;
FIG. 7 illustrates the unlocking of the pallet from the carriage of the automatic positioning system;
FIG. 8 illustrates the pallet ejector mechanism present within the automatic pallet handling apparatus;
FIG. 9 illustrates the automatic control system associated with the pallet handling apparatus of FIGS. 2-9;
FIG. 10 illustrates the flow of computer commands within the automatic control system of FIG. 9 so as to facilitate the automatic loading of a pallet;
FIG. 11 illustrates the flow of computer commands within the automatic control system of FIG. 9 so as to monitor the removal of an ejected pallet;
FIGS. 12a and 12b illustrate the flow of computer commands within the automatic control system of FIG. 9 so as to facilitate the unloading of a pallet;
FIGS. 13a through 13e illustrate program logic within the automatic control system of FIG. 9 that facilitates the automatic processing of pattern files; and
FIGS. 14a through 14c illustrate the program logic within the automatic control system of FIG. 9 that facilitates the interactive identification of stitch pattern files with respect to pallets entered by the attendant.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an automatic sewing machine system having X, Y positioning with respect to a sewing machine head 20 is generally shown.
A pallet 22 is illustrated as being in registered relationship with respect to the sewing machine head 20. The pallet may be of the "join and sew" type wherein several pieces of work are to be prearranged within the pallet. An example of such a pallet is disclosed in U.S. Pat. No. 3,988,993, entitled, "Pallet For Registering and Securing a Workpiece". It is to be appreciated that the workpiece within such a pallet may for instance comprise a number of different pieces which must be joined and sewed together before further pieces can be thereafter added. In this regard, a first stitch pattern may be required to perform the first join and sew operation. This would be followed by adding still further pieces to the sewn workpiece and again presenting the prearranged pieces of work for a second join and sew operation. This second join and sew operation would require a second stitch pattern unique to the workpiece that is then being presented.
It is also to be appreciated that a series of different stitch patterns requiring, for instance, different colored thread might need to be sewn. In this instance, it might be advisable to completely sew a number of workpieces requiring the same color thread before changing the thread color and again presenting the workpieces for sewing a second stitch pattern.
The pallet 22 is mounted to a carriage 24 which is driven in a Y direction along a cylindrical axis 26 by a motor 27. The cylindrical axis 26 is mounted on a frame 28 which is moved in an X direction by a pair of motors 30 and 32. It is to be appreciated that the aforementioned X-Y positioning apparatus has been disclosed as only the preferred embodiment of a positioning system for use in the present invention.
The pallet 22 is moved into position relative to the carriage 24 by a pallet handling system 34. As will be explained in detail hereinafter, the pallet handling system 34 is operative to simultaneously handle at least three pallets. These pallets will occupy respectively an input position, a middle position, and an output position. The pallet 22 is illustrated in FIG. 1 as being in the middle position which allows for automatic sewing.
Referring now to FIG. 2, the pallet 22 is illustrated in the input position within the pallet handling system 34. In particular, the pallet 22 is seen to rest on a left shelf 36 and a right shelf 38 of the pallet handling system 34. The pallet has been previously loaded onto the left and right shelves via a pair of rollers 40 and 42.
Referring to FIG. 3, a corner of the pallet 22 is shown in the process of being loaded onto the right shelf 38. It is to be noted that the pallet 22 is still being rolled into place over the roller 42. The corner of the pallet 22 is seen to have a pallet identification code 44 impressed thereon. The pallet identification code 44 consists of two separately coded surface areas 46 and 48. The coded surface area 46 is opaque and non-reflective whereas the coded surface area 48 is reflective. It is to be appreciated that various combinations of reflective and non-reflective coded surfaces may occur within the pallet identification code 44. In this regard, the following combinations of coded surfaces may be present in accordance with the present invention.
______________________________________Coded Surface 46 Coded Surface 48______________________________________Opaque ReflectiveReflective OpaqueReflective Reflective______________________________________
The pallet identification code 44 is presented to a pallet identification sensor device 50 when the pallet 22 is moved back against a limit stop 51. When this occurs, the pallet identification sensor device 50 optically senses the coded surfaces 46 and 48. This is done by a pair of separate optical sensors within the pallet identification sensor device 50. Each optical sensor measures the reflection of light from the coded surface presented thereunder. In accordance with the preferred embodiment of the invention, the optical sensor reading the opaque encoded surface of FIG. 3 will produce a logically low signal condition on a line 52. On the other hand, the optical sensor device which senses the reflective coded surface 48 will produce a logically high signal on a line 53. The coded significance of the logic level signals produced as a result of reading the pallet identification code 44 will be further discussed hereinafter. For the present, it is merely to be noted that the condition where both optical sensors do not sense a reflection is reserved for a condition where no pallet is present under the pallet identification sensor device 50.
The lines 52 and 53 are connected to an automatic control system which is illustrated in FIG. 9. The details of this control system will be discussed hereinafter in conjunction with FIG. 9. For the present, it is merely to be noted that the control system senses the presence of the pallet in response to the signal conditions on the lines 52 and 53. The control system thereafter sequentially operates the elements comprising the pallet handling system 34 so as to move the sensed pallet through various defined pallet positions. This sequential operation of the elements is premised on the conditions of various switches present within the pallet handling system. These switches interface with the automatic control in much the same manner as the sensor 50. The mechanical operation of the pallet handling system will now be discussed before turning to the detailed description of the automatic control in FIG. 9.
The pallet identification sensor device 50 and the limit stop 51 are adjustably positioned within the pallet handling system 34 by a slidable mount 54 which can be fixed in any position via a set screw 55. In this manner, the position of the pallet identification sensor device 50 can be adjusted so as to accommodate different sized pallets. The mounting structure for the pallet identification sensor device 50 furthermore includes a pivotal mount 56 which allows the pallet identification sensor to be pivoted out of the way during sewing head maintenance.
Having now described the loading and sensing of the pallet 22 at the top input position, it is now appropriate to turn to the various functioning mechanisms which permit the pallet 22 to assume the middle position within the pallet handling system. Referring to FIG. 4, the left portion of the pallet handling system 34 is illustrated in detail. The left portion of the pallet 22 is illustrated in place on the left shelf 36. This position of the pallet 22 is directly above the carriage 24 to which it is to be ultimately attached. In this regard, the pallet 22 is seen to have two V-notched grooves 58 and 60 located along opposing sides near each corner of the pallet. The V-notches 58 and 60 will ultimately be engaged by a pair of wedges 62 and 64 appearing at either end of the carriage 24 as is shown in FIG. 6. The wedge 62 will be driven into engagement with the V-notch 58 by a pallet clamping mechanism 66 which is attached to the one end of the carriage 24. The wedge 64 is affixed to the other end of the carriage 24 by an arm 68. The wedge 64 acts as a fixed registration for the V-notch 60 during the clamping action of the pallet clamping mechanism 66. The various elements comprising the pallet clamping mechanism 66 will be fully discussed hereinafter.
The manner in which the left edge of the pallet 22 drops downward to the carriage 24 will now be described. As has been previously noted, the left edge of the pallet with the V-notches 58 and 60 to either side rests on the left shelf 36 as shown in FIG. 4. An air cylinder 70 having an output shaft 72 is pivotally attached to the left shelf 36. Upon actuation of the air cylinder 70, the output shaft 72 extends outwardly so as to thereby rotate the left shelf 36 downwardly. The left shelf 36 rotates about a pivotal attachment 74 associated with a frame member 76 and a pivotal attachment (not shown) associated with a frame member 78. When the left shelf 36 has thus been rotated downwardly, the left edge of the pallet 22 drops past it onto a pallet support 80 associated with the wedge 62 and a pallet support 82 associated with the wedge 64. The pallet support 82 is not shown in FIG. 4 but can be seen in FIG. 2. The pallet support 82 is seen to be a tab located underneath the wedge 64. The tab has a sufficient support area projecting outwardly around the perimeter of the wedge 64. This outward tab portion supports a pallet in the vicinity of the V-notch 60 as is illustrated in FIG. 6. The pallet support 80 is also seen to have a tab portion supporting the pallet in the vicinity of the V-notch 58 in FIG. 6. Referring again to the left shelf 36 in FIG. 4, it is seen that a cam member 84 is attached thereto. The cam member 84 is in contact with a limit switch 86 when the left shelf has moved downwardly so as to allow the pallet 22 to drop onto the pallet support members 80 and 82. The cam member is depicted in FIG. 2 as being in contact with a limit switch 88 when the left shelf is in an upward position. As will be explained in detail hereinafter, the automatic control utilizes the switches 86 and 88 during the movement of the left shelf 36.
The automatic control is operative to now cause the right side of the pallet 22 to be lowered. Referring to FIG. 5, the right side of the pallet 22 is seen to rest on the right shelf 38 at an elevated position. The right shelf 38 is pivotally connected to an upper bar 90 of a four bar linkage. The upper bar 90 is rotated downwardly about a pivotal point 92 by an air cylinder 94. The retraction of the output shaft 95 of the air cylinder 94 causes the right shelf 38 to assume the position denoted in dotted outline by 38'. The position of the pallet 22 when thus held by the right shelf in the position labelled 38' is illustrated by the dotted outline form labelled 22'. It is to be appreciated that the pallet 22' still rests within the right shelf 38' in this downward position which is only a short distance from the bed 96 of the sewing machine head 20. The pallet 22 is next caused to drop onto the bed 96 by the retraction of an output shaft 97 associated with the air cylinder 98. In this regard, the output shaft 97 associated with the air cylinder 98 is pivotally connected to a lower bar 100 of the double bar linkage. The position of the right shelf 38 following the retraction of the output shaft 97 associated with the air cylinder 98 is illustrated by the dotted outline denoted as 38". This latter position of the right shelf 38 is such as to completely clear the pallet 22" which now rests on the reference base 96. The pallet 22" has now reached the middle position within the pallet handling system. The right shelf 38 can now be rotated upwardly relative to the pivotal point 92 without interfering with the pallet 22". As will become apparent hereinafter, this latter rotation of the right shelf 38 occurs after the pallet has been clamped by the pallet clamping mechanisms 66 and 68. In any event, the right shelf 38 is reset by first actuating the air cylinder 94 so as to extend the output shaft 95 associated therewith so as to cause the upper bar 90 to rotate about the pivotal point 92. The air cylinder 98 is thereafter actuated so as to extend the output shaft 97 associated therewith so as to thereby cause the lower bar 100 to further position the right shelf upwardly into its reset position.
Once the pallet has assumed the middle position denoted by 22", it can be clamped by the pallet clamping mechanism 66. Referring to FIG. 4, the elements of the pallet clamping mechanism 66 are illustrated in exploded relationship to one another. The wedge 62 is attached to a pivotal lever 102 which rotates within a fixture 104 forming part of the casting for the carriage 24. Only a portion of the pivotal lever 102 is illustrated within the fixture 104. This portion is seen to include an arm 106 pivotally connected to an output shaft 108 of an air cylinder 110. The output shaft 108 and the air cylinder 110 are clearly shown in FIG. 6. The output shaft 108 is operative to extend outwardly into contact with an adjustable limit stop 112. The outward extension of the shaft 108 causes the pivot lever 102 to rotate about the axis 114 defined by the fixture 104. The rotation of the pivot lever 102 about this axis causes the wedge 62 to move into the notch 58 of the pallet 22 as is shown in FIG. 6. It is to be appreciated that the aforementioned motion of the pivotal lever 102 is against the spring biasing force of a spring 116 connecting the pivotal lever 102 to an eyelet anchor 117 shown in FIG. 6.
It is hence to be appreciated that actuation of the air cylinder 110 causes its output shaft 108 to extend thereby rotating the pivotal lever 102 about the axis 114. This forces the wedge 62 strongly against the notch 58 which in turn urges the notch 60 strongly against the wedge 64. The thus clamped pallet 22 is clearly shown in FIG. 6.
It is to be noted that a heel 118 of the pallet support member 80 is positioned within a cradle 120 in FIG. 6. The cradle 120 is operative to maintain the pallet support member 80 in position below the pallet 22 during the aforementioned clamping or latching operation. The pallet support member 80 is also maintained in place by virtue of a spring 122 attached between a post 124 extending upwardly from the pallet support member 80 and a tab 126 connected to the pivotal lever 102. In this regard, the tensioned spring 122 produces a biasing force on the post 124 which tends to cause the post 124 to engage a rearward curved portion 125 of the pivotal lever 102. This biasing of the post 124 against the curved portion 125 maintains a toe portion of the pallet support member 80 underneath the pallet 22. This position of the pallet support member 80 is maintained during the pattern controlled movement of the pallet 22 with respect to the sewing machine 20. It is to be noted that before the aforementioned movement can take place, it is first of all necessary to move the carriage 24 along the axis 26 so as to remove the pallet support member 80 from within the cradle 120. This is essentially a command of movement in the Y-direction before any movement in the X-direction.
When the pattern stitching has been completed, the X-Y positioning system of FIG. 1 moves the pallet 22 again back to the position illustrated in FIG. 6. At this time, the air cylinder 110 is exhausted. The spring 116 exerts a biasing force on the pivotal lever 102 so as to rotate the pivotal lever about the axis 114. This also causes the shaft 108 to thereby retract within the exhausted air cylinder 110. The result is that the wedge 62 at the end of the pivotal lever 102 disengages from the V-notch 58 within the pallet 22.
Referring to FIG. 7, the wedge 62 is illustrated as being withdrawn from the notch 58. FIG. 7 furthermore discloses the actuation of an air cylinder 128 associated with the cradle 120. In this regard, the output shaft 129 of the air cylinder 128 is seen to have moved from a first dotted outline position to a second retracted position. The cradle 120 slides along a guide 130 extending outwardly from the frame of the pallet handling system 34 as is shown in FIG. 4. This movement of the cradle 120 along the guide 130 trips a switch 131. The switch 131 is attached to a downwardly extending member 132 which is connected to the frame of the pallet handling apparatus 34. Referring to FIG. 5, the switch 131 is seen to normally be closed when the output shaft 129 is extended so as to maintain the pallet support 80 in position underneath the pallet. The switch 131 opens when it engages a slot 133 within the slidable attachment to the cradle 120. This later event occurs during retraction of the output shaft 129 which moves the cradle 120 and hence the slot 133 relative to the stationary switch 131 allowing it to open.
The movement of the cradle 120 causes the pallet support member 80 which is registered therein to be rotated backwardly about the axis 114 as is illustrated in FIG. 7. This causes the toe portion of the pallet support member 80 to clear the underside of the pallet 22 as is shown in FIG. 7. The front edge of the pallet 22 now drops downwardly as a result of the removal of the toe portion of the pallet support member 80. The pallet drops down onto a pallet ejector system 134 as shown in FIG. 2. In this regard, a pair of holes 136 and 138 within the pallet 22 are engaged by a pair of aligned pins 140 and 142. The pins 140 and 142 are located on blocks 144 and 146 whose top surfaces stop and support the pallet 22 around the respective holes 136 and 138.
Referring to FIG. 8, the pallet 22 is illustrated as resting on the block 144 with the pin 140 penetrating the hole 136. The block 144 is seen to house a vertical plunger 148 which cooperates with a switch 150 so as to sense the presence of the pallet 22. In other words, when the hole 136 successfully locates over the pin 140, the plunger 148 depresses and closes the switch 150. The switch 150 triggers the automatic control which in turn starts the ejection of the pallet 22. This is accomplished by actuating an air cylinder 152 so as to retract an output shaft 154. The output shaft 154 is pivotally attached to a drive link 156 which is affixed to a shaft 158 of the ejector mechanism. The retraction of the output shaft 154 causes a counterclockwise rotation of the shaft 158. Referring to FIG. 2, the blocks 144 and 146 are seen to be held by a pair of vertical struts 160 and 162 having bases 164 and 166 physically attached to the shaft 158. The shaft 158 in turn is rotatable within a pair of journalled supports 168 and 170 which are affixed to a base 171 illustrated in FIG. 5. The blocks 144 and 146 are pivotally attached to the struts 160 and 162 so as to maintain a proper engagement with the pallet 22 during ejection. The degree of movement of the blocks 144 and 146 with respect to the struts 160 and 162 is limited by a pair of pivotally attached coupling links 172 and 174. In this regard, the coupling links 172 and 174 are each respectively pivotally attached to both the blocks 144 and 146 as well as the journalled supports 168 and 170.
Referring to FIG. 8, the movement of the ejector mechanism 134 during retraction of the output shaft 154 of the air cylinder 152 is illustrated. As has been previously discussed, this causes a rotation of the shaft 158 which in turn moves the struts 160 and 162 outwardly. The ejection path of the block 144 suspended atop the strut 160 and the link 172 is shown in dotted outline form in FIG. 8. The pallet is seen to slide down an adjustable sloped guide surface 176. The sloped guide surface 176 is adjustable along a rail 177 so as to accommodate various sized pallets. When the ejector mechanism 134 has moved the pallet 22 halfway outward, a switch 178 is released by a contact 180 affixed to the shaft 158 as shown in FIG. 2. The contact 180 is configured so as to open the switch 178 when the ejector mechanism 134 is halfway outward. In this regard, the contact 180 actually loses contact with the switch 178 at the halfway point. The contact 180 ultimately assumes a spaced position from the switch 178 as is indicated in dotted outline form. The opening of the switch 178 is a signal to the automatic control that ejection is actually taking place. The pallet is brought outward to a position 22'" that allows the attendant or operator to easily grasp and remove the pallet. This can actually be done during or after the loading of the next pallet into the middle position wherein it is clamped or locked into the carriage 24. In this manner, the sewing machine 20 does not lose valuable time due to the attendant having to immediately handle the completed pallet 22.
Referring to FIG. 9, an automatic digital control system for the pallet handling system 34 is illustrated. The digital control system is seen to include a programmed central processor unit 200 which is connected via an address and data bus 202 to an output port 204, an input port 206, and a keyboard/display controller 208. The central processor receives a clocking signal for internal timing purposes from a clock 209. The central processor unit 200 is preferably an Intel 8085 microprocessor which is an eight bit microprocessor available from the Intel Corporation. The address and data bus 202 is preferably a multibus available from Intel Corporation with the Intel 8085 microprocessor. The output port 204 is preferably an interfacing circuit identifiable as an Intel 8212 circuit which is compatible with the address and data bus 202. In a like manner, the input port 206 is an Intel circuit identifiable as an 8255-A and the keyboard/display controller 208 is an Intel circuit 8279.
The keyboard/display controller 208 interfaces with a keyboard 210 and a display 212. The keyboard can be any of a variety of commercially available keyboards interfacing with the controller 208 via a control bus 214. In this regard, the keyboard/display controller 208 merely scans the eight bits of information available over the control bus 214 and stores the same for subsequent communication with the central processor unit 200 via the address and data bus 202. It is to be noted that the keyboard/display controller 208 will be receiving eight bits of ASCII coded information from the keyboard 210 via the control bus 214. The ASCII code is a standard eight bit binary code for various keys present on commercially available keyboards. It is to be furthermore noted that the keyboard/display controller 208 will transmit keyboard information to the central processor unit 200 in ASCII code. The central processor 200 will convert the thus received information for its internal processing. Any transmittal of information back to the keyboard/display controller 208 will be previously coded in ASCII by the central processor 200. The keyboard/display controller 208 receives the ASCII coded character information from the central processor 200 via the address and data bus 202 and provides character generation information to the display 212 via a display bus 216 in a well-understood manner. It is to be understood that the display 212 can be any of a number of commercially available displays capable of responding to character generation information from the keyboard/display controller 208.
The output port 204 is seen to have six separate bilevel signal outputs identifiable as 218 through 228. The signals from the bilevel signal outputs 218 through 228 are applied to solid state relays 230, 232, 234, 236, 238 and 240. Each relay respectively converts a logically high bilevel signal applied thereto to a 24 volt AC signal that can be applied to a respective solenoid associated therewith. It is to be understood that each solenoid governs the action of a pneumatic valve associated with one of the pneumatic air cylinders present in the pallet handling system. A valve can either exhaust or admit air into the respective air cylinder in response to the 24 volt AC signal being impressed on its solenoid. The particular air cylinder and corresponding valve action is a matter of arbitrary choice according to the present invention since the bilevel signal condition present on the respective bilevel outputs 218 through 228 can either be set logically high or logically low to accomplish the appropriate action of the air cylinder. In other words, if it is necessary to issue a logically high signal at a particular bilevel output so as to impress a 24 volt AC signal on the corresponding solenoid in order to obtain an extension of the output shaft of the respective air cylinder, then such a signal would issue when the extension was desired. On the other hand, a commercially available pneumatic air cylinder requiring a lack of solenoid excitation for the extension of the output shaft would experience an appropriate logically low signal condition at the corresponding bilevel output. Accordingly, the signal conditions present at the respective bilevel outputs 218-228 will hereinafter be described in terms of the desired effect, namely, extension or retraction of the output shaft of the respective air cylinder.
Referring again to the specific solenoids in FIG. 9, it is to be noted that a solenoid 242 controls the pneumatic action of the air cylinder 70. It will be remembered that the air cylinder 70 dictates the movement of the left shelf 36. In like manner, the solenoid 244 controls the pneumatic air cylinder 94 associated with the right shelf 38. Solenoid 246 is associated with pneumatic air cylinder 98 which controls the withdrawal of the right shelf 38. Solenoid valve 248 is associated with pneumatic air cylinder 110 which controls the pallet clamping mechanism 66. Solenoid valve 250 is associated with air cylinder 128 which controls the movement of the cradle 120. Finally, a solenoid valve 252 controls the air cylinder 152 associated with the pallet ejector mechanism 134.
The input port 206 receives seven logic level signals at bilevel signal inputs 254, 256, 258, 260, 262, 264 and 266. Each bilevel signal input receives a logic level signal from a respective buffer circuit associated with a switch within the pallet handling mechanism 34. Referring first to the bilevel signal input 254, it is seen that a buffer circuit 268 provides a bilevel signal to this input in response to the closing of the switch 86. It will be remembered that the closed switch 86 indicates a downward position of the left shelf 36. The buffer circuit 268 is seen to comprise a noise filter circuit 270 in combination with an optical isolator circuit 272 and a bounce filter circuit 274. The noise filter 270 merely filters the electrical noise from the switch signal whereas the optical isolator 272 provides a further isolated signal that is applied to the conventional bounce filter circuit 274 which samples the signal from the optical isolator and provides an appropriate output signal only when the sampled signal is consistent for a period of time approximating 20 milliseconds. In this manner, an appropriate bilevel signal is applied to the bilevel signal input 254 of the input port 206.
The signal state of the bilevel signal input 254 is preferably logically low for a closed switch condition. In this regard, the switch 86 is preferably an electronic switch which generates a logically high signal condition when closed. This signal state is inverted by the various circuits comprising the buffer circuit 268. This results in a logically low signal state at the bilevel signal input 254 for the closed switch condition. It is to be noted that this signal conversion will prevail for the other bilevel signal inputs which are connected through respective buffer circuitry to various switches within the pallet handling system. This signal conversion need not however be followed in practicing the invention if the significance of a given state at a given bilevel input is taken into account within the software program resident within the central processor 200.
A buffer circuit 276 having the same internal configuration as that of buffer circuit 274 is connected to the switch 88. It will be remembered that the switch 88 defines an upward level position of the left shelf 36 when closed. The buffer circuit 276 is operative to produce a logically low bilevel signal to the bilevel signal input 256 in response to a closure of the switch 88.
A buffer circuit 278 processes the signal condition of the switch 131 through to the bilevel signal input 258. It will be remembered that the switch 131 closes when the cradle 120 is positioned outwardly so as to reset the pallet support 80 for subsequent support of a received pallet.
A buffer circuit 280 processes the signal condition of the switch 150 through to the bilevel signal input 260. It will be remembered that the switch 150 closes when the pallet has been engaged by the pallet ejector mechanism 134. This closed switch condition results in a logically low bilevel signal input 260.
A buffer circuit 282 processes the signal condition of the switch 178 through to the bilevel signal input 262. It will be remembered that the switch 178 opens when the pallet has been moved halfway to the extreme outward position by the ejector mechanism 134. This results in a logically high bilevel signal input 262.
A pair of buffer circuits 284 and 286 receive bilevel signals present on the lines 52 and 53 from the pallet identification sensor 50. It will be remembered that the pallet identification sensor 50 is operative to produce either logically high or logically low signal conditions on the lines 52 and 53 in response to particular pallet codes 44. These logic level signal conditions are inverted by the respective buffer circuits 284 and 286 and thereafter presented to the bilevel signal inputs 264 and 266. For the present, it is merely to be noted that the signals on the lines 52 and 53 will be logically low when a pallet is not registered with the pallet identification sensor 50. This will result in logically high signal conditions on the bilevel signal inputs 264 and 266.
As has been previously noted, the buffer circuit 276 is comprised of the same three elements as the buffer circuit 268, namely a noise filter, an optical isolator and a bounce filter. This can also be said of the buffer circuits 278, 280, 282, 284 and 286.
Referring again to the central processor unit 200, it will be remembered that this unit is preferably an Intel 8085 microprocessor. This unit is available with various amounts of randomly addressable memory which is otherwise known as main memory. This main memory normally contains the software programming necessary to operate and respond to the various digital logic present in FIG. 9. The main memory furthermore contains software programming which controls the digital logic necessary to run the motion control system as well as the sewing machine. This latter programming and associated logic do not form part of the present invention. In addition, the main memory includes an allocated portion reserved for the data base utilized by the programs. This data base includes stitch pattern files defining various stitch patterns that are to be sewn on workpieces mounted within the pallets.
The aforementioned programs and data base are normally read into the main memory via one or more tape cassettes. Each tape cassette is inserted into a cassette transport 288 which is driven under the control of a cassette controller 290. The cassette controller 290 transmits the information from the cassette to the main memory of the central processor 200 via the address and data bus 202. The control interfacing whereby information is loaded into the main memory from a tape cassette is well known in the art.
Referring now to FIG. 10, a flow chart of a program resident in the main memory of the central processor 200 is illustrated. This program governs the loading of a pallet into the pallet handling system 34 and will hereinafter be referred to as the PALLET LOAD program. The program begins with a run authorization having been received from an EXECUTIVE program in an initial step 300. The EXECUTIVE program will be described in detail hereinafter. For the present, it is merely to be understood that the EXECUTIVE program will authorize a run when a pallet is in place on the shelves 36 and 38 and a stitch pattern has been prescribed for the loaded pallet.
When the run authorization is received, the central processor 200 proceeds to a step 301 and sets a FLAG A equal to zero. This software flag is utilized by a PALLET UNLOAD program in a manner which will be described hereinafter.
The central processor 200 next issues a RETRACT command signal to the bilevel output 224 of the output port 204 as is indicated by the step 302 in FIG. 10. This is accomplished by specifically addressing the output port 204 and thereafter transmitting an appropriate logic level signal thereto. As has been previously discussed, the signal state of the logic level signal will depend on the configuration of the pneumatic air cylinder that is to be actuated. If the air cylinder is to be exhausted so as to retract the output shaft when the solenoid is deenergized, then the signal at bilevel output 224 will be logically low. On the other hand, if the solenoid must be energized to exhaust the air or if the air must be admitted to retract the output shaft, then the command signal at the bilevel output 224 would be logically high. In any event, the appropriate logic level command signal is generated by the programmed computer and applied to the solid state relay 236. This in turn appropriately energizes or deenergizes the solenoid 248 associated with the air cylinder 110. The net result is that the output shaft 108 of the air cylinder 110 is retracted so as to release the clamping mechanism 66. It is to be noted that the clamping mechanism 66 may already have been released. In this instance, the issuing of the RETRACT command merely is a redundant check on the status of the pallet clamping mechanism 66.
The next step 304 of the central processor 200 is to issue an EXTEND command signal to the bilevel output 218 of the output port 204. This triggers the solid state relay 230 so as to apply a signal condition to the solenoid 242 which allows an outward extension of the shaft 72 associated with the air cylinder 70. Referring to FIG. 4, the outward extension of the shaft 72 results in the left shelf 36 being lowered. The central processor 200 awaits the tripping of the switch 86 which occurs when the left shelf 36 is fully downward. In this regard, the closed switch condition 86 is filtered by the noise filter 270 isolated by the optical isolator 272 and thereafter retained by the bounce filter 274 so as to result in a logically low signal level condition being applied to the bilevel signal input 254. This logically low signal level will be detected by the central processor unit 200 in the step 306 within the flow chart of FIG. 10.
Following a confirmation that the left shelf 36 is down, the central processor 200 issues a RETRACT command signal at the bilevel output 220 of the output port 204 as is indicated by step 308. This RETRACT command triggers the solid state relay 232 so as to apply a signal condition to the solenoid 244 which allows the output shaft 95 of the air cylinder 94 to retract. Referring to FIG. 5, it will be remembered that the retraction of the output shaft 95 of the air cylinder 94 allows the right shelf 38 to be lowered so as to drop the right edge of the pallet from the top input position.
Referring again to the flow chart of FIG. 10, it is noted that the central processor unit counts out a delay of 200 milliseconds in a step 310. This defines an appropriate time for the right shelf 38 to assume the downward position. It is to be noted that the counting out of the delay is accomplished by establishing a count and thereafter decrementing the count by the clock signal from the clock 209.
Following the assumption of a downward position by the right shelf 38, the central processor 200 in a step 312 issues a RETRACT command signal at the bilevel output 218 of the output port 204. This reverses the signal state of the solid state relay 230 so as to apply a signal condition to the solenoid 242 which allows the output shaft 72 associated with the air cylinder 70 to retract and hence raise the left shelf 36. Referring to FIG. 4, the switch 88 is contacted when the left shelf assumes an upward position. The closed signal state of the switch 88 results in a logically low signal state being applied to the bilevel input 256 via the buffer circuit 276. This logically low signal state at the bilevel input 256 is noted by the central processor 200 which addresses the input port 206 and asks whether the bilevel signal input signal 256 has switched low. This is accomplished in a step 314 in FIG. 10.
The central processor 200 next issues a RETRACT command signal in a step 316 to the bilevel output 222 of the output port 204. Referring to FIG. 9, the relay 234, associated with the bilevel output 204, provides a signal condition on the solenoid 246 which results in a retraction of the output shaft of the air cylinder 98. As is seen in FIG. 5, this results in a withdrawal of the right shelf 38. This latter movement of the right shelf 38 allows for an appropriate clearance of the pallet 22 which now rests on the reference base 96. This constitutes the middle position for a pallet within the pallet handling system.
Referring again to FIG. 10, it is seen that the central processor 200 sets up a first delay count of 430 milliseconds in a step 318 following the issuance of the RETRACT command signal at the bilevel output 222. It will be remembered that the clock 209 provides a clock signal to the central processor 200 for the purpose of timing out a delay established by the central processor 200. White the central processor is thus timing out the delay, it also issues an EXTEND command signal in a step 320 to the bilevel output 224 of the output port 204. This triggers the solid state relay 236 so as to apply a signal condition to the solenoid 248 which causes the output shaft 108 of the air cylinder 110 to move outwardly. Referring to FIG. 6, this results in the pivotal lever 102 rotating about the axis 114 so as to apply a clamping pressure to the pallet which has been previously dropped onto the pallet supports 80 and 82. As a result of the clamping action, the pallet is now mated to the carriage 24 and is ready for subsequent positioning under the sewing machine head 20. Before any such positioning can occur, it is first of all necessary for the first delay count to have timed out indicating that the right shelf 38 has in fact reached a withdrawn position. This is provided for by the step 322 calling for the delay count to have been timed out in FIG. 10.
Following the timing out of the first delay, the central processor 200 is operative in a step 324 to issue an EXTEND command signal to the bilevel output 220 of the output port 204. This command triggers the solid state relay 232 so as to apply a signal condition to the solenoid 244 which causes the output shaft 95 of the air cylinder 94 to extend upwardly. This in turn causes the right shelf 38 to move upwardly as is shown in FIG. 5. The central processor 200 sets up a second delay count of 430 milliseconds in a step 326 and times out the second delay count so as to allow adequate time for the movement of the output shaft 95 of the air cylinder 94. The timing out is accomplished by a step 328 which utilizes the clocking signal from the clock 209 to time out the count of 430 milliseconds established in the step 326.
The central processor thereafter in a step 330 issues an EXTEND command signal at the bilevel output 222 of the output port 204. This triggers a solid state relay 234 so as to apply a signal condition to the solenoid 246 which causes an outward extension of the output shaft 97 of the air cylinder 98 as is shown in FIG. 5. This constitutes the final step in resetting the right shelf 38 to its upward position. The central processor 200 has now sequenced the left shelf 36 and right shelf 38 through a complete set of movements so as to drop the pallet to the middle position within the pallet handling system 34. The central processor 200 has moreover clamped the thus delivered pallet to the carriage 24 and reset both the left shelf 36 and the right shelf 38. This will allow for the loading of an additional pallet onto the thus reset shelves.
The central processor 200 is operative to call for the movement of the clamped pallet while another pallet is being loaded onto the reset shelves 36 and 38. In accordance with the invention, the movement of the pallet can actually occur as early as the end of step 320. At this point, the withdrawing of the right shelf 38 does not interfere with the movement of the pallet 22. The resetting of the right shelf 38 from a withdrawn and lowered position, as dictated by steps 324 to 330, will also not interfere with the movement of the pallet. The only requirement relative to the initial movement of the pallet is that the carriage 24 first be moved along the axis 26 in the Y-direction toward the sewing machine head 20. This initial movement will disengage the heel 118 of the pallet support from the cradle 120 in FIG. 6.
It is to be appreciated that a motion control program for the aforementioned movement resides in the main memory of the central processor 200. This motion control program utilizes a stored file of stitch pattern information which dictates the synchronized movement of the pallet containing a workpiece underneath a reciprocating sewing needle within the sewing head 20. This is identified broadly as the STITCH MODE in FIG. 10. Following the successful execution of a desired stitch pattern, the pallet containing the finished workpiece is returned to the position illustrated in FIG. 6. This requires a final movement of the carriage 24 along the axis 26 so as to reposition the heel 118 of the pallet support within the cradle 120. This is preparatory to further processing of the clamped pallet by the pallet handling system.
Referring now to FIG. 11, a MONITOR program is illustrated in flow chart form. This MONITOR program resides in the central processor unit 200 and is moreover active during the aforementioned stitching mode. In this regard, the MONITOR program is periodically executed for the purpose of ascertaining the status of any pallet that is to be removed by the operator or machine attendant. It will be remembered that the pallet handling system 34 has the capability of moving a finished pallet to an outward position for removal by the operator. The control for this particular processing of the pallet will be explained in detail hereinafter. For the moment, it is merely necessary to note that a pallet may in fact be present on the pallet handling mechanism 134. In this regard, the MONITOR program of FIG. 11 begins with a step 332 wherein the central processor 200 addresses the input port 206 and asks whether or not the bilevel signal input 260 has been switched high. Referring to FIG. 8, it will be remembered that a pallet resting on the block 144 of the pallet handling mechanism 134 will cause a plunger 148 to close a switch 150. This closure of the switch 150 will be processed by the buffer circuit 280 so as to produce a logically low signal condition at the bilevel input 260. As long as this logically low signal condition exists, the central processor 200 merely addresses the bilevel signal input 260 and does nothing further. On the other hand, when the bilevel signal input 260 switches logically high, the central processor 200 counts out a delay of three seconds as is indicated in a step 334 in FIG. 10. This is accomplished by setting up a count of three seconds and allowing the clock 209 to decrement the count to zero. At this time, the central processor sets a FLAG A equal to binary one in a step 336. This provides an indication that three seconds have elapsed following removal of the pallet by the operator. As will become apparent hereinafter, this three second delay is used to trigger the resetting of the pallet ejector mechanism 134. The lapse of three seconds allows the operator sufficient time to remove the pallet before the pallet ejector mechanism 134 begins this reset motion.
Referring now to FIGS. 12a and 12b, a flow chart depicts a PALLET UNLOAD program which dictates the sequential operation of the central processor 200 during a pallet unloading sequence. In this regard, a previously loaded pallet has been presented to the sewing machine head 20 for sewing and is now ready for the pallet unloading sequence. This is indicated by an end of stitching mode notation in FIG. 12a. It is to be understood that the end of stitching mode juncture depicted in FIG. 12a would include the repositioning of the heel 118 of the pallet support within the cradle 120 as is shown in FIG. 6.
The first inquiry made by the central processor 200 is to ask whether the bilevel signal input 260 is logically low in a step 338. It will be remembered from the previous discussion of FIG. 11, that the bilevel signal input 260 is logically low when the switch 150 associated with the pallet handling mechanism 134 is closed indicating that a pallet still rests on the ejector mechanism 134. If the pallet has not been removed by the operator during the course of the stitching mode, then the central processor 200 follows the "YES" path in FIG. 12a to a step 340 and transmits the ASCII coded message "REMOVE OLD PALLET" to the display 212. As has been previously discussed, the central processor 200 communicates with the keyboard/display controller 208 over the address and data bus 202 in the standard ASCII code. The keyboard/display controller 208 in turn transmits character generator signals over a display bus 216 to the display 212. The message is thereafter displayed in normal fashion on the display 212.
The central processor 200 now asks in step 342 whether the bilevel signal input 260 has switched high indicating removal of the pallet from the pallet handling mechanism 134. If the pallet still remains on the pallet handling mechanism 134, the "NO" path is pursued back to step 340 and the "REMOVE OLD PALLET" message is again transmitted to the display 212. The bilevel signal input 260 will again be addressed by the central processor 200 to ascertain whether or not the input signal has switched logically high indicating the removal of the pallet from the pallet handling mechanism 134. When this finally occurs, the "YES" path is pursued and the central processor 200 transmits ASCII message "THANKS" to the display 212 in a step 344. The central processor 200 now counts out a delay of three seconds in a step 346 and thereafter sets a FLAG A equal to binary one in a step 348. It will be remembered that this sequence of steps assures that the operator will be allowed sufficient time to remove the pallet.
Following the setting of the FLAG A equal to one, the central processor thereafter asks the keyboard/display controller 208 in a step 350 whether or not a "START" has been entered on the keyboard 210. The central processor 200 awaits the "START" signal from the keyboard 210 before following the "YES" path back to step 338. It will be noted that the loop which has just been discussed is premised on the pallet not having been unloaded at the end of the stitching mode. This requires that the machine be again started by the operator as is evidenced by the step 350 requiring a "START" authorization again. This program loop is avoided if the pallet has been previously removed prior to the end of stitching mode. In this regard, the bilevel signal input 260 will be logically high causing a "NO" answer to the inquiry by the central processor 200 in step 338. The "NO" path will hence be followed from the step 338 to a step 352 in FIG. 12a. The step 352 calls for the central processor 200 to ask whether or not the FLAG A is equal to one indicating that three seconds have elapsed following removal of the pallet. It will be remembered that the FLAG A does not indicate a binary one signal condition until three seconds have elapsed so as to allow the operator to remove the pallet. This could still be timing out in the event that the MONITOR program began counting out three seconds towards the end of the stitching mode. In any event, the central processor 200 awaits the setting of the FLAG A equal to one. When this occurs, the central processor in a step 354 issues an EXTEND command signal at the bilevel output 228 of the output port 204. Referring to FIG. 9, the presence of an EXTEND command signal at the bilevel output 228 triggers the solid state relay 240 so as to apply a signal condition to the solenoid 252 which causes the output 154 of the air cylinder 152 to extend. This extension of the output 154 of the air cylinder 152 causes the ejector mechanism 134 to rotate backwardly to its reset position.
The central processor 200 next asks in a step 356 whether the bilevel signal input 262 has switched low. Referring to FIG. 9, it is seen that the bilevel signal input 262 receives a buffered signal from the switch 178 through the buffer circuit 282. The switch 178 closes when the ejector mechanism 134 has moved inward halfway. This closed switch condition will result in the logically low signal state being indicated at the bilevel input 262. When the ejector mechanism has thus been sensed as having moved halfway inwardly, the central processor 200 resets the FLAG A equal to zero in a step 358.
The central processor 200 next issues a RETRACT command signal to the bilevel output 224 of the output port 204 in step 360. This triggers the solid state relay 236 so as to apply a signal condition to the solenoid 248 resulting in the retraction of the output shaft 108 associated with the air cylinder 110. This deactivates the clamping mechanism 66 as has been previously discussed with regard to FIG. 7. Specifically, the wedge 62 is disengaged from the groove 58 of the pallet 22. The pallet now merely lies on the pallet supports 80 and 82 as well as the reference base 96. Referring again to FIG. 12a, the central processor 200 assures that the aforementioned action has occurred by counting out a delay of 100 milliseconds in a step 362 following issuance of the RETRACT command to the bilevel output 224 in step 360. When the delay has thus been timed out, the central processor in a step 364 issues a RETRACT command signal to the bilevel output 226 of the output port 204. Referring to FIG. 9, the RETRACT command signal present at the bilevel output 226 triggers the solid state relay 238 so as to apply an appropriate signal condition to the solenoid 250. This allows the output 129 of the air cylinder 128 to retract so as to cause the cradle 120 housing the heel 118 of the pallet support to move backward in the manner shown in FIG. 7. The toe of the pallet support 80 is moved out from underneath the pallet so as to allow the pallet to drop downward at its front edge.
Referring now to FIG. 12b, it is seen that the flow chart depicted therein is a continuation of the sequential logic illustrated in FIG. 12a. In particular, it is to be noted that the first step of FIG. 12, namely, step 364 is merely a repeat of the last step performed by the central processor 200 in FIG. 12a. The next step 366 to be implemented by the central processor in FIG. 12b is that of asking whether or not the bilevel signal input 260 has switched low. Referring to FIG. 9, it is seen that the bilevel signal input 260 receives a buffered signal from the switch 150. The bilevel signal input will be logically low when the switch 150 has closed. It will be remembered from the discussion of FIG. 8 that the switch 150 is closed when a pallet rests on the pallet ejector mechanism. When this condition occurs, the "YES" path is pursued in FIG. 12b. The central processor 200 next issues a RETRACT command at the bilevel output 228 in a step 368. This RETRACT command present at the bilevel output 228 triggers a solid state relay 240 so as to apply a signal condition to the solenoid 252 which retracts the output shaft 154 of the air cylinder 152 in FIG. 8. This retraction causes the ejector mechanism 134 to move outwardly so as to transport the pallet to a position whereby it may be removed by the operator of the machine. The outward ejection motion is monitored by the central processor 200 in a step 370 which asks whether the bilevel signal input 262 has switched logically high. In this regard, the switch 178 switches open when the pallet ejector mechanism 134 is halfway through its outward motion. When the bilevel signal input 262 has switched high, the central processor 200 issues an EXTEND command to the bilevel output 226 in a step 372. Referring to FIG. 9, this triggers the solid state relay 238 so as to apply a signal condition to the solenoid 250 which extends the output 129 of the air cylinder 128. This causes the cradle 120 to engage the heel 118 of the pallet support so as to move the pallet support 80 back into a reset position. This position is illustrated in FIG. 6. The reset position of the pallet support 80 allows a pallet to be supported between the pallet support 80 and the pallet support 82. Referring to step 374 of FIG. 12b, the central processor 200 checks to see whether or not the pallet support 80 is in fact in position. This is accomplished by asking whether or not the bilevel signal input 258 has gone logically low. In this regard, the switch 131 associated with the cradle 120 will have closed when the output shaft 129 is fully extended. When this signal condition occurs, the central processor 200 proceeds "to the EXECUTIVE program". As will be explained in detail hereinafter, the EXECUTIVE program is operative to process a pallet present on the shelves 36 and 38 when a valid stitch pattern file has been assigned to the pallet.
The sensing of a pallet by the aforementioned EXECUTIVE program is premised on a sensing of the pallet identification code. It will be remembered from the discussion of the pallet identification code 44 in FIG. 3 that two separately coded surface areas 46 and 48 are presented underneath a pair of optical sensors in the pallet identification sensor device 50. The coded surface area 46 is sensed by one optical sensor which produces a bilevel signal on the line 52. The coded surface 48 is sensed by the other optical sensor which produces a bilevel signal on the line 53. The coded surfaces 46 and 48 may each either be opaque or reflective. A reflective surface produces a logically high signal condition on the respective line 52 or 53 whereas an opaque surface produces a logically low signal condition. These signal conditions are inverted by the respective buffer circuits 284 and 286 in FIG. 9 so as to produce the reverse signal condition at the bilevel inputs 264 and 266. Attaching a binary one significance to a logically high bilevel signal input and a binary zero to a logically low bilevel signal input results in the following binary significance relative to the coded surfaces 46 and 48:
______________________________________Coded Coded Bilevel BilevelSurface 46 Surface 48 Signal Signal(line 52) (line 53) Input 264 Input 266Opaque Reflective 1 0Reflective Reflective 0 1Reflective Reflective 0 0______________________________________
As has been previously noted, the condition wherein both areas are non-reflective is reserved for a "no-pallet present" situation. The EXECUTIVE program will attach a numerical significance to each of the above two bit binary code combinations in a manner which will be described hereinafter. The EXECUTIVE program will moreover assure that one or more particular stitch pattern files are assigned to each thus identified pallet. This assignment of a stitch pattern files to a pallet is accomplished through interactive communication with the operator as set forth in a sub program within the EXECUTIVE program. This as well as other features of the EXECUTIVE program will be more fully appreciated during the description of the program hereinafter. In this regard, the EXECUTIVE program appears in flow chart form in FIGS. 13a, 13b, 13c, 13d and 13e. It is to be noted that the ends of a first figure may be matched with the beginnings of a next figure by merely matching up the alphabetic labels on the flowchart lines of the respective figures.
Referring to FIG. 13a, the EXECUTIVE program begins with a pre-processing step 400 wherein a database is loaded from a peripheral memory into the main memory of the central processor 200. This peripheral memory preferably consists of a cassette system comprising a cassette transport driven under the control of a cassette controller. Such a peripheral memory system is illustrated in FIG. 9. It is noted that the cassette controller 290 communicates with the central processor 200 via the address and data bus 202. Cassette systems having the capability to communicate via an address and data bus with a central processor are well known in the art. The database which is thus loaded into the main memory of the central processor 200 via the bus 202 preferably includes up to nine separate stitch pattern files and a directory for these files. Each stitch pattern file preferably comprises one or more blocks of data wherein a block of data preferably equals 256 eight bit bytes of information. Each block of data contains X and Y motion information for the carriage 24 as well as instructions for the synchronized movement of the sewing needle within the sewing head 20. The directory for the nine stitch pattern files includes at least two bytes of information per file. The first byte is a numerical index for the first block of data of the file. The second byte indicates the number of data blocks that have been allocated to the particular file. It is to be appreciated that the directory will comprise a minimum of only eighteen bytes of information if nine stitch pattern files are to be maintained. Directory information for each numbered stitch pattern file is easily obtained by merely noting where the first directory byte is stored and thereafter counting up in multiples of two to the desired two bytes of directory information.
It is to be understood that while a particular database has been described, various other approaches to organizing the storage of stitch pattern files may also be used with the present invention. For instance, a series of stitch pattern files occupying consecutively addressable storage locations could also be used together with a directory containing the first address for each stitch pattern file and the number of addressable storage locations set aside for that file.
The next step 402 illustrated in FIG. 13a is that of initializing two software references which are to be used within the program. The first of these software references, namely, PAL is utilized for the purpose of assigning a stitch pattern file to a particular pallet. The other software reference, namely, RLATCH is utilized within the EXECUTIVE program as a run authorization. The use of these software references will be more fully understood hereinafter. For the present, it is merely to be noted that a setting of the RLATCH equal to minus one will assure that a run authorization does not occur.
The next step 404 within the executive program is to establish three separate tables denoted as TABLE 1, TABLE 2 and TABLE 3. Each of these tables is to have a predefined number of addressable storage locations capable of receiving file numbers which designate stitch pattern files. In the particular embodiment disclosed herein, file numbers will range from "1" through "9". The predefined number of addressable storage locations can hence be arbitrarily set at nine so as to allow each table to accommodate all nine file numbers. It is to be noted that in most instances, a table will actually have considerably less than all nine file numbers. The number of stitch pattern files in a table is normally a function of how many different sewing patterns are to be sewn on a workpiece prearranged within a pallet having a given code. For instance, a workpiece may only require three different stitch patterns to complete all sewing requirements. In this instance only three of the nine addressable storage locations in a table associated with that pallet code would be utilized.
All of the addressable storage locations in the thus established tables of step 404 are initially set equal to minus one in a step 406. The negative one condition of an addressable storage location within a table will be utilized as an indication that a file number has not been assigned thereto.
Step 408 sets up software references PTR 1, PTR 2, and PTR 3. These particular software references will be utilized to point to addressable storage locations within the respective tables established in step 404. Each pointer is initially set equal to the first addressable storage location in a respective table. This will mean that the first, tenth and eighteenth addressable storage locations in a set of twenty seven consecutive addressable storage locations set aside for the tables will constitute the initial pointer values of PTR 1, PTR 2, and PTR 3. As will become apparent hereinafter, a pointer can always be changed within the program so as to contain the address of the storage location which is next desired within a given table. This is normally accomplished by incrementing the pointer by one. This incrementing normally continues until an addressable storage location is encountered that has a stored value of minus one indicating that not all addressable storage locations have been utilized within the table. On the other hand, the incrementing can continue until the ninth addressable storage location is encountered. In either instance, the respective pointer is returned to the initialized pointer address value established in step 408.
The next step 410 within the EXECUTIVE program is to ask whether all bilevel inputs of input port 206 are logically high. This step is merely asking whether an operative automatic pallet handling system 34 has been connected to the central processor unit 200. In this regard, it is impossible for all bilevel inputs to maintain the same signal state in the event that a pallet handling system is appropriately connected. In this regard, it will be remembered that for instance the signal states of the bilevel inputs 254 and 256 can never be in the same signal state. In other words, the switches 86 and 88 associated with these particular bilevel inputs cannot be both simultaneously closed since they each represent different positions of the left shelf 36. In the event that all bilevel signal states agree, the YES path is pursued and the RLATCH reference is set equal to one in a step 412. This setting assures that the machine will not merely run in an automatic mode on the presumption that pallets are being sequenced through a pallet handling system. On the other hand, the machine can be operated in a manual mode in a manner which will be apparent hereinafter. This allows for the manual operation of the machine utilizing the EXECUTIVE program even without a properly functioning pallet handling apparatus or without any pallet handling apparatus.
In the event that an automatic pallet handling system with associated switches is appropriately connected to the input port 206, the NO path will be pursued out of step 410 to a step 414. Step 414 requires the central processor 200 to specifically sense the bilevel signal inputs 264 and 266. It will be remembered that a set of logically high signal conditions at both bilevel inputs 264 and 266 indicate that a pallet has not been presented to the pallet identification sensor device 50. In this regard, the central processor 200 is operative to check for this condition in a step 416 by asking whether or not the binary values of both bilevel signal inputs are binary one indicating a no pallet condition. If in fact a pallet has not been registered, then the YES path is pursued back to step 414 and the central processor again senses the bilevel signal inputs until such time as a pallet has been registered.
Referring again to step 416 in FIG. 13a, if a pallet is sensed, then the NO path is pursued to a next step 418 in FIG. 13b wherein the binary values of the sensed bilevel signal inputs 264 and 266 are inverted and thereafter stored in the software reference PAL. Referring to the binary values present at the bilevel inputs 264 and 266, it will be remembered that the following combinations of binary zeroes and ones may occur:
______________________________________ Input 264 Input 266______________________________________ 1 0 0 1 0 0______________________________________
It is to be appreciated that the inversion accomplished in step 422 will result in the following correspondence between the stored binary in PAL and the bilevel inputs 264 and 266:
______________________________________Input 264 Input 266 PAL______________________________________1 0 010 1 100 0 11______________________________________
It is to be appreciated that the above two bits of stored binary in PAL represent numerical values one, two and three in decimal. Accordingly, the stored two bits in PAL will be treated by the programmed central processor 200 as identifying either a pallet 1, pallet 2 or pallet 3. On the other hand, the operator of the machine will recognize a pallet 1, 2 or 3 by the following combinations of coded surfaces:
______________________________________Pallet Coded CodedNumber Surface 46 Surface 48______________________________________1 Opaque Reflective2 Reflective Opaque3 Reflective Reflective______________________________________
It is to be appreciated that the above numerical significance attaching to the coded surfaces 46 and 48 is arbitrary. Other encodings could occur with the ultimate numerical significance attaching to the encodings being decoded as decimal one, two, and three in the PAL software reference.
Referring again to FIG. 13b, the central processor proceeds from step 418 to a step 420 and asks for the signal status of RLATCH. If RLATCH is equal to zero, indicating an automatic mode of operation, then the "YES" path is pursued. On the other hand, if the RLATCH is other than zero, then it is set equal to one in step 422. It is to be noted that the path pursued after setting the RLATCH equal to one in step 412 also now converges.
The next sequence of steps is to basically associate the stored numerical pallet code in PAL with one of the three tables, TABLE 1, TABLE 2, or TABLE 3. In this regard, step 424 asks whether the bit contents of the software reference PAL are equal to one. If the answer is YES, then step 426 is pursued and the central processor 200 stores the contents of the addressable storage location in TABLE 1 currently pointed to by PTR 1 in a software reference PATN. It is to be appreciated that the contents of this addressable storage location will initially be minus one. On the other hand, this addressable storage location will ultimately contain a binary representation of a particular file number that will be entered later on in a TABLE ENTRY program which will be explained in detail hereinafter. In like manner, steps 428 and 430 ask whether or not the numerical pallet code stored in the software reference PAL is equal to two and if YES, the bit contents of the addressable storage location in TABLE 2 currently pointed to by PTR 2 are stored in the software reference PATN. In the event that a NO answer is obtained to the question posed in step 428, then the central processor proceeds to a step 432 and stores the bit contents of the addressable storage location currently to by PTR 3 in the software reference PATN since this is the only other possible numerical pallet code. At this point in time, the software reference PATN has either the bit contents of an addressable storage location from TABLE 1, TABLE 2 or TABLE 3 stored therein as a result of steps 424 through 432.
The next step 434 is to ask whether the software reference PATN is equal to minus one. This will in fact be the case initially as none of the tables will have anything other than a minus one. On the other hand, if at least one stitch pattern file has been previously assigned to a pallet in a manner which will be described hereinafter, then the NO path is pursued out of step 434. In this event, the central processor 200 executes a step 436 wherein an ASCII message is transmitted to the display 212 which begins with the word "FILE" and thereafter the numerical designation "M" which represents the bit contents of the software reference PATN. In this regard, the software reference PATN will have the bit contents of the particular addressable storage location pointed to as a result of steps 426, 430, or 432.
In the event that at least one stitch pattern file has not been assigned to the sensed pallet, then the YES path will be pursued out of step 434. The central processor 200 now sets RLATCH equal to one in step 438 so as to assure that an automatic run will not occur if a file has not in fact been assigned. The central processor next transmits in a step 440 the ASCII message "FILE*" to display 212. This communication to the operator of the machine indicates that a file has not been assigned to the pallet that is thus registered under the sensor 50.
Accordingly, the central processor 200 asks the keyboard display controller 208 whether a keyboard entry has been made on the keyboard 210. This is step 442. It is to be noted that the central processor 200 asks whether or not a keyboard entry has been made regardless of whether or not step 436 has been executed. In this manner, an opportunity is allowed for changing the assigned stitch pattern file which has been previously indicated to the operator in step 436. If a keyboard entry has not been made following display of messages in either steps 436 or 440, then the NO path is pursued from step 442 in FIG. 13b to a step 444 in FIG. 13c. Step 444 inquires as to the status of the software reference RLATCH. It will be remembered that RLATCH is initially set equal to minus one in step 402. It is also to be noted that RLATCH is set equal to one in a step 412 if a pallet handling system is not detected in step 410. In either of these cases, the NO path will be pursued out of step 444 back through a common return junction "C" to step 410. The central processor will hence remain in a loop defined by the NO path out of step 444 until the RLATCH is set equal to zero in a manner which will hereinafter be described.
Referring to FIG. 13b, if a keyboard entry has been made in step 442, then the central processor 200 proceeds via a YES path out of step 442 to a step 446 in FIG. 13c. The central processor reads and saves the keyboard value "N" from the controller 208 in the step 446. It will be remembered that the controller 208 provides an ASCII coded signal to the central processor via the eight bit bus 202. In this regard a particular ASCII code will be provided for each key on the keyboard 210. The eight bits of information constituting the value "N" must be analyzed to determine which key has been depressed on the keyboard 210. This is accomplished by first asking in a step 448 whether the value "N" constitutes the ASCII code for an "ENTER" key. This can be any key on the keyboard 210 which has been previously defined as the ENTER key. If the ENTER key has been depressed then a YES path is pursued to a step 450. Wherein a TABLE ENTRY program is implemented. The TABLE ENTRY program will be explained in detail hereinafter. For now, it is merely to be understood that the TABLE ENTRY program allows the operator of the machine to assign stitch pattern files to TABLE 1, TABLE 2, or TABLE 3.
Referring again to step 448, if the ENTER key has not been depressed, then the central processor proceeds along the NO path to a step 452. Step 452 inquires as to whether the keyboard value "N" denotes a START key. Again this is merely asking whether a particular predefined ASCII coded key (that has been arbitrarily defined as the START key) has been depressed. If the answer is in the negative, then a NO path is pursued back through the common return junction C in FIG. 13a to step 410. If on the other hand, the START key has been depressed, then the central processor proceeds to a step 454 wherein the value of the software reference PATN is queried. It will be remembered that the software reference PATN will contain the contents of an addressable storage location pointed to by one of the pointers PTR 1, PTR 2, or PTR 3 as set forth in steps 426, 430 or 432. If the pointed to storage location has not had a previous file number entered therein, then the value of the storage location and hence PATN will be a minus one. In this case, the central processor will pursue a YES path from the step 454 to a step 456 which transmits the message "NO FILE" to the display 212. The central processor will maintain the message for one second before returning back to step 410 via common return junction C in FIG. 13a.
Referring again to step 454, if the software reference PATN is other than minus one, then the NO path is pursued to a step 458 wherein the central processor sets the RLATCH equal to zero. This setting of the RLATCH equal to zero allows the central processor 200 to operate in an automatic mode unless otherwise interrupted. The central processor 200 now proceeds to a step 460 after having initially set the RLATCH equal to zero in step 458.
Step 460 merely repeats the question asked in step 410 as to whether all bilevel inputs of input port 206 are in the same signal state. It will be remembered that this step is merely asking whether an operative pallet handling system has been connected to the central processor 200. If an operative pallet system is present, then the bilevel inputs to the input port 206 will not all be in the same signal state as previously discussed relative to step 410. This will result in the central processor 200 pursuing the NO path from step 460 to step 462.
Step 462 calls for an implementation of the PALLET LOAD program which has been previously illustrated and discussed in FIG. 10. It will be remembered that his program sequentially operates the pallet handling mechanism 34 so as to drop a pallet from the input load position to the middle position wherein the pallet is mated to the carriage 24 of the X, Y motion control system. When the last step of the PALLET LOAD program is implemented, the central processor moves to step 464 within FIG. 13d of the EXECUTIVE program.
It is to be noted that step 464 is directly pursued out of step 460 in the event that an operative pallet handling system is not determined to be present. Specifically, if all bilevel inputs are in the same signal state, then the YES path is pursued from step 460 to step 464. As will be explained hereinafter, this allows for the automatic sewing of an assigned stitch pattern file without a pallet handling apparatus being present.
Step 464 causes the central processor 200 to consult the directory and locate the bytes of information corresponding to the file number "M" stored in the software reference PATN. It will be remembered that the directory is organized on the basis of an equal number of information bytes for each stitch pattern file. In this manner, the number of bytes for each file is merely multiplied by the number "M" so as to arrive at the first byte of information for the file "M". It will be remembered that the first byte of directory information for each file is the numerical index for the first block of data associated with the file.
The memory address within the main memory of the central processor 200 is calculated from this numerical index in step 466. Specifically, the numerical index for the first block of data is multiplied by 100 hexadecimal (otherwise known as 256 decimal) and the results are added to the first addressable memory location of the portion of main memory allocated to data. In other words, a normal partitioning of the main memory dictates that storage space first be set aside for needs other than data. The address of the next available storage location would constitute the address of the first addressable memory location of that portion of main memory allocated to data. The computer stores the results of the calculation in 466 as the first address for the stitch pattern. The next step 468 is to execute the stitch pattern file which has thus been located within main memory. It is to be noted that the step 468 also calls for the periodic implementation of the MONITOR program. It will be remembered from FIG. 11 that the MONITOR program checks as to the status of any pallet awaiting removal by the operator from the ejector mechanism. Following the end of the stitching pattern, the central processor 200 immediately moves to a step 470 which asks whether the software reference PAL is equal to one. It will be remembered that the software reference PAL contains the numerical value of the pallet code sensed in step 414. This numerical value is stored in the software reference PAL in step 418 and is thereafter utilized in steps 424 to 432 to consult the correct table that is to be associated with the sensed pallet code. The stitch pattern file number obtained from the addressable storage location in the thus consulted table defines the stitch pattern that is sewn immediately upstream of step 470. It is the purpose of step 470 to ascertain whether it was TABLE 1 that was thus consulted in steps 424 to 432. In the event that this was the case, PAL will be equal to one and the YES path will be pursued from step 470 to a step 472 wherein the question is asked whether PTR 1 has reached the last addressable storage location in TABLE 1. It will be remembered from the discussion of step 404 that there are preferably nine addressable storage locations in each table. Step 472 hence asks whether the current value of PTR 1 is equal to the ninth address within the twenty-seven consecutive addresses set aside to define the addressable storage locations in step 404. If PTR 1 is determined to be at the last addressable storage location in TABLE 1, then the YES path is pursued from step 472 to a step 474. Step 474 resets PTR 1 to the address of the first addressable storage location. It will be remembered that this address has been defined in step 404 when TABLE 1 was established.
Referring again to step 472, if PTR 1 has not reached the last addressable storage location in TABLE 1, than the NO path is pursued to a step 476 wherein the pointer PTR 1 is incremented by one so as to contain the address of the next addressable storage location in TABLE 1. The central processor now proceeds to a step 478 and inquires as to whether the contents of the addressable storage location now pointed to are equal to minus one. It will be remembered that all addressable storage locations need not contain file numbers. In the event that only three stitch pattern files are necessary within a table, then the fourth through the ninth storage locations will merely contain minus ones. Step 478 hence merely is asking whether the pointer has gone past the last successive storage location in TABLE 1 to have a file number. In the event that this is the case, the YES path is pursued to step 474 wherein the PTR 1 is again set equal to the address of the first addressable storage location in TABLE 1. In this manner, the PTR 1 is always reset to the first addressable storage location of TABLE 1 after all assigned stitch pattern file numbers in the table have been utilized.
Referring again to step 478, if the contents of the addressable storage location now pointed to by PTR 1 are not minus one, then the address contained within PTR 1 is not disturbed. The central processor proceeds out of step 478 along a NO path to a common junction downstream of step 474. At this point, the address in the software reference PTR 1 is either pointing to the first addressable storage location in TABLE 1 by virtue of step 474 or to the next addressable storage location to contain a stitch pattern file number as has been determined in step 478. The EXECUTIVE program is now ready to proceed to a step 480 based on the fact that the pointer for TABLE 1 is correctly pointing to the appropriate storage location. It will, however, be remembered that the above is premised on the software reference PAL being equal to one in step 470 so as to require the changing of the software reference PTR 1.
Referring to step 470, it is seen that if the software reference PAL is not equal to one, then a NO path is pursued to a step 482. Step 482 determines whether the pallet code sensed in step 414 and thereafter stored in PAL is either two or three. In the event that the pallet code is two, then a YES path is pursued to step 484. Step 484 as well as steps 486, 488 and 490 analyze the pointed PTR 2 in much the same manner as has been previously discussed for PTR 1. In other words, PTR 2 is either the reset back to the address of the first addressable storage location of TABLE 2 in step 486 or is incremented by one in step 488 so as to point to an addressable storage location containing a file number as verified in step 490.
Referring again to step 482, if the pallet code in the software reference PAL is three, then the NO path is pursued to a series of steps 492 through 498. In this regard, the software reference PTR 3 is either reset back to the address of the first addressable storage location of TABLE 3 in the step 494 or is incremented by one in step 496 so as to point to an addressable storage location in TABLE 3 containing a file number as verified in step 498.
It is to be noted that following the correct setting of either PTR 2 or PTR 3, the central processor proceeds to the step 480 in much the same manner as has been previously discussed for PTR 1. In this manner, either PTR 1, PTR 2 or PTR3 has been appropriately set upstream of step 480. The particular pointer having been determined by the pallet code present within the software reference PAL.
Referring now to step 480, it is seen that the central processor is now inquiring as to whether all bilevel signal inputs of input port 206 are in the same signal state. This again is asking the same question as has been previously asked in steps 404 and 460 namely, is an operative pallet handling apparatus present. In the event that a pallet handling apparatus is not present, the YES path is pursued through common junction "D" to step 412 in FIG. 13a. Referring to step 412, it is seen that the central processor 200 sets the RLATCH equal to one to assure a non-automatic mode of operation when executing the EXECUTIVE program without a pallet handling apparatus.
Referring again to step 480, it is seen that the NO path is pursued in the event that all bilevel signal inputs are not in the same signal state. This path will be taken if an operative pallet handling apparatus is present. The central processor 200 proceeds along the NO path to the PALLET UNLOAD program of step 481. This program is illustrated in FIGS. 12a and 12b. It will be remembered that the execution of the stitch pattern file brings the pallet back to the position within the pallet handling mechanism 34 so as to allow for subsequent unloading. The unloading occurs in the manner dictated by the program steps outlined in FIGS. 12a and 12b. At the end of the PALLET UNLOAD program the central processor 200 again returns through common junction "C" to step 410 in FIG. 13a. At this point, the operator will most likely have loaded another pallet which can be sensed by the pallet identification sensor 50. This will result in the NO path being pursued out of the step 416 in FIG. 13a. The central processor 200 continues in the automatic mode through step 418 wherein the sensed pallet code is converted to a numerical value and stored in the software reference PAL. The central processor next associates the numerical value of the sensed pallet code stored in PAL with the appropriate table of file numbers in steps 424 through 432. The contents of the addressable storage location of the appropriate table are stored in the software reference PATN. The stitch pattern file number which is thus stored in PATN is displayed in step 436. If this stitch pattern file number is not changed by the operator depressing a key on the keyboard, then the central processor will pursue the NO path out of step 442 to step 444. Since the automatic mode has not been interrupted, the RLATCH remains equal to zero, and the YES path is pursued to step 460. The central processor notes that an automatic pallet handling system is present so as to require execution of the PALLET LOAD program in step 462. The stitch pattern file, denoted by the file number "M", is accessed from main memory and thereafter executed in step 468. The central processor now proceeds to set the pointer of the table that was used to obtain the file number of the stitch pattern that has just been executed. This is done in steps 470 through 478 and 482 through 498 by noting the value of the software reference PAL and accordingly setting the pointer of the table associated therewith. The central processor proceeds to step 480 and again notes that automatic pallet handling is present so as to require execution of the PALLET UNLOAD program in step 481. The completed pallet is thereafter unloaded and the central processor 200 returns through common junction "C" to the beginning of the EXECUTIVE program. This automatic processing of pallets will continue until such time as either a pallet is not timely loaded by the operator so as to be sensed following the completion of the stitching of the previous pallet or until such time as a pallet is not appropriately removed at the "EJECT" position. In this latter instance, the PALLET UNLOAD program of FIGS. 12a and 12b will interrupt the automatic sequence and request a "START" authorization from the operator.
It is also to be noted that the machine can be operated without a pallet handling apparatus. Referring to step 410, it is seen that the YES path is pursued in the event that an operative pallet handling apparatus is not initially found by the central processor 200. The RLATCH is set equal to one in step 412 and the central processor next inquires in step 424 as to whether the software reference PAL equals one. It will be remembered that the initial status of the software reference PAL is set equal to one in step 402. The status of the software reference PAL will result in the YES path being pursued from step 422 to step 426. The central processor 200 now stores the contents of the addressable storage location of TABLE 1 pointed to by PTR 1 in the software reference PATN. The file number appearing in the thus read storage location will be displayed in step 436 and the central processor will cycle through step 442 until a keyboard entry has been detected. If the START key is depressed, the central processor will proceed through step 452 to step 460 and inquire as to whether a pallet handling apparatus is present. Since there isn't, the YES path is pursued from step 460 to step 464 which in conjunction with step 466 locates the identified stitch pattern file in memory. The stitch pattern file is thereafter accessed and executed in step 468. Following completion of the stitch pattern, the central processor sets the software reference PTR 1 to the next appropriate storage location in TABLE 1. The central processor now notes that an operative pallet handling apparatus is not present in step 480. This results in the YES path being pursued through common junction "D" back to step 412 which again sets the RLATCH equal to one. This will again dictate a non-automatic mode of operation. If the operator has manually or otherwise clamped another pallet into place, then the stitch pattern file currently pointed to in TABLE 1 by PTR 1 will be executed following depression of the START key by the operator. It is of course to be noted that the operator can change this stitch pattern file prior to depressing the START key. In this regard, the stitch pattern file number is always displayed in step 436 allowing the operator the option of depressing the "ENTER" key. This will be detected in step 448 and the central processor will proceed to the step 450 wherein the TABLE ENTRY PROGRAM is entered.
Before discussing the TABLE ENTRY PROGRAM in detail, it is to be merely noted that this table can also be entered during the automatic mode. In this regard, the operator merely need depress the ENTER key any time prior to step 442. The EXECUTIVE program will immediately proceed to step 450. It is still furthermore to be noted that the EXECUTIVE program will require entry into the TABLE ENTRY program in the event that a stitch pattern file number has not been assigned to a particular pallet code sensed in step 414. It will be remembered that all addressable storage locations in each table are initially set equal to minus one in step 406. Any pallet code that is sensed for the first time in step 414 will be associated with a table in step 426, 430 or 432 that has all addressable storage locations equal to minus one. This will mean that the software reference PATN will be minus one in step 434. This will result in a switch to a non-automatic mode in step 438 if the EXECUTIVE program has previously been in an automatic mode. On the other hand, the EXECUTIVE may already have been in a non-automatic mode in which case the setting of the RLATCH equal to one in step 438 is redundant. In either event, the central processor will proceed to step 448 and transmit the ASCII message "FILE*" to display 212. This is a message to the operator essentially asking that a file assignment be made to the pallet which has been presented. The central processor will continue to cycle through the step 442 waiting for the ENTER key to be depressed. When this occurs, the central processor will proceed along the YES path from step 448 to step 450 which implements the TABLE ENTRY PROGRAM of FIGS. 14a-14c.
Referring to FIG. 14a, the TABLE ENTRY PROGRAM is seen to begin with a step 500 which asks whether the software reference PAL is equal to one. It will be remembered that the software reference PAL is equal to one if a pallet handling system is not in place. The software reference PAL might otherwise be equal to one if a pallet code having a numerical value of one has been sensed in step 414. In either event, the central processor noting a PAL equal to one condition will pursue a YES path out of step 500 to a step 502. Step 502 sets all addressable storage locations of TABLE 1 equal to minus one. This essentially wipes out any file numbers that have been previously stored in TABLE 1. Step 502 is, of course, redundant if no file numbers have been previously stored. In either event, the central processor proceeds to a step 504 and sets the software reference PTR 1 equal to the address of the first addressable storage location in TABLE 1. This address has been previously established in step 404 of the EXECUTIVE program and is hence available for use in step 504. TABLE 1 is now ready to receive new stitch pattern file numbers beginning at its first addressable storage location.
Referring again to step 500, it is to be noted that if the software reference PAL is not equal to one, then a NO path is pursued to a step 506. Step 506 determines whether the sensed pallet code of step 414 that is stored in PAL is either a two or a three. In the event that the pallet code is two, the central processor will proceed to set all addressable storage locations in TABLE 2 equal to minus one in a step 508. The software reference PTR 2 will thereafter be set equal to the address of the first addressable storage location of TABLE 2 in a step 510. Referring again to step 506, if the pallet code is three, the central processor will proceed to set all addressable storage locations of TABLE 3 equal to minus one in a step 512. The software reference PTR 3 will thereafter be set equal to the address of the first addressable storage location of TABLE 3 in a step 514.
It is to be noted that following the setting of a pointer in either TABLE 1, TABLE 2 or TABLE 3, the central processor proceeds to a step 516 in the TABLE ENTRY PROGRAM. The RLATCH is set equal to one in step 516 so as to assure a non-automatic mode of operation. The central processor now awaits a keyboard entry from the operator in a step 518. The central processor proceeds to a step 520 when a keyboard entry has been made and both reads and stores the keyboard value "N" from the controller 208. As has been previously discussed, the keyboard values from the controller 208 will be in ASCII code. The central processor now proceeds to step 522 and asks whether the keyboard value "N" corresponds to the ASCII code for the EXIT key. It is to be appreciated that the EXIT key can be any arbitrarily designated key on the keyboard 210 which is not otherwise being used. This designated key will have an ASCII code that is to be used as the basis of comparison in step 522. Assuming that depression of the EXIT key has not been detected in step 522, the central processor proceeds to a series of steps 524 (appearing in FIG. 14a) and 526 (appearing in FIG. 14b). Step 524 asks whether the keyboard value is less than 31 hexadecimal whereas step 526 asks whether the keyboard value is greater than 39 hexadecimal. This hexadecimal range defines the numerical keys one to nine on the keyboard 210. It is to be understood that depression of any other key on the keyboard 210 (other than the EXIT key which is covered by step 422) will result in either of the YES paths being taken out of steps 524 or 526 to a step 528 in FIG. 14b. Step 528 transmits the message "ENTER DIGIT" to the display 212. This essentially advises the operator to depress only numerical keys on the keyboard 210. the "ENTER DIGIT" message is followed by a further message generated in step 530. This further message is a "FILE*" which asks the operator to again attempt to make a file assignment. The central processor now returns to step 518 via common return junction "E". Step 518 awaits the next keyboard entry. When a numerical key from one to nine has been depressed, the central processor will proceed through steps 524 and 526 to a step 532. At this point, the central processor will subtract hexadecimal 30 from the keyboard value "N" and store the result "M" in the software reference PATN. The next step 534 is to transmit the message "FILE M" to the display 212 wherein "M" represents the contents of the software reference PATN. The central processor now proceeds in a step 536 to consult the directory and inquire as to whether there are any blocks of data noted for file "M". In this regard, it will be remembered that the directory contains a byte of information relative to each file which indicates the number of data blocks for the file. If this byte indicates zero data blocks, then there is in fact no stitch pattern file resident within the memory under this file number. In this case, the YES path is pursued from step 536 to a step 538. Step 538 transmits an ASCII message of "NO FILE" to the display 212. This message is displayed for at least one second so as to assure that the operator receives the message. The central processor thereafter transmits the message "FILE*" in step 530 and proceeds to common return junction "E" upstream of step 518. Step 518 now awaits the next keyboard entry. The operator is moreover aware that the previous keyboard entry did not identify a valid file within the machine. Specifically the message "NO FILE" of step 538 has told the operator that no such stitch pattern file exists.
Assuming that the next keyboard entry is a numerical key identifying a file having a certain number of blocks of data, the central processor will proceed through the step 536 along a NO path to a step 540. Step 540 now asks whether the software reference PAL is equal to one. The software reference PAL will be equal to one if either a pallet code of one has been sensed or if a manual mode of operation is in effect through step 412. In either event, the central processor will proceed to a step 542 wherein the contents "M" of the software reference PATN are stored in the storage location of TABLE 1 currently pointed to by PTR 1. This will be the first addressable storage location in TABLE 1 by virtue of step 504 if this is the first successful keyboard entry passing through step 536 to step 540. The central processor proceeds to step 544 and inquires as to whether the software reference PTR 1 contains the address of the last addressable storage location in TABLE 1. This address is known by virtue of step 404 wherein TABLE 1 was established. If PTR 1 does not contain the address of the last addressable storage location (so as to be pointing thereto), the central processor will proceed to a step 546. Step 546 increments the address of PTR 1 so as to point to the next addressable storage location in TABLE 1. The central processor now returns via common junction "E" to step 518 and awaits the next keyboard entry. It is also to be noted that the central processor will directly return to step 518 from step 544 in the event that PTR 1 is at the last addressable storage location.
Referring again to step 540, in the event that the software reference PAL does not equal one, the central processor will proceed along a NO path to a step 548. Step 548 asks whether the software reference PAL is equal to two. This will be the case if a pallet code of two has been sensed in step 414. In the event that PAL is equal to two, the central processor will proceed to step 550 and store the contents "M" of the software reference PATN in the storage location currently pointed to by PTR 2. The central processor will then proceed through steps 552 and 554 and increment the software reference PTR 2 if the same is not already pointing to the last addressable storage location of TABLE 2. Having this updated the status of PTR 2, the central processor will proceed via common return junction "E" to step 518 and await the next keyboard entry.
Referring again to step 548, in the event that the software reference PAL does not equal two, the central processor will proceed to a step 556 on the basis that the pallet code stored in PAL has a numerical value of three. The central processor will store the contents "M" of the software reference PATN in the addressable storage location of TABLE 3 currently pointed to by PTR 3. The central processor will thereafter proceed through steps 558 and 560 and update the status of PTR 3. The central processor will thereafter proceed via common return junction "E" to step 518 and await the next keyboard entry.
It is to be appreciated that the operator can enter up to nine stitch pattern file numbers in any of the tables by virtue of respectively cycling through the TABLE ENTRY program. In this regard each file number that has been approved by the program will be stored in the appropriate table of file numbers. It is moreover to be understood that the operator may choose to enter only one stitch pattern file number into a particular table. In this latter instance, all addressable storage locations of the table other than the first will contain minus ones.
When the operator has entered the last file number to be assigned to a particular table, the EXIT key is depressed on the keyboard 210. This is detected in step 522 of the TABLE ENTRY program. Referring to step 522, the keyboard value "N" is checked to see whether it corresponds to the ASCII code for the EXIT key. In the event that this is the case, the central processor will proceed to a step 562 and inquire as to whether the software reference PAL is equal to one. If the answer is YES, the central processor proceeds in a step 564 to reset the software reference PTR 1 to the address of the first addressable storage location of TABLE 1. This allows the central processor to exit from the TABLE ENTRY program with an appropriate table of file numbers defined in TABLE 1 and the pointer for this table pointing to the first addressable storage location within the thus established table. The central processor exits in a step 566 of the TABLE ENTRY program to a step 444 within the EXECUTIVE program. Since the RLATCH is equal to one, the EXECUTIVE program will await the depression of the start key. The central processor will thereafter sew one of the stitch patterns assigned to the particular pallet code through the TABLE ENTRY program each time that code is sensed. The stitch pattern sewn will depend on which storage location is currently being pointed to within the table of file numbers established in the TABLE ENTRY program.
Referring again to step 562, it is to be noted that if the software reference PAL is other than one, the central processor proceeds to a step 568. Step 568 asks whether the pallet code stored in the software reference PAL is equal to two. In the event that the answer is YES, the software reference PTR 2 is set equal to the address of the first addressable storage location in TABLE 2. This is done in a step 570. If the answer is NO in step 568, the central processor proceeds to a step 572 and assumes that the pallet code resident in the software reference PAL is three. The central processor hence resets the software reference PTR 3 to the address of the first addressable storage location of TABLE 3 in a step 572.
It is to be noted that the central processor proceeds to exit from the TABLE ENTRY program via step 566 after either step 570 or step 572. In this regard the appropriate table of file numbers has been established and the pointer for this table is pointing to the first addressable storage location of that table.
It is to be appreciated that the TABLE ENTRY program can be utilized to establish tables of file numbers for three distinct pallet codes. Each of these codes when sensed within the EXECUTIVE program, will result in a stitch pattern being sewn. The particular stitch pattern there sewn will depend on where a pointer is pointing within a table of file numbers particularly established for the particularly sensed pallet code. These stitch patterns will be successively sewn in the manner dictated by the table.
From the foregoing, it is to be understood that a preferred embodiment has been disclosed of a interactive communication system whereby a number of stitch patterns can be arbitrarily assigned to each of a number of pallets having individual pallet codes associated therewith. It is to be appreciated that alternative elements to those disclosed in the preferred embodiment may be used without departing from the scope of the invention.
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A system is disclosed for assigning stitch patterns that are to be automatically sewn on workpieces presented to an automatic sewing machine. The system is capable of receiving a number of communications that identify separate stitch patterns that are to be sewn on a workpiece. The system analyzes these communications and either accepts or rejects the communications as valid stitch pattern assignments. In the event that a communication is accepted, it is stored in a recallable sequence of stitch patterns that are to be sewn on the workpiece.
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FIELD OF THE INVENTION
The present invention relates to golf clubs formed by metal injection molding. More specifically, the present invention relates to putters formed by metal injection molding.
BACKGROUND OF THE INVENTION
Golf clubs are formed through a variety of methods. Commonly, a golf club head is forged or cast and then machined to the requisite dimensions and desired aesthetic quality. These processes have proven to be time consuming, inefficient, and expensive.
Recently, powdered injection molding has come to the forefront of golf club manufacturing. Metal injection molding or (MIM) is a manufacturing process which combines the versatility of plastic injection molding with the strength and integrity of machined, pressed or otherwise manufactured small, complex, metal parts. The process generally involves combining fine metal powders of a diameter of less than 45 micrometers with plastic binders (various thermoplastics, waxes, and other materials), which allow the metal to be injected into a mold using standard plastic injection molding machines.
After the part is molded and before the binders are removed, the post molding product is referred to as a “green part.” The next step is to remove the binders and flow agents with solvents and thermal processes. The resultant metal part is then sintered at temperatures great enough to bind the particles but not melt the metal. This process results in a golf club that has a crisp, clean appearance similar to a golf club subjected to a milling process. However, this process requires powdered metals, which are expensive.
For example, U.S. Pat. No. 6,478,842 generally discloses a unitary golf club head made by metal injection molding. This requires that the entire volume of the club head is formed from powdered metal, which, as mentioned above, is cost prohibitive based on the cost of powdered metals.
Therefore, what is needed is a golf club that can be produced efficiently and with a low volume of powdered metal, while maintaining performance characteristics and aesthetic quality.
SUMMARY OF THE INVENTION
The present invention relates to methods of making a golf club head utilizing metal injection molding. In particular, the present invention relates to methods of forming putter type golf clubs. However, as would be appreciated by those of ordinary skill in the art, the present invention also relates to other types of golf club heads.
In one embodiment, a frame for the golf club head is composed of a first material. The first material may be composed of stainless steel, titanium, titanium alloys, tungsten alloys, aluminum alloys, or similar materials or combinations thereof. The frame is positioned into a mold where a combination of a powdered metal and a binding agent is injected into the mold and around the frame. The powdered metal is comprised of stainless steel, titanium, titanium alloys, tungsten alloys, aluminum alloys, similar materials, or combinations thereof. In addition, the powdered metal may be comprised of particles with an average diameter of less than about 40 micrometers. The binding agent may be water soluble. Optionally, a flow agent may also be added to the combination.
The molded product or “green part” is removed from the mold and washed with a solvent to remove the binding agent. The solvent may be water or another solvent specifically selected to remove the binding agent. The washed product is then subjected to a sintering process to further remove the binding agent and to fuse the metal particles together.
In another embodiment, the frame is positioned in a mold that is designed to include a void in the green part. The mold may be designed such that the green part contains a void of about 10 percent to about 75 percent of the total possible volume of the mold. The total possible volume of the mold is calculated using the outermost dimensions of the mold.
A combination of a powdered metal and a binding agent is then injected into the mold and around the frame. The powdered metal may be composed of stainless steel, titanium, titanium alloys, tungsten alloys, aluminum alloys, similar materials, or combinations thereof. In addition, the powdered metal may be composed of particles with an average diameter of less than about 40 micrometers. In one embodiment, the binding agent may be water soluble. A flow agent may also be added to the combination.
The green product is subjected to a solvent and a sintering process. After the sintering process, a second material may be added to fill the voids resulting from the mold design. The second material may be composed of an epoxy, thermoplastic, thermoset, loaded or impregnated polymer, bulk molding compound, or similar materials, or combinations thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention can be ascertained from the following detailed description that is provided in connection with the drawing(s) described below:
FIG. 1 is a block diagram of a process according to an embodiment of the invention;
FIG. 2 is a block diagram of a process according to an embodiment of the invention; and
FIG. 3 is a block diagram of a process according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to a process for forming a golf club using metal injection molding with an emphasis on reducing the cost and increasing the efficiency of the overall process. In particular, the process of the invention involves metal injection molding combined with the use of fillers, frames, or a combination thereof to produce an inexpensive and aesthetically pleasing golf club head.
For example, the metal injection molding process, which generally involves mixing fine metal powders with binders to form a feedstock that is injection molded into a closed mold, may be used to envelop a frame to form a golf club head. After ejection from the mold, the binders are chemically or thermally removed from the golf club head so that the part can be sintered to high density. During the sintering process, the individual metal particles metallurgically bond together as material diffusion occurs to remove most of the porosity left by the removal of the binder. The sintering process thus shrinks the part, providing a net shape that can be used as-is or further worked to add additional features or improve tolerances.
The present invention contemplates the use of the process for a variety of golf club heads and other golf club parts. In one embodiment, putter-type golf club heads are formed using the process of the invention.
Co-Molding
In one embodiment, a co-molding process is used to form a club head (shown generally in FIG. 1 ). Initially, a frame or inner skeleton of the club head is formed through known methods. For example, the frame may be cast or forged. In addition, the frame can be made from any metal or metal alloy typically used to form golf clubs. Example metals for use as a frame include, but are not limited to, stainless steel, titanium, titanium alloys, tungsten alloys, aluminum alloys, or similar materials or combinations thereof. In one embodiment, the frame corresponds to a putter head.
The frame is then subjected to a metal injection molding process that adds a metallic body around the frame. In particular, the frame may be inserted into a mold where a feedstock of powdered metal and a binding agent are heated and injected into a closed mold surrounding the frame.
Feedstock in accordance with the present invention may be prepared by blending the powdered metal with the binder, and then heating the blend to form a slurry. Uniform dispersion of the powdered metal in the slurry may be achieved by employing high shear mixing. The slurry may then be cooled to ambient temperature and then granulated to provide the feedstock for the metal injection molding.
The amount of powdered metal and binder in the feedstock may be selected to optimize moldability while insuring acceptable green densities. In one embodiment, the feedstock used for the metal injection molding portion of the invention may include at least about 40 percent by weight powdered metal, preferably about 50 percent by weight powdered metal or more. In one embodiment, the feedstock includes at least about 60 percent by weight powdered metal, preferably about 65 percent by weight or more powdered metal. In yet another embodiment, the feedstock includes at least about 75 percent by weight powdered metal. The binder may be present in an amount of about 50 percent or less by weight of the feedstock. In one embodiment, the binder is present in an amount ranging from 25 percent to about 50 percent by weight. In another embodiment, the binder is present in an amount of about 30 percent to about 40 percent by weight of the feedstock.
Examples of suitable powdered metals for use in the feedstock include, but are not limited to: stainless steel including martensitic and austenitic stainless steel, steel alloys, tungsten alloys, soft magnetic alloys such as iron, iron-silicon, electrical steel, iron-nickel (50Ni-50F3), low thermal expansion alloys, or combinations thereof. In one embodiment, the powdered metal is a mixture of stainless steel and tungsten alloy.
As known to those of ordinary skill in the art, stainless steel is an alloy of iron and at least one other component that imparts corrosion resistance. As such, in one embodiment, the stainless steel is an alloy of iron and at least one of chromium, nickel, silicon, molybdenum, or mixtures thereof. Examples of such alloys include, but are not limited to, an alloy containing about 1.5 to about 2.5 percent nickel, no more than about 0.5 percent molybdenum, no more than about 0.15 percent carbon, and the balance iron with a density ranging from about 7 g/cm 3 to about 8 g/Cm 3 ; an alloy containing about 6 to about 8 percent nickel, no more than about 0.5 percent molybdenum, no more than about 0.15 percent carbon, and the balance iron with a density ranging from about 7 g/cm 3 to about 8 g/cm 3 ; an alloy containing about 0.5 to about 1 percent chromium, about 0.5 percent to about 1 percent nickel, no more than about 0.5 percent molybdenum, no more than about 0.2 percent carbon, and the balance iron with a density ranging from about 7 g/cm 3 to about 8 g/cm 3 ; an alloy containing about 2 to about 3 percent nickel, no more than about 0.5 percent molybdenum, about 0.3 to about 0.6 percent carbon, and the balance iron with a density ranging from about 7 g/cm 3 to about 8 g/cm 3 ; an alloy containing about 6 to about 8 percent nickel, no more than about 0.5 percent molybdenum, about 0.2 to about 0.5 percent carbon, and the balance iron with a density ranging from about 7 g/cm 3 to about 8 g/cm 3 ; an alloy containing about 1 to about 1.6 percent chromium, about 0.5 percent or less nickel, no more than about 0.5 percent molybdenum, about 0.9 to about 1.2 percent carbon, and the balance iron with a density ranging from about 7 g/cm 3 to about 8 g/cm 3 ; and combinations thereof.
Suitable tungsten alloys include an alloy containing about 2.5 to about 3.5 percent nickel, about 0.5 percent to about 2.5 percent copper or iron, and the balance tungsten with a density ranging from about 17.5 g/cm 3 to about 18.5 g/cm 3 ; about 3 to about 4 percent nickel, about 94 percent tungsten, and the balance copper or iron with a density ranging from about 17.5 g/cm 3 to about 18.5 g/cm 3 ; and mixtures thereof.
The particle size of the powdered metals for use in the feedstock may range from about 1 μm to about 45 μm. In one embodiment, the particle size is from about 1 μm to 30 μm in diameter. In another embodiment, the particle size is from about 1 μm to 20 μm in diameter.
The binding agent may be any suitable binding agent that does not destroy or interfere with the powdered metals. In one embodiment, the binder is an aqueous binder. In another embodiment, the binder is an organic-based binder to prevent reaction between the water present in an aqueous binder with the powdered metal if the feedstock is to be stored long periods before use. Examples of binders suitable for use with the present invention include, but are not limited to, thermoplastic resins, waxes, and combinations thereof. Non-limiting examples of thermoplastic resins include polyolefins such as acrylic polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyethylene carbonate, polyethylene glycol, and mixtures thereof. Suitable waxes include, but are not limited to, microcrystalline wax, bee wax, synthetic wax, and combinations thereof.
In one embodiment, the binder is a combination of a high melting point thermoplastic resin and a low melting point oil or wax, such as the system disclosed in U.S. Pat. No. 4,765,950. This type of binder aids in preventing cracking of the green part during cooling.
The binders may also contain plasticizers, such as dioctyl phthalate, diethyl phthalate, di-n-batyl phthalate and diheptyl phthalate.
In addition, the binders may contain additives such as antioxidants, coupling agents, surfactants, elasticizing agents, dispersants, and lubricants as disclosed in U.S. Pat. No. 5,950,063, which is hereby incorporated by reference in its entirety. Suitable examples of antioxidants include, but are not limited to thermal stabilizers, metal deactivators, or combinations thereof. In one embodiment, the binder includes about 0.1 to about 2.5 percent by weight of the binder of an antioxidant. Coupling agents may include but are not limited to titanate, aluminate, silane, or combinations thereof. Typical levels range between 0.5 and 15% by weight of the binder.
Once the frame has been surrounded by the composition, the post molding product or “green part” is then removed from the mold and allowed to cool. The binders are then chemically or thermally removed. For example, the green part may be washed with a solvent to remove the binding agent. In one embodiment, the binding agent is water soluble and water is used as the solvent. In another embodiment, the binding agent is removed by thermal treatment at a temperature of about 300° C. or less. In one embodiment, the thermal treatment is conducted at a temperature of about 275° C. or less, preferably from about 200° C. to about 250° C.
The binder removal process may be a two-stage process. In particular, a portion of the binder may first be removed to open up a pore network within the green part. The remaining binder may then be subsequently removed through the open pore network that has been created. This two-stage process removes the binder without creating internal cracks or voids within the part. For example, in the case of a binder that includes a high melting point thermoplastic and a low melting point oil or wax, after the molded part is cooled, the lower melting point component is selectively dissolved leaving a porous structure from which the higher melting point component can be efficiently removed by thermal debinding. The resulting part is then referred to as a “brown part.”
The brown part is then subjected to a sintering process at a temperature sufficient to remove any remaining binder, create metallurgical bonds between the metal particles, and cause densification. As would be understood by those of ordinary skill in the art, the temperature is dependent on the materials in the feedstock. In one embodiment, the sintering is carried out at temperatures ranging from about 1200° C. to about 1450° C. (about 2200° F. to about 2642° F.), preferably about 1260° C. to 1430° C. (about 2300° F. to 2600° F.) for a predetermined period of time. For example, the sintering process may be from about 35 minutes to about 2.5 hours. In one embodiment, the time is from about 45 minutes to about 2 hours. In another embodiment, the time is from about 55 minutes to about 1.75 hours. In still another embodiment, the time is from about 60 minutes to 1.5 hours.
The sintering process may be carried out in controlled atmosphere furnaces (sometimes in vacuum) at a temperature below the melting point of the metal. As such, the exact composition of the sintering atmosphere depends on the metal or metals being sintered. For example, in some cases, a straightforward atmosphere containing hydrogen is all that is required. Although the atmospheric conditions may vary for the particular materials present, a person skilled in the art of metal injection molding would be able to determine the correct atmospheric conditions for a particular material.
After sintering, any voids that may be present due to the design of the mold may be filled with a filling agent. Suitable filling agents include, but are not limited to, epoxies, thermoplastics, thermosets, loaded or impregnated polymers, bulk molding compounds, and combinations thereof.
The use of a frame in this aspect of the invention reduces the amount of powdered metal that is actually needed to form the club head, which, in turn, reduces the overall cost of the materials. In addition, the combination of a filling agent and a frame further reduces the amount of powdered metal that is needed to form the club head, which reduces the overall cost of the materials.
While the finished club head may be subjected to secondary operations such as heat treatment, machining, grinding, tumbling, polishing, milling, welding, or tooling to create more detail, the process of the invention does not require such additional steps because the shape complexity available with the process of the invention is improved over the prior methods to form a club head.
In fact, the sintering process results in a decrease in the volume of the club head. According to one embodiment, the sintering process results in less than about 20 percent volume loss. For example, the green part may “shrink” about 10 percent to about 20 percent from its original size during sintering to achieve final component density of about 90 to about 98 percent of full density, preferably about 96 to about 98 percent of full density. In one embodiment, the green part shrinks about 15 percent or less from its original size. In another embodiment, the green part shrinks about 12 percent or less from its original size as a result of sintering.
This size reduction is beneficial in the club head design. In particular, because the green part is formed from a mold that is actually about 20 percent larger than the final product, more detail may be incorporated into the part because of the larger initial size. This results in less need for detailed finishing work, which also typically adds to the manufacturing cost.
Pocketed Molds
The mold used for metal injection molding the club head according to the present invention may be designed to allow one or more pockets or voids to form in the green part. By filling the pockets or voids with a filling agent, the overall amount of powdered metal is reduced and, thus, the overall material and process costs can be reduced.
This aspect of the invention may be used with or without the frame discussed previously. For example, in one embodiment, the process of the invention is directed to designing a mold that allows one or more voids to form in the green part and metal injection molding the club head. Such a mold may be used independently of the frame and metal injection molding process described above (shown generally in FIG. 2 ) or, in the alternatively, in combination with the frame and metal injection molding process (shown generally in FIG. 3 ).
In particular, the mold may be designed such that the resulting green part has about 10 percent to about 75 percent of the total possible volume of the mold as empty space. The total possible volume of the mold is calculated by using the outermost dimensions of the mold. In another embodiment, the volume of the empty space may be about 25 percent to about 60 percent of the total possible volume of the mold. Alternatively, the volume of the empty space may be about 40 percent to about 50 percent of the total possible volume of the mold.
For example, the mold may take any outermost shape. In one embodiment, the mold is rectangular in shape. The mold may also have one or more protrusions that take up space. When the green part is removed from the mold, the volume previously occupied by the protrusions in the mold will result in hollow areas in the green part.
The green part may then subjected to the same washing, binder removal and sintering processes as outlined in the previous embodiment.
As with the previously described embodiment, any post-sintering voids that may be present due to the design of the mold may be filled with a filling agent. Suitable filling agents include, but are not limited to, epoxies, thermoplastics, thermosets, loaded or impregnated polymers, bulk molding compound, and combinations thereof.
Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.
The invention described and claimed herein is not to be limited in scope by the specific embodiments herein disclosed, since these embodiments are intended as illustrations of several aspects of the invention. Any equivalent embodiments are intended to be within the scope of this invention. Indeed, various modifications of the invention in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims. All patents and patent applications cited in the foregoing text are expressly incorporate herein by reference in their entirety.
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The present invention relates to a method for forming golf club head using metal injection molding and the resulting golf club head. The method of the invention allows for a lower volume of powdered metal than current metal injection molding processes thereby decreasing overall production cost.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Chinese Patent Application No. 201010104815.6, filed on Jan. 29, 2010, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to the field of switching networks, and in particular, to a method, a device and a system for forwarding multicast packets.
BACKGROUND OF THE INVENTION
A switching network in the prior art can provide unicast services and multicast services. The unicast services are point-to-point services, for example, an Internet access service is a common unicast service. The multicast services are point-to-multipoint services, and common multicast services include an Internet Protocol Television (IPTV) service and a Layer 2 multipoint Virtual Private Network (VPN) service, such as a Virtual Private Lan Service (VPLS) service. As the multicast services gradually rise, it becomes a hot research spot.
Take the IPTV service as an example. When multicast packets are forwarded, one channel represents one multicast data stream and one multicast data stream is indicated by one Multicast Group Identifier (MID). Viewers who watch the channels (may be called “multicast group members”) may be different, the viewers are connected to different physical ports of a network device, and the network device forwards in distinction each multicast data stream in order to avoid wasting bandwidth. For example, if the physical port is the one indicated by the MID, a multicast packet is sent to the physical port; otherwise, no multicast packet is sent to the physical port.
The prior art provides a method for implementing multicast packet forwarding by a two-stage replication technology using the same MID. After receiving a multicast packet, a line card obtains the MID of the multicast packet by looking up a table, and then the line card sends the multicast packet together with the MID to a switch fabric card. The switch fabric card performs first stage replication, in which the switch fabric card uses the MID as an index to look up a multicast replication table saved therein, obtains line cards corresponding to the multicast packet, and sends the multicast packet and the MID to the line cards. The line cards perform second stage replication, in which the line cards use the MID as an index to look up a multicast replication table saved therein, obtain physical ports corresponding to the multicast packet, and send the multicast packet to each physical port indicated by the MID.
In the implementation of the present invention, the inventor finds that the prior art at least has the following problems. In the current multicast services, the required number of the multicast groups is increasingly growing, for example, up to 1 M (million) multicast groups. At this time, the capacity of a multicast replication table saved by a switch fabric card also becomes increasingly larger. For example, in a system with 1 M multicast groups and 64 line cards, the required capacity of the multicast replication table is 1 M*64 bit=64 Mbit. However, the storage capacity of the switch fabric card is merely tens of K, which can hardly meet the requirement, thus failing to implement multicast packet forwarding.
SUMMARY OF THE INVENTION
In order to solve the problems in the prior art, the present invention is directed to a method, a device and a system for forwarding multicast packets.
In order to achieve the above objectives, the present invention adopts the following technical solutions.
A method for forwarding multicast packets is provided, which includes:
receiving a multicast packet, and a first forwarding identifier and a second forwarding identifier of the multicast packet;
obtaining a destination line card corresponding to the multicast packet according to the first forwarding identifier; and
forwarding the multicast packet and the second forwarding identifier to the destination line card, in order that the destination line card obtains a port corresponding to the multicast packet according to the second forwarding identifier.
A network device is provided, which includes:
a receiving unit, configured to receive a multicast packet, and a first forwarding identifier and a second forwarding identifier of the multicast packet;
a line card obtaining unit, configured to obtain a destination line card corresponding to the multicast packet according to the first forwarding identifier received by the receiving unit; and
a forwarding unit, configured to forward the multicast packet and the second forwarding identifier to the destination line card, in order that the destination line card obtains a port corresponding to the multicast packet according to the second forwarding identifier.
A switching system is further provided. The system includes at least one line card which includes destination line cards. The system further includes at least one network device.
The network device is configured to receive a multicast packet, and a first forwarding identifier and a second forwarding identifier of the multicast packet, obtain a destination line card corresponding to the multicast packet according to the first forwarding identifier, and forward the multicast packet and the second forwarding identifier to the destination line card, in order that the destination line card obtains a port corresponding to the multicast packet according to the second forwarding identifier. The destination line card is configured to obtain the port corresponding to the multicast packet according to the second forwarding identifier, and forward the multicast packet to the port.
The technical solutions of the present invention use two identifiers to implement multicast packet forwarding. The first forwarding identifier is configured to obtain the destination line card corresponding to the multicast packet, and the second forwarding identifier is configured to obtain the port corresponding to the multicast packet. By controlling the number of the first forwarding identifiers, the capacity of a multicast replication table saved by a switching network can be reduced. The technical solutions of the present invention remove the redundant data stored repeatedly in the switching network, and reduce the requirement on the storage capacity of the switching network, thus implementing forwarding of a large number of multicast packets.
DETAILED DESCRIPTION OF THE DRAWINGS
To illustrate the technical solution according to the embodiments of the present invention or in the prior art more clearly, the accompanying drawings for describing the embodiments or the prior art are given briefly below. Apparently, the accompanying drawings in the following description are only some embodiments of the present invention, and persons of ordinary skill in the art can derive other drawings from the accompanying drawings without creative efforts.
FIG. 1 is a schematic flow chart of a method for forwarding multicast packets according to an embodiment of the present invention;
FIG. 2 is a schematic structural view of a router for implementing multicast packet forwarding according to another embodiment of the present invention;
FIG. 3 is a schematic view of an implementation of a line card according to another embodiment of the present invention;
FIG. 4 is a schematic structural view of a line card having sub-line cards according to another embodiment of the present invention;
FIG. 5 is a schematic structural view of a network device according to yet another embodiment of the present invention;
FIG. 6 is a schematic structural view of another network device according to yet another embodiment of the present invention;
FIG. 7 is a schematic structural view of yet another network device according to yet another embodiment of the present invention; and
FIG. 8 is a schematic structural view of a switching system according to yet another embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The technical solutions of the present invention are elaborated below with reference to accompanying drawings. Evidently, the embodiments described below are for the exemplary purpose only, without covering all embodiments of the present invention. Persons of ordinary skill in the art can derive other embodiments from the embodiments given herein without making any creative effort, and all such embodiments are covered in the protection scope of the present invention.
According to an embodiment of the present invention, a method for forwarding multicast packets is provided. Referring to FIG. 1 , the method includes:
Step 11 : receiving a multicast packet, and a first forwarding identifier and a second forwarding identifier of the multicast packet;
Step 12 : obtaining a destination line card corresponding to the multicast packet according to the first forwarding identifier; and
Step 13 : forwarding the multicast packet and the second forwarding identifier to the destination line card, in order that the destination line card obtains a port corresponding to the multicast packet according to the second forwarding identifier.
In order to describe clearly the technical solutions of the present invention, in the embodiments of the present invention, the terms “first” and “second” are used to distinguish the same items or similar items with basically the same function and effect.
The Steps 11 to 13 can be implemented by a switching network. After the Step 13 , an embodiment of the present invention further includes: forwarding, by the destination line card, the multicast packet to the corresponding port by using the received second forwarding identifier, in which, the port may be a physical port or logical port. The first forwarding identifier is a newly added identifier, and an existing MID may be used as the second forwarding identifier.
The number of the first forwarding identifiers is controlled according to the capacity of the switching network, and the first forwarding identifier may be set in various manners. In an embodiment, when the storage capacity of the switching network is very limited, all the multicast packets with the same destination line card have the same first forwarding identifier, or when the storage capacity of the switching network is abundant, all the multicast packets with the same destination line card are divided into several groups, and the same first forwarding identifier is set for the multicast packets in each group.
The technical solution according to the embodiment of the present invention uses two identifiers to implement multicast packet forwarding. The first forwarding identifier is configured to obtain the destination line card corresponding to the multicast packet, and the second forwarding identifier is configured to obtain the port corresponding to the multicast packet. By controlling the number of the first forwarding identifiers, the capacity of a multicast replication table saved by the switching network can be significantly reduced. The technical solution according to the embodiment of the present invention significantly reduces the requirement on the storage capacity of the switching network, thus implementing forwarding of a large number of multicast packets.
Another embodiment of the present invention provides a method for forwarding multicast packets, which is described in detail in the following.
The embodiment of the present invention is described by taking a scenario where a switching network implements multicast packet forwarding through switch fabric cards as an example, but the present invention is not limited thereto, and other functional modules or other chips integrated with switch fabric cards may be used to implement multicast packet forwarding. In the embodiment of the present invention, the replication function of switch fabric cards and the replication function of line cards are decoupled, and compared with the processing method in the prior art that the same identifier is used to control two-stage replication, different identifiers are used to control the switch fabric cards and the line cards respectively, the number of the identifiers of the switch fabric cards is small (for example, merely tens of K), and the number of the identifiers of the line cards is large (for example, 1 M), thus reducing the requirement on the capacity of the switch fabric cards.
Because data on the line cards is stored on an off-chip Random Access Memory (RAM), such as a Dynamic Random Access Memory (DRAM) or Static Random Access Memory (SRAM), it is no doubt that identifier information required by 1 M multicast packets can be stored. The present invention dose not adopt the processing method of setting an off-chip RAM for the switch fabric cards, because this solution leads to a high cost, increases the volume occupied by the board and reduces the device integration.
Multicast packet forwarding may be implemented through a network device with internal switch fabric cards, such as a router or an Ethernet switch in the embodiment of the present invention. FIG. 2 is a schematic structural view of a router according to an embodiment of the present invention. Referring to FIG. 2 , the router includes several line cards and switch fabric cards, in which the switch fabric cards interconnect the line cards, and may be implemented through an independent board or by integrating on a main control chip of the router.
One line card or more line cards may be set on one board. Referring to FIG. 3 , line card A and line card B are set on one board. One line card provides one or more physical ports, or may provide one or more logical ports, and one physical port may contain a plurality of logical ports. The line cards receive or send data packets through physical ports and/or logical ports. The processing capability of the line cards is usually 10 Gbps or 40 Gbps, and common physical ports provided by the line cards include Gigabit Ethernet (GE) interface, LOGE, OC48 POS (Optical Carrier-48 Packet Over SONET), and OC192 POS.
When multicast packets are forwarded, the following steps are performed.
In Step S1, a line card at the input end sends a multicast packet and two forwarding identifiers to a switch fabric card.
It can be known through in-depth analysis that, in the process of two-stage replication during multicast packet forwarding, the switching network needs to know the destination line card corresponding to all multicast packet members of one multicast group, and the destination line card needs to know a set of physical ports and/or logical ports corresponding to all multicast packet members of one multicast group. Because the number of the line cards is one or two orders of magnitude smaller than the number of the ports, the total number of the set of the destination line cards is much smaller than the total number of the set of the ports.
Therefore, corresponding to each multicast packet, two different identifiers are set for forwarding, for example, a first forwarding identifier expressed as MID_F and a second forwarding identifier expressed as MID_S. MID_F indicates the set of the destination line cards, MID_S indicates the set of the physical ports or logical ports, and the number of MID_F is much smaller than the number of MID_S. For example, as for a system with 1 M multicast packets and 64 line cards, if each multicast packet has one or more users on the 64 line cards (that is to say, each multicast packet has one or more ports on the 64 line cards), that is, the multicast packets have the same destination line cards, and one or more users on the line cards are distributed randomly in the 48 GE interfaces. At this time, the number of MID_F is one (indicating broadcast to 64 line cards), and the number of MID_S is at most 1 M (if every port is different, the number of MID_S is the most, 1 M; if not every point is different, the number of MID_S is smaller than 1 M).
After the line card at the input end receives the multicast packet, relevant data is looked up to obtain the first forwarding identifier and the second forwarding identifier, in which, the relevant data contains a corresponding relation between multicast packets, and first forwarding identifiers and second forwarding identifiers.
Two identifiers are set for the multicast packet in the embodiment of the present invention: the first forwarding identifier and the second forwarding identifier. The number of the first forwarding identifiers is controlled according to the capacity of the switching network, and the first forwarding identifier may be set in various manners. In an embodiment, when the storage capacity of the switching network is very limited, all the multicast packets with the same destination line card have the same first forwarding identifier, or when the storage capacity of the switching network is abundant, all the multicast packets with the same destination line card are divided into several groups, and the same first forwarding identifier is set for the multicast packets in each group.
An existing MID may be directly used as the second forwarding identifier.
In Step S2, the switch fabric card receives the multicast packet, and the first forwarding identifier and the second forwarding identifier of the multicast packet sent by the line card. The switch fabric card stores the multicast packet in one or more memories.
In Step S3, the switch fabric card obtains a destination line card corresponding to the multicast packet according to the first forwarding identifier, which includes at least the following two manners.
First Manner
The switch fabric card looks up a saved multicast replication table according to the first forwarding identifier, and obtains the destination line card corresponding to multicast packet, in which the multicast replication table indicates a corresponding relation between first forwarding identifiers and destination line cards.
In this manner, because a large number of data packets may correspond to the same destination line card, the destination line card corresponding to one MID_F only needs to be saved once in the multicast replication table, thus significantly reducing the storage space occupied by the multicast replication table.
Second Manner
When the first forwarding identifier is set, the destination line card corresponding to the multicast packet is directly indicated in the first forwarding identifier, and the switch fabric card directly obtains the destination line card corresponding to the multicast packet according to the first forwarding identifier.
The first forwarding identifier may be implemented by a bitmap or a link-list. For example, when the number of line cards in a router is 64, the first forwarding identifier (MID_F) may be replaced by one 64bit bitmap. When the nth bit of the bitmap is one, it means that the nth line card is a member of the multicast group. Thus, through the first forwarding identifier implemented by the bitmap, it can be known which line cards are the destination line cards of the current multicast packet.
In this manner, it is not required to set a multicast replication table for the switch fabric card, thus reducing the requirement on the storage capacity of the switching network to the maximum extent.
The switch fabric card extracts a multicast packet from a memory, replicates the multicast packet and then sends the multicast packet to the destination line cards.
In Step S4, the destination line card obtains a port corresponding to the multicast packet according to the second forwarding identifier (MID_S), and forwards the multicast packet to the port.
Each destination line card receives and stores the multicast packet sent by the switch fabric card. After the ports corresponding to the multicast packet are obtained, the multicast packet is replicated, and then the multicast packet is sent to the ports.
The ports may be physical ports or logical ports, such as Label Switch Tunnel (LST), QinQ ports or Virtual LAN (VLAN) ports. A physical port may contain a plurality of logical ports. If MID_S is implemented through an existing MID, the processing method of the Step S4 is the same as the processing method in the prior art when a line card receives a multicast packet and an MID.
Further, some line cards have sub-line cards. Referring to FIG. 4 , the line card includes two sets of interface chips (such as a framer), forwarding chips (such as a packet processor, PP), and traffic management (TM) chips, which share a switch interface, that is, the line card has two sub-line cards.
At this time, the destination line card needs to find the destination sub-line card corresponding to the multicast packet. In this case, in order to ensure that the destination line card can find the corresponding destination sub-line card, when or after the switch fabric card obtains the destination line card corresponding to the multicast packet and forwards the multicast packet and the MID_S to the destination line card, the method further includes: forwarding, by the switch fabric card, the first forwarding identifier (MID_F) to the destination line card.
The destination line card first obtains the destination sub-line card according to MID_F, and then the destination sub-line card obtains a physical port or a logical port corresponding to the multicast packet according to MID_S, and forwards the multicast packet to the physical port or logical port.
The technical solution according to the embodiment of the present invention sets the same first forwarding identifier for the multicast packets with the same destination line cards by analyzing in depth the characteristics of the process of multicast packet forwarding and by using the feature that many multicast packets have the same destination line card in the first stage replication, and implements multicast packet forwarding by using the two-stage forwarding identifiers. The technical solution according to the embodiment of the present invention removes the redundant data stored repeatedly in the switching network, and significantly reduces the requirement on the storage capacity of the switching network, thus implementing forwarding of a large number of multicast packets.
According to yet another embodiment, a network device is further provided. Referring the FIG. 5 , the device includes:
a receiving unit 51 , configured to receive a multicast packet, and a first forwarding identifier and a second forwarding identifier of the multicast packet;
a line card obtaining unit 52 , configured to obtain a destination line card corresponding to the multicast packet according to the first forwarding identifier received by the receiving unit 51 ; and
a forwarding unit 53 , configured to forward the multicast packet and the second forwarding identifier to the destination line card, in order that the destination line card obtains a port corresponding to the multicast packet according to the second forwarding identifier.
Because in the process of two-stage replication during multicast packet forwarding, a switching network needs to know the destination line card corresponding to all multicast packet members of one multicast group, and the destination line card needs to know a set of physical ports or logical ports corresponding to all multicast packet members of one multicast group. Because the number of the line cards is one or two orders of magnitude smaller than the number of the ports, the total number of the set of the destination line cards is much smaller than the total number of the set of the ports.
Therefore, in the embodiment of the present invention, corresponding to each multicast packet, two different identifiers are set for forwarding, for example, a first forwarding identifier expressed as MID_F and a second forwarding identifier expressed as MID_S. MID_F indicates the set of the destination line cards, MID_S indicates the set of the physical ports or logical ports, and the number of MID_F is much smaller than the number of MID_S.
Further, referring to FIG. 6 , according to the different manners of obtaining the destination line card, the network device further includes:
a saving unit 54 , configured to save a multicast replication table, in which the multicast replication table indicates a corresponding relation between first forwarding identifiers and destination line cards, and multicast packets with the same destination line card have the same first forwarding identifier.
At this time, the line card obtaining unit 52 is specifically configured to look up the multicast replication table saved by the saving unit according to the first forwarding identifier, and obtain the destination line card corresponding to the multicast packet.
Alternatively, when the first forwarding identifier is set, the destination line card corresponding to the multicast packet is directly indicated in the first forwarding identifier, and then the line card obtaining unit 52 directly obtains the destination line card corresponding to the multicast packet according to the first forwarding identifier. For example, the first forwarding identifier may be implemented by a bitmap or a link-list. At this time, the line card obtaining unit 52 is specifically configured to directly obtain the destination line card corresponding to the multicast packet according to the first forwarding identifier, in which the first forwarding identifier is implemented by a bitmap or a link-list.
Further, by analyzing in depth the characteristics of the process of multicast packet forwarding and by using the feature that many multicast packets have the same destination line card, the same first forwarding identifier may be set for the multicast packets with the same destination line card, so that the storage space occupied by the multicast replication table is greatly decreased, thus significantly reducing the requirement on the storage capacity of the switching network.
The line card obtains the port corresponding to the multicast packet according to the second forwarding identifier, and forwards the multicast packet to the port. Further, when the line card has sub-line cards, the destination line card needs to find a destination sub-line card corresponding to the multicast packet first. In order to ensure that the destination line card can find the corresponding destination sub-line card, referring to FIG. 7 , the switch fabric card further includes: an identifier sending unit 55 , configured to forward the first forwarding identifier to the destination line card. At this time, the destination line card first obtains the destination sub-line card according to the first forwarding identifier, and then the destination sub-line card obtains a physical port or a logical port corresponding to the multicast packet according to the second forwarding identifier, and forwards the multicast packet to the physical port or logical port. At this time, the destination line card is configured to obtain the destination sub-line card according to the first forwarding identifier, and the destination sub-line card is configured to obtain the port corresponding to the multicast packet according to the second forwarding identifier and forward the multicast packet to the port.
As for the specific operation modes of functional modules and units in the device embedment of the present invention, reference is made to the method embodiments of the present invention. The functional modules and units in the device embodiment of the present invention may be implemented independently, or may be implemented by integrating in one or more units. For example, the network device may be implemented by the switch fabric cards.
The technical solution according to the embodiment of the present invention uses two identifiers to implement multicast packet forwarding. The first forwarding identifier is configured to obtain the destination line card corresponding to the multicast packet, and the second forwarding identifier is configured to obtain the port corresponding to the multicast packet. By controlling the number of the first forwarding identifiers, the capacity of the multicast replication table saved by the switching network can be significantly reduced. The technical solution according to the embodiment of the present invention removes the redundant data stored repeatedly in the switching network, and significantly reduces the requirement on the storage capacity of the switching network, thus implementing forwarding of a large number of multicast packets.
As shown in FIG. 8 , according to yet another embodiment of the present invention, a switching system is provided, which includes at least one line card 82 . The at least one line card includes destination line cards, that is, the at least one line card includes a destination line card corresponding to a multicast packet. The system further includes at least one network device 81 .
The network device 81 is configured to receive a multicast packet, and a first forwarding identifier and a second forwarding identifier of the multicast packet, obtain a destination line card 82 corresponding to the multicast packet according to the first forwarding identifier, and forward the multicast packet and the second forwarding identifier to the destination line card 82 , in order that the destination line card 82 obtains a port corresponding to the multicast packet according to the second forwarding identifier.
The destination line card 82 is further configured to obtain the port corresponding to the multicast packet according to the second forwarding identifier, and forward the multicast packet to the port.
Further, the network device 81 is further configured to forward the first forwarding identifier to the destination line card.
The destination line card 82 includes destination sub-line cards, and is configured to obtain a destination sub-line card according to the first forwarding identifier. The destination sub-line card is configured to obtain the port corresponding to the multicast packet according to the second forwarding identifier and forward the multicast packet to the port.
The technical solution according to the embodiment of the present invention uses two identifiers to implement multicast packet forwarding. The first forwarding identifier is configured to obtain the destination line card corresponding to the multicast packet, and the second forwarding identifier is configured to obtain the port corresponding to the multicast packet. By controlling the number of the first forwarding identifiers, the capacity of a multicast replication table saved by a switching network can be significantly reduced.
The technical solution according to the embodiment of the present invention removes the redundant data stored repeatedly in the switching network, and significantly reduces the requirement on the storage capacity of the switching network, thus implementing forwarding of a large number of multicast packets.
It is clear to persons skilled in the art that the present invention may be accomplished through software plus a necessary universal hardware platform. Based on this, the technical solutions of the present invention or the part that makes contributions to the prior art can be substantially embodied in the form of a software product. The computer software product may be stored in a storage medium, such as a Read-Only Memory/Random Access Memory (ROM/RAM), a magnetic disk or an optical disk, an d contain several instructions configured to instruct a computer device (for example, a personal computer, a server, or a network device) to perform the method described in the embodiments of the present invention or in some parts of the embodiments.
The above descriptions are merely specific embodiments of the present invention, but not intended to limit the protection scope of the present invention. Any variations or replacements that can be easily thought of by persons skilled in the art within the technical scope of the present invention shall fall within the protection scope of the present invention as defined by the appended claims.
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In the field of switching networks, a method, a device and a system for forwarding multicast packets are disclosed, which significantly reduce the requirement on the storage capacity of the switching network, thus implementing forwarding of a large number of multicast packets. The method includes: receiving a multicast packet, and a first forwarding identifier and a second forwarding identifier of the multicast packet; obtaining a destination line card corresponding to the multicast packet according to the first forwarding identifier; and forwarding the multicast packet and the second forwarding identifier to the destination line card. The method, device and system for forwarding multicast packets are applicable to situations where it is required to forward multicast packets in a single-level switching network or a multi-level switching network.
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BACKGROUND OF THE INVENTION
There have been developed disposable cooking thermometers particularly useful in cooking meat and poultry to a proper or desire degree of "doneness". One type of such a timer has a spring-loaded stem disposed in a hollow barrel and normally held therein by locking the inner stem end in a fusible material which melts or softens at a desired predetermined temperature. It is desirable, and generally necessary, to ensure retention of the fusible material within the barrel of the timer to prevent possible contamination of the meat or poultry in which the timer is inserted. Various types of sealing arrangements have been proposed to this end and a wide variety of stem locking arrangements have been developed. At least certain of these arrangements and developments have been directed to minimizing the complexity and cost of the timer because this type of timer must necessarily have a low cost inasmuch as it is disposable.
It is also necessary for this type of timer to be highly reliable, for otherwise overcooking or undercooking of meat or poultry will result. Consequently, precise assembly of small parts is required as well as careful control of the properties of the fusible material. Another possible cause of unreliable operation arises from the nature of the environment of assembly and use of the timer. In the processing of poultry, for example, it is common to subject the carcass to successive baths of differing liquids that may include butter or butter substitute, brine, etc. Also in the cooking of poultry there are released juices and fats that may harden during continued exposure to elevated temperatures. The various liquids that may come in contact with a time during the life thereof, as generally noted above, could affect operation of the timer if allowed to enter the barrel of same. Thus it is also important to seal the timer against liquids entering same prior to actuation of the timer to extend the stem thereof. Most timers of this of type do not fully seal the interior thereof from intrusion of foreign substances into the barrel without the provision of additional elements and structure beyond that required for proper operation in a dry environment. This then reduces the overall reliability of disposable cooking thermometers or timers.
SUMMARY OF INVENTION
The present invention comprises an improvement in disposable cooking timers of the pop-up type wherein a stem is moved partially out of a barrel inserted in meat or poultry at a predetermined temperature of the timer as an indication that cooking is completed. Improvements of the present invention include an improved visibility of the actuated condition of the timer, as well as a improved visibility of the timer itself for ready location and removal by the user. Another improvement lies in the assembly of the timer, wherein the structure of the present invention prevents inadvertent damage of the inner end of the stem during assembly and prevents cocking or misalignment of the stem in the barrel. A further improvement lies in the complete sealing of the interior of the timer barrel during assembly and use of the timer to prevent possible intrusion of foreign substances into the timer during processing, preparation and/or cooking of meat or poultry in which the timer is inserted.
The timer of the present invention generally includes a hollow open ended barrel adapted to be inserted into meat or poultry and having a stem disposed within such barrel and normally retained therein against spring pressure by a fusible material engaging the inner stem end and inner barrel opening. A variety of different internal configurations of the timer are possible and references is made to U.S. Pat. No. 4,421,053, and reference cited therein for example, in this respect. In accordance with the present invention the outer stem end is provided with an integral enlargement or umbrella having a generally flat undersurface perpendicular to the stem axis and a generally flat upper surface that may be slightly convex. This umbrella top of the outer stem is adapted to cooperate with a top exterior flange about the barrel and having a flat upper surface perpendicular to the axis of the barrel. The umbrella top of the stem extends a substantial distance radially outward from the stem, in the form of a circle in end view. The stem and barrel are preferably formed of nylon or the like and of different colors such as a white barrel and red stem and top. While such coloring is not necessary, it does improve the visibility of the actuated position of the stem in extended location denoting end of cooking.
Timers of the type improved upon by the present invention commonly included as internal ridge and flange arrangement wherein the stem is assembled in the barrel against the force of a spring therein by physically forcing the stem downwardly into the open barrel end to snap the stem flange through a small ridge about the interior of the barrel. This assembly of the stem and barrel is commonly accomplished by placing the barrel in a retainer, inserting the stem with a spring about same and applying a force as by an air cylinder to the outer end of the stem. Prior timers of this type with a small stem end may be easily tilted or cocked during the foregoing operation so that they bind in the barrel and may not later slidably engage same for extension when released by the fusible material. Furthermore, application of this force, as by an air cylinder or the like, may press the stem too far into the barrel to then damage the inner stem end as by bending same. The present invention, by the provision of the enlarged relatively flat upper surface of the outer stem end, provides for substantially automatic alignment of the stem with the barrel when the stem is engaged by the piston of an air cylinder or the like, and furthermore, engagement of the under surface of the outer stem end with the upper surface of the barrel flange provides a positive stop whereby the stem cannot be forced too far into the barrel to possible damage the inner stem end.
A further feature of the present invention lies in the complete sealing of the interior of the timer at the time of assembly by positive engagement of the enlarged stem end with the barrel flange at the facing flat surfaces thereof to produce a tight seal to prevent the entry of foreign substances into the barrel about the stem. It is noted in this respect that the stem and barrel are assembled with the fusible material within the barrel being in a molten state, and this material is solidified before the stem is released from the pressure applied by the air cylinder or the like employed in assembly. Thus a very tight fit of the under surface of the outer stem end with the upper surface of the barrel flange is achieved and these tightly engaging mating surfaces then prevent liquids or the like from seeping into the interior of the barrel.
BRIEF DESCRIPTION OF DRAWINGS
The present invention is illustrated as to a particular preferred embodiment in the accompanying drawings, wherein:
FIG. 1 is a side elevation view of a timer in accordance with present invention;
FIG. 2 is a top plan view of the timer of FIG. 1;
FIG. 3 is a central longitudinal sectional view of the timer of FIG. 1 in extended or actuated position and taken in the plane 3--3 of FIG. 2; and
FIG. 4 is a schematic illustration of the assembly of stem and barrel of the timer of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENT
The present invention provides an improvement in a disposable cooking thermometer and, referring to FIG. 1 of the drawings, there will be seen to be shown such a thermometer or timer 11 generally including a barrel 12 having a pointed lower end 13 and a flange 14 about the upper end thereof. The barrel is provided with exterior barbs 16 for retaining the timer in the body of meat or poultry in which it may be inserted by the point 13. Commonly the timer is inserted in meat or poultry so that the barrel flange 14 rests against the exterior surface of same.
The timer 11 also includes a stem 21 having an enlarged upper end somewhat in the form of an umbrella 22. The stem 21 fits into a bore 17 of the barrel 12 in slidable relation therein and a spring 23 is disposed about the stem 21 beneath a flange 24 about the stem in spaced relationship to the umbrella 22. The length of the stem 21 from the underside of the umbrella 22 to the inner end of the stem is slightly less than the distance from the top of the barrel flange 14 to the inner end of the barrel bore 17. Thus the stem is adapted into fit entirely within the bore 17 of the barrel 12 and a fusible material 26 is disposed in the inner end of the barrel bore for engaging the stem to normally retain same within the barrel.
The internal configuration of the barrel 12 and the configuration of the lower portion of the stem 21 may be similar to the structure illustrated in my prior U.S. Pat. No. 4,421,053 and to this end the lower end of the stem 21 has a reduced diameter terminating in an enlargement 31 adapted to fit through a small opening 32 in the barrel bore leading to an enlarged chamber 33 containing the fusible material 26. A shoulder 34 is formed about the barrel bore above the opening 32 and spring 23 is disposed about the stem between the underside of the stem flange 24 and the shoulder 34.
With regard to insertion of the stem in the barrel and retention of same it is noted that a small tapered ridge 41 is formed about the interior of the barrel 12 preferably adjacent to the top of the bore 17 therein to define an internal diameter substantially equal to the diameter of the stem flange 24. Atop the stem flange 24 there is provided a radial flange extension 42 having a flat shoulder 43 atop same with a tapered surface 44 extending downwardly from the shoulder to the main portion of the stem flange 24. The diameter of the shoulder 43 on the stem flange 24 is slightly greater than the internal diameter of the bore of the barrel at the ridge 41 thereabout. The stem and barrel are formed of material such as nylon which may be readily injection molded and which is impervious to heat at and above temperatures that may be experienced by the timer in use and which is impervious to materials and substances which may come in contact with the timer during processing of meat or poultry in which the timer may be inserted and also during cooking of such meat or poultry. In addition, the material of the stem and barrel, such as nylon, has a limited resilient deformation under pressure with a "memory" whereby the structures thereof return to original size and shape after such limited deformation. It is thus possible to force the stem into the barrel by limited deflection of the stem flange enlargement 42 and the barrel ridge 41 to press the stem flange enlargement through the ridge 41. Reverse movement of the stem is not, however, possible inasmuch as the flat shoulder 43 on the stem flange enlargement 42 will abutt the underside of the barrel ridge 41 to lock the stem within the barrel.
The present invention provides for a particular relationship between enlarged top 22 of the stem and the barrel flange 14. In this respect it is noted that the diameter of the barrel flange 14 is of the order of two to three times the diameter of the barrel 12 and the diameter of the upper enlarged end 22 of the stem 21 is of the order of the diameter of the barrel flange. The radial extent of the umbrella 22 may, of course, be varied and need not extend all the way out to the edge of the flange 14, however, substantial mating surfaces are provided for good sealing. It will thus be seen that the top of the stem has a substantial diameter to thereby provide a highly visible portion of the stem for maximizing the appearance of the extended position of the stem. This then provides a user of the timer, such a housewife, with a far better view of the position of the stem, which is important in any type of pop up timer and of even greater importance in a two stage timer such as disclosed in my prior U.S. Pat. No. 4,421,053.
In addition to the foregoing, the underside 51 of the stem top 22 is configured to mate with the upper surface 52 of the barrel flange 14. Preferably these surfaces are planar and are disposed perpendicularly to the central longitudinal axis of the stem and barrel, although it is possible to form mating annular grooves and ridges in these surfaces if desired. The stem 21 may also be provided with a taper 54 at the juncture of stem and umbrella, as shown in FIG. 3, and this mates with an annular depression 56 about the top of the barrel bore in order to further improve sealing and alignment of stem and barrel. Note that the taper 54 on the stem fits entirely into the barrel taper 56 to prevent lateral displacement of the stem in the barrel. This configuration provides for mating of the surfaces 51 and 52 which extend a substantial distance radially outward from the stem and barrel bore so as to provide a positive seal about the top of the timer when the stem is fully inserted in the barrel and retained therein by the solidified fusible material 26. This seal prevents the possible intrusion of foreign substances into the bore of the barrel prior to release of the stem 21 by the melting or softening of the fusible material 26 at the predetermined cooking temperature. The timer of the present invention is adapted to undergo a variety of different processes after insertion in the poultry, for example, such as soaking in a variety of liquids, freezing, thawing, basting and cooking. In each of these processes it is possible for liquids, for example, to seep into the interior of the barrel and possibly interfere with ultimate operation of the timer to reduce the reliability of thereof. The structure of the present invention prevents this from happening.
The umbrella or parasol top 22 of the stem 21 hereof is provided with a relatively flat upper surface 53 which may, as illustrated, have a slight curvature. This upper surface 53 is adapted to be engaged by means applying a downward force to the stem during assembly of the timer, and in this respect reference is made to FIG. 4, schematically illustrating a portion of the assembly operation. In assembly, the barrel 12 is firmly held in a upright position as by disposing the barrel through an aperture 61 in a fixed plate 62 with the barrel flange 14 resting upon the upper surface of the plate. The fusible material 26 in the bottom of the barrel bore is heated to melting temperature and the stem 21, with the spring 23 thereabout, is then lowered into the bore of the barrel so that the stem flange enlargement 42 rests upon the ridge 41 about the internal bore 17 of the barrel. In order to force the stem downwardly into the barrel it is necessary to apply a force to the top of the stem and this is commonly accomplished by a pneumatic cylinder 66 having a controllably extensible plunger or piston rod 67 aligned for movement axially of the timer mounted in the plate 62. It will be seen that in this operation, the rod 67 of the cylinder 66 will engage the top surface 53 of the enlarged end 22 of the stem 21. Inasmuch as this top surface 53 is relatively flat and perpendicular to the axis of the stem and thus to the axis of the barrel in its mount, it will be seen that the stem is forced axially downwardly into the barrel without the application of any side forces that might tend to cock or tilt the stem during entry into the barrel. This is in direct contrast to the situation with a small rounded end on the stem 12 wherein the cylinder rod 67 may easily apply lateral forces to the stem in forcing the stem downwardly into the barrel so as to tilt the stem somewhat and to force the stem into cocked relationship with the barrel whereby the stem may be locked into the barrel so that it will not release. In addition, the mating surfaces of the stem end and barrel flange provide a positive stop for movement of the stem into the barrel. This is particularly important to prevent possible engagement of the inner end of the stem with the bottom of the barrel bore that could produce bending of the bottom of the stem so that it would not be able to move upwardly through the constricted opening 32 in the barrel and would thus prevent the stem from being released to move out of the barrel when the fusible material 26 is softened or melted. As previously noted, the length of the stem is fixed during manufacture, as for example, in an injection mold. Likewise, the length of barrel between the upper surface 52 of the flange thereof to the bottom of the barrel bore is fixed in manufacture in the same manner. Thus with the engagement of the surfaces 51 and 52 there will result an exact location of the enlarge stem end 31 within the chamber 32 of the barrel to preclude possible prior art difficulties in assembly that could reduce reliability of the resultant timer. Furthermore the perpendicular relationship of the surfaces 51 and 52 to the axis of the stem and barrel respectively will cause the stem to be automatically righted to coincide the axes of the stem and barrel even if the stem were inadvertently slightly tilted in original insertion in the barrel. Continued forcing of the stem downwardly even in tilted relationship to the barrel will cause the surfaces 51 and 52 to initially engage at one side and continued application of a downward force would cause the stem to be tilted back to align the axis of stem and barrel so that the surface 51 and 52 are in continuous contact over the entire surface areas.
It will be seen from the foregoing that the timer of the present invention provides material improvements over prior art timers, by the provision of particular structures and relationships of structures between stem and barrel particularly at the upper ends thereof. Not only does the present invention provide for improved visibility of the position of the stem with respect to the barrel but there is also herein provided for a positive sealing of the interior of the barrel prior to actuation of the stem to extend therefrom and material improvement in assembly of stem and barrel to prevent relationships which could prevent release of the stem to pop out of the barrel.
Although the present invention has been described above with respect to a single preferred embodiment thereof, it will be apparent to those skilled in the art that modifications and variations are possible within the spirit and scope of the present invention, and thus it is not intended to limit the invention to precise terms of descriptions or details of illustration.
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A poultry or meat cooking timer has a hollow barrel with an open top slidably receiving a stem with an inner end immersed in a fusible holding material in the barrel to normally hold the stem within the barrel against the force of a spring in the barrel urging the stem outwardly therefrom. The stem has an integral tapered flange thereabout that is force fitted through an inner barrel ridge near the top of the barrel bore and the stem has a large top with a substantially flat surface for engaging a barrel flange for positively sealing the stem and barrel in normal retracted stem position to prevent intrusion of foreign substances into the barrel bore prior to stem release by the fusible material at a predetermined temperature.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 10/235,240 filed on Sep. 4, 2002 which is a non-provisional of U.S. provisional application No. 60/317,338 filed on Sep. 4, 2001. This application is also a continuation-in-part of U.S. patent application Ser. No. 10/458,085, filed Jun. 9, 2003. The entirety of each of the above are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The American Lung Association (ALA) estimates that nearly 16 million Americans suffer from chronic obstructive pulmonary disease (COPD) which includes diseases such as chronic bronchitis, emphysema, and some types of asthma. The ALA estimated that COPD was the fourth-ranking cause of death in the U.S. The ALA estimates that about 14 million and 2 million Americans suffer from emphysema and chronic bronchitis respectively.
Those inflicted with COPD face disabilities due to the limited pulmonary functions. Usually, individuals afflicted by COPD also face loss in muscle strength and an inability to perform common daily activities. Often, those patients desiring treatment for COPD seek a physician at a point where the disease is advanced. Since the damage to the lungs is irreversible, there is little hope of recovery. Most times, the physician cannot reverse the effects of the disease but can only offer treatment and advice to halt the progression of the disease.
To understand the detrimental effects of COPD, the workings of the lungs requires a cursory discussion. The primary function of the lungs is to permit the exchange of two gasses by removing carbon dioxide from arterial blood and replacing it with oxygen. Thus, to facilitate this exchange, the lungs provide a blood gas interface. The oxygen and carbon dioxide move between the gas (air) and blood by diffusion. This diffusion is possible since the blood is delivered to one side of the blood-gas interface via small blood vessels (capillaries). The capillaries are wrapped around numerous air sacs called alveoli which function as the blood-gas interface. A typical human lung contains about 300 million alveoli.
The air is brought to the other side of this blood-gas interface by a natural respiratory airway, hereafter referred to as a natural airway or airway, consisting of branching tubes which become narrower, shorter, and more numerous as they penetrate deeper into the lung. Specifically, the airway begins with the trachea which branches into the left and right bronchi which divide into lobar, then segmental bronchi. Ultimately, the branching continues down to the terminal bronchioles which lead to the alveoli. Plates of cartilage may be found as part of the walls throughout most of the airway from the trachea to the bronchi. The cartilage plates become less prevalent as the airways branch. Eventually, in the last generations of the bronchi, the cartilage plates are found only at the branching points. The bronchi and bronchioles may be distinguished as the bronchi lie proximal to the last plate of cartilage found along the airway, while the bronchiole lies distal to the last plate of cartilage. The bronchioles are the smallest airways that do not contain alveoli. The function of the bronchi and bronchioles is to provide conducting airways that lead air to and from the gas-blood interface. However, these conducting airways do not take part in gas exchange because they do not contain alveoli. Rather, the gas exchange takes place in the alveoli which are found in the distal most end of the airways.
The mechanics of breathing include the lungs, the rib cage, the diaphragm and abdominal wall. During inspiration, inspiratory muscles contract increasing the volume of the chest cavity. As a result of the expansion of the chest cavity, the pleural pressure, the pressure within the chest cavity, becomes sub-atmospheric. Consequently, air flows into the lungs and the lungs expand. During unforced expiration, the inspiratory muscles relax and the lungs begin to recoil and reduce in size. The lungs recoil because they contain elastic fibers that allow for expansion, as the lungs inflate, and relaxation, as the lungs deflate, with each breath. This characteristic is called elastic recoil. The recoil of the lungs causes alveolar pressure to exceed atmospheric pressure causing air to flow out of the lungs and deflate the lungs. If the lungs' ability to recoil is damaged, the lungs cannot contract and reduce in size from their inflated state. As a result, the lungs cannot evacuate all of the inspired air.
In addition to elastic recoil, the lung's elastic fibers also assist in keeping small airways open during the exhalation cycle. This effect is also known as “tethering” of the airways. Tethering is desirable since small airways do not contain cartilage that would otherwise provide structural rigidity for these airways. Without tethering, and in the absence of structural rigidity, the small airways collapse during exhalation and prevent air from exiting thereby trapping air within the lung.
Emphysema is characterized by irreversible biochemical destruction of the alveolar walls that contain the elastic fibers, called elastin, described above. The destruction of the alveolar walls results in a dual problem of reduction of elastic recoil and the loss of tethering of the airways. Unfortunately for the individual suffering from emphysema, these two problems combine to result in extreme hyperinflation (air trapping) of the lung and an inability of the person to exhale. In this situation, the individual will be debilitated since the lungs are unable to perform gas exchange at a satisfactory rate.
One further aspect of alveolar wall destruction is that the airflow between neighboring air sacs, known as collateral ventilation or collateral air flow, is markedly increased as when compared to a healthy lung. While alveolar wall destruction decreases resistance to collateral ventilation, the resulting increased collateral ventilation does not benefit the individual since air is still unable to flow into and out of the lungs. Hence, because this trapped air is rich in CO 2 , it is of little or no benefit to the individual.
Chronic bronchitis is characterized by excessive mucus production in the bronchial tree. Usually there is a general increase in bulk (hypertrophy) of the large bronchi and chronic inflammatory changes in the small airways. Excessive amounts of mucus are found in the airways and semisolid plugs of this mucus may occlude some small bronchi. Also, the small airways are usually narrowed and show inflammatory changes.
Currently, although there is no cure for COPD, treatment includes bronchodilator drugs, and lung reduction surgery. The bronchodilator drugs relax and widen the air passages thereby reducing the residual volume and increasing gas flow permitting more oxygen to enter the lungs. Yet, bronchodilator drugs are only effective for a short period of time and require repeated application. Moreover, the bronchodilator drugs are only effective in a certain percentage of the population of those diagnosed with COPD. In some cases, patients suffering from COPD are given supplemental oxygen to assist in breathing. Unfortunately, aside from the impracticalities of needing to maintain and transport a source of oxygen for everyday activities, the oxygen is only partially functional and does not eliminate the effects of the COPD. Moreover, patients requiring a supplemental source of oxygen are usually never able to return to functioning without the oxygen.
Lung volume reduction surgery is a procedure which removes portions of the lung that are over-inflated. The portion of the lung that remains has relatively better elastic recoil, providing reduced airway obstruction. The reduced lung volume also improves the efficiency of the respiratory muscles. However, lung reduction surgery is an extremely traumatic procedure which involves opening the chest and thoracic cavity to remove a portion of the lung. As such, the procedure involves an extended recovery period. Hence, the long term benefits of this surgery are still being evaluated. In any case, it is thought that lung reduction surgery is sought in those cases of emphysema where only a portion of the lung is emphysematous as opposed to the case where the entire lung is emphysematous. In cases where the lung is only partially emphysematous, removal of a portion of emphysematous lung which was compressing healthier portions of the lung allows the healthier portions to expand, increasing the overall efficiency of the lung. If the entire lung is emphysematous, however, removal of a portion of the lung removes gas exchanging alveolar surfaces, reducing the overall efficiency of the lung. Lung volume reduction surgery is thus not a practical solution for treatment of emphysema where the entire lung is diseased. Moreover, conventional lung volume reduction surgery is an open surgical procedure which carries the risk of surgical complications and requires a significant period of time for recuperation.
Both bronchodilator drugs and lung reduction surgery fail to capitalize on the increased collateral ventilation taking place in the diseased lung. There remains a need for a medical procedure that can alleviate some of the problems caused by COPD. There is also a need for a medical procedure that alleviates some of the problems caused by COPD irrespective of whether a portion of the lung, or the entire lung is emphysematous. The production and maintenance of collateral openings through an airway wall allows air to pass directly out of the lung tissue responsible for gas exchange. These collateral openings serve to decompress hyperinflated lungs and/or facilitate an exchange of oxygen into the blood.
Methods and devices for creating and maintaining collateral channels are discussed in U.S. patent application Ser. No. 09/633,651, filed on Aug. 7, 2000; U.S. patent application Ser. Nos. 09/947,144, 09/946,706, and 09/947,126 all filed on Sep. 4, 2001; U.S. Provisional Application No. 60/317,338 filed on Sep. 4, 2001; U.S. Provisional Application No. 60/334,642 filed on Nov. 29, 2001; U.S. Provisional Application No. 60/367,436 filed on Mar. 20, 2002; and U.S. Provisional Application No. 60/374,022 filed on Apr. 19, 2002 each of which is incorporated by reference herein in its entirety.
Although creating an opening through an airway wall may overcome the shortcomings associated with bronchodilator drugs and lung volume reduction surgery, various problems can still arise. When a hole is surgically created in tissue the healing cascade is triggered. This process is characterized by an orderly sequence of events, which can be broadly classified into distinct phases. These phases proceed in a systematic fashion, with a high degree of integration, organization, and control. However, the various stages are not sharply delineated, but overlap considerably, and factors affecting one phase have a stimulatory or inhibitory effect on the overall process.
The result of this wound healing process is tissue proliferation that can occlude or otherwise close the surgically created opening. Additionally, in the event an implant is deployed in the surgically created opening to maintain the patency of the opening, the implant may become encapsulated or filled with tissue thereby occluding the channel.
Drug eluting coronary-type stents are not known to overcome the above mentioned events because these stents are often substantially cylindrical (or otherwise have a shape that conforms to the shape of a tubular blood vessel). Hence, they may slide and eject from surgically created openings in an airway wall leading to rapid closure of any channel. Additionally, the design and structure of the coronary-type stents reflect the fact that these stents operate in an environment that contains different tissues when compared to the airways not to mention an environment where there is a constant flow of blood against the stent. Moreover, the design of coronary stents also acknowledges the need to place the stent within a tubular vessel and avoid partial restenosis of the vessel after stent placement so that blood may continue to flow. In view of the above, implants suited for placement in the coronary are often designed to account for factors that may be insignificant when considering a device for the airways.
Not surprisingly, experiments in animal models found that placement of coronary drug eluting stents (i.e., paclitaxel drug eluting vascular stents and sirolimus drug eluting stents) into the airway openings did not yield positive results in maintaining the patency of the opening. The shortcomings were both in the physical structure of the stent which did not lend itself to the airways as well as the inability of those drug eluting devices to control the healing cascade caused by creation of the channel. The majority of these devices filled with tissue at an early stage and an inspection of the remainder of the implanted devices indicated imminent closure.
An understanding of the distinctions between the healing response in the coronary versus the airways may explain this outcome. For purposes of our discussion, the healing response in both the coronary and the lungs may be divided into approximately four stages as measured relative to the time of the injury: 1) acute phase; 2) sub-chronic phase; 3) chronic phase; and 4) late phase.
In the coronary, after trauma caused by the placement of a coronary stent, the healing process begins in the acute phase with thrombus and acute inflammation. During the sub-chronic phase, there is an organization of the thrombus, an acute/chronic inflammation and early neointima hyperplasia. In the following chronic phase, there is a proliferation of smooth muscle cells along with chronic inflammation and adventitial thickening. In the late stage of the healing process there is chronic inflammation, neointimal remodeling, medial hypertrophy and adventitial thickening.
Based upon the observations in a rabbit model, the healing response in the airway begins with a fibrinous clot, edema hemorrhage, and fibrin deposition. In the sub-chronic phase there is re-epithelialization, mucosal hypertrophy, squamous metaplasia, fibroplasias and fibrosis. In the chronic phase, while the epithelium is intact and there is less mucosal hypertrophy, there is still fibroplasia and fibrosis. In the late stage the respiratory epithelium is intact and there is evidence of a scar.
Accordingly, the unique requirements of the airways and collateral channels calls for specific features for any implant used in collateral channels. For example, these implants/conduits are often placed across three different tissue zones; namely the parenchyma, the newly sectioned airway wall, and the interior of the airway surface. Each different zone may have a different reaction to the presence of the implant/conduit. The parenchyma may build up a layer of scar tissue around the conduit, which may eventually eject the implant or block the air path on the parenchyma side of the conduit. The airway wall may undergo a healing response as a result of the trauma of the procedure. This healing response and associated tissue growth may restrict air-flow through the implant. Furthermore, mucus from the airways may deposit in to the conduit thereby further occluding the conduit.
In addition, placement of an implant or conduit within the collateral channel may present additional structure requirements for the devices. For example, surgeons often use radiological imaging to place coronary stents within the vasculature. In most cases, placement of coronary stents is critical so that the ends of the coronary stent straddle the vascular obstruction. In contrast, a surgeon placing an implant in collateral channels is often using a remote access device such as a bronchoscope or endoscope that allows for direct observation of the device during placement. For proper placement of the implant, and in cases where it is important to “sandwich” the airway wall, it is necessary to identify the center and/or edges of the conduit or implant prior to expansion of the device. It follows that failure to properly place the implant may result in detachment of the implant (via insufficient attachment to the airway wall), pneumothorax (if the implant is advanced too distally and breaches the pleural cavity), or deployment of the implant wholly in the lung parenchyma exterior to the airway wall. Accordingly, such devices may require a visual indicator to assist the medical practitioner during placement and to offer a measure of safety so that the device is not improperly advanced/deployed thus creating additional complications.
Accordingly, there remains a need for devices and methods that specifically address the requirements discussed herein.
BRIEF SUMMARY OF THE INVENTION
The devices and methods described herein serve to maintain the patency of a channel surgically created in an organ such as an airway wall. In particular, the devices and methods are suited for placement within a channel created within the airway wall and prevent closure of the channel such that air may flow through the channel and into the airway.
It is noted that the devices and methods described herein have particular use for individuals having emphysema and COPD. However, the devices and methods could also benefit any individuals having hyperinflation of the lungs.
Delivery devices for delivering the implants and/or creating the opening are described in U.S. Provisional Application No. 60/488,33, filed Jul. 18, 2003, and U.S. patent application Ser. No. 10/894,876 (U.S 2005/0056292A1 ) entitled DEVICES FOR MAINTAINING PATENCY OF SURGICALLY CREATED CHANNELS IN TISSUE, and filed on Jul. 19, 2004, the entirety of both are herein incorporated by reference.
Implants of the present invention may include a support member having a structure that is adapted for placement within a wall of a body organ, especially an airway wall.
When used in the lungs implants of the present invention modify the healing response of the lung tissue (e.g., at the site of newly created hole/channel) for a sufficient time until the healing response of the lung tissue subsides or reduces such that the hole/channel becomes a persistent air path. For example, the implant and bioactive substance will modify the healing response for a sufficient time until the healing response is reduced and, from a visual observation, the body treats the opening essentially as a natural airway passage rather than as an injury to the airway wall.
Variations of the invention include implants having compositions comprising a polymer which either serves as a carrier for the agent or as a delivery barrier for the agent. In those variations of the implant used in the airways, the composition may provide a steady release rate of bio-active substance as well as have a sufficient amount of available bio-active substance to modify the healing response of the lung tissue. As described herein, such a delivery system takes advantage of the tissue environment surrounding the airways.
The antiproliferative agent of the present invention is one that modifies a healing response. Various agents are discussed below, examples include a microtubule stabilizing agent such as taxol or paclitaxel, or a microtubule destabilizing agent such as vincristine, vinblastine, podophylotoxin, estramustine, noscapine, griseofulvin, dicoumarol, a vinca alkaloid, or a combination thereof. Furthermore, the agent may include steroids, non-steroidal anti-inflammatories, rapamnycin, dactinomycin, sirolimus, everolimus, Abt-578, tacrolimus, and a combination thereof. It is noted that the composition or implant may also include additional substance as required by the location of the implant. Such substances may affect/suppress mucus production, provide protection against bacteria, or maintain sterility of the implant site or surrounding tissue. It is contemplated that the bio-active substances listed herein includes all forms of the substances (e.g., analogs, derivatives, salt forms and crystalline forms.)
Variations of the invention also may include visualization features which provide assistance when attempting to place the implant from within an organ and having no or little direct visibility outside of the organ.
The invention may also include additional features such as valves within the implant to regulate flow or provide a protective barrier.
It is contemplated that though the invention includes a combination of support member and bioactive substance, it is noted that the structural configurations of several, if not all, of the support members provide unique advantages that lend themselves to use in securing the implant about a wall of an organ. Therefore, it is further contemplated that the structural configurations may also provide inventive embodiments without the bioactive substance.
This application is also related to the following applications 60/420,440 filed Oct. 21, 2002; 60/387,163 filed Jun. 7, 2002; Ser. No. 10/235,240 filed Sep. 4, 2002; Ser. No. 09/947,144 filed Sep. 4, 2001; Ser. No. 09/908,177 filed Jul. 18, 2001; Ser. No. 09/633,651 filed Aug. 7, 2000; and 60/176,141 filed Jan. 14, 2000; Ser. No. 10/080,344 filed Feb. 21, 2002; Ser. No. 10/079,605 filed Feb. 21, 2002; and Ser. No. 10/280,851 filed Oct. 25, 2002. Each of which is incorporated by reference herein. Accordingly, where not inconsistent with the principles described herein, features and aspects of the invention may be combined with the various implants and conduits described in the above related applications.
BRIEF DESCRIPTION THE DRAWINGS
FIGS. 1A-1C illustrate various states of the natural airways and the blood-gas interface.
FIG. 1D illustrates a schematic of a lung demonstrating a principle of the invention described herein.
FIGS. 2A-2B illustrates deployment of an implant of the present invention.
FIGS. 3A-3C provide various views of a variation of an implant of the present invention.
FIGS. 4A-4C are views of an additional variation of the invention.
FIGS. 5A-5C and 6 A- 6 B illustrate a variation of the invention having control members in an alternating fashion about the implant and additional control members at an end of the implant.
FIGS. 7A-7C illustrate a variation of the invention where the proximal portion and the distal portion are of differing sizes.
FIGS. 8A-8B illustrate additional variations of delivering an bioactive agent with the present invention.
FIGS. 9A-9C illustrate variations of the present invention having visualization marks or features.
FIG. 10A-10B illustrate variations of the invention having valves and barriers within the device.
FIG. 11A-11B illustrate histology samples comparing conventional devices and an implant of the present invention.
FIG. 12 illustrates pre-clinical data of an animal model comparing conventional devices, coronary drug eluting stents, and implants of the present invention.
DETAILED DESCRIPTION
Described herein are devices (and methods) for improving the gas exchange in the lung. In particular, methods and devices are described that serve to maintain and extend the patency of collateral openings or channels through an airway wall so that air is able to pass directly out of the lung tissue and into the airways. This facilitates exchange of oxygen into the blood and decompresses hyper inflated lungs.
By “channel” it is meant to include, but not be limited to, any opening, hole, slit, channel or passage created in the tissue wall (e.g., airway wall). The channel may be created in tissue having a discrete wall thickness and the channel may extend all the way through the wall. Also, a channel may extend through lung tissue which does not have well defined boundaries such as, for example, parenchymal tissue.
FIGS. 1A-1C are simplified illustrations of various states of a natural airway and a blood gas interface found at a distal end of those airways. FIG. 1A shows a natural airway 100 which eventually branches to a blood gas interface 102 .
Although not shown, the airway comprises an internal layer of epithelial pseudostratified columnar or cuboidal cells. Mucous secreting goblet cells are also found in this layer and cilia may be present on the free surface of the epithelial lining of the upper respiratory airways. Supporting the epithelium is a loose fibrous, glandular, vascular lamina propria including mobile fibroblasts. Deep in this connective tissue layer is supportive cartilage for the bronchi and smooth muscle for the bronchi and bronchioles.
FIG. 1B illustrates an airway 100 and blood gas interface 102 in an individual having COPD. The obstructions 104 impair the passage of gas between the airways 100 and the interface 102 . FIG. 1C illustrates a portion of an emphysematous lung where the blood gas interface 102 expands due to the loss of the interface walls 106 which have deteriorated due to a bio-chemical breakdown of the walls 106 . Also depicted is a constriction 108 of the airway 100 . It is generally understood that there is usually a combination of the phenomena depicted in FIGS. 1 A- 1 C. Often, the states of the lung depicted in FIGS. 1B and 1C may be found in the same lung.
FIG. 1D illustrates airflow in a lung 118 when implants 200 are placed in collateral channels 112 . As shown, collateral channels 112 (located in an airway wall) place lung tissue parenchyma 116 in fluid communication with airways 100 allowing air to pass directly out of the airways 100 whereas constricted airways 108 may ordinarily prevent air from exiting the lung tissue parenchyma 116 . While the invention is not limited to the number of collateral channels which may be created, it is to be understood that 1 or 2 channels may be placed per lobe of the lung and perhaps, 2-12 channels per individual patient. However, as stated above, the invention includes the creation of any number of collateral channels in the lung. This number may vary on a case by case basis. For instance, in some cases in an emphysematous lung, it may be desirable to place 3 or more collateral channels in one or more lobes of the lung.
FIGS. 2A-2B illustrate deployment of a variation of an implant 200 of the present invention. As discussed herein, the implant 200 is well suited for maintaining an opening in a wall of a body organ. In this example, the illustration depicts the implant 200 as deployed into a collateral channel 112 formed in a wall of an airway 100 . Referring to FIG. 2A , a delivery device 300 carrying the implant 200 is advanced to the site and inserted into the channel 112 . The delivery device 300 may optionally be constructed to also form the channel 112 . Furthermore, the delivery device 300 may extend from an access device such as an endoscope or bronchoscope 302 , or it may be directly advanced to the site.
FIG. 2B illustrates deployment of the implant 200 in the airway wall 100 . As shown, an expandable member, such as a balloon 304 , expands the implant 200 into a non-cylindrical shape that is able to sandwich or capture the tissue 100 between the expanded portions of the implant 200 . In some variations of the invention, the implant 200 forms a non-cylindrical (e.g., a “grommet” or “hour-glass”) shape that is suited, when used in the airways, for limiting movement of the implant 200 within the tissue opening and securing the implant 200 about the perimeter of the tissue opening in the airway wall. For example, the implant 200 expands in the mid portion and flares at the ends to retain itself within the opening in the airway wall. Also, as illustrated, the grommet shape of the implant 200 extends only minimally into the airway.
As noted above, the implant is suited for placement about an opening in the wall of an organ. In some cases, the implant is suited to placement in an organ having a thin wall. Through observation, applicants noted that airway wall thickness is fairly proportional to the diameter of the airway lumen by approximately a factor of ⅙. While the invention is not limited to use in any particular sized airway, on average the implant is placed in airways ranging from 3 mm to 15 mm in diameter with respective airway wall thicknesses of 0.5 mm to 2.5 mm. Therefore, in many variations of the invention, the grommet or hour-glass shape will be suitable to retain itself on the relatively thin airway wall tissue. In forming this shape, a variation of the implant 200 shrinks in axial length as it secures itself within the channel. Shrinking in axial length may also provide additional benefit as it reduces the length of the implant 200 that extends into the airway. This reduction in length may prevent unwanted tissue damage to the airway wall and/or occlusion of the airway.
In additional variations of the invention, the implant 200 must not only capture relatively thin tissue, but must also maintain a minimum internal diameter to allow sufficient air flow. For example, a fewer number of implants may be used given a sufficiently large diameter. In such cases it is undesirable for the implant 200 to constrict in internal diameter as it forms the non-cylindrical shape. In other variations, the entire implant is expandable, but a portion of the implant 200 expands to a greater amount as compared to a remainder of the implant. Such a configuration allows for the entire implant 200 to expand while still forming a non-cylindrical shape.
As described below, the implants of the present invention include a support member and a composition that maintain patency of the channel. Variations of the invention include support members selected from a mesh or woven structure either of which are comprised of a metal alloy(e.g., stainless steel, titanium, a shape-memory alloy, etc.), a polymer, a ceramic, or a combination thereof. The support member provides a structure that mechanically maintains patency of the channel as well as provides a delivery means for the composition or other substances as described herein. It is specifically noted that while the variations of the present invention are suited for use in the airways, the invention is not limited to such applications. Rather, the variations of the present invention may be used in various applications as appropriate.
FIG. 3A illustrates a planar view of a variation of an implant 200 where the support member 202 is in the unexpanded shape. In this variation, the support member 202 comprises a plurality of struts or members and has a proximal portion 204 , a distal portion 206 , and a mid-portion 208 therebetween.
A composition 212 , as described herein, is located on the implant. The composition 212 may encapsulate the support member 202 , or it may be located on an exterior or interior surface. Alternatively, it may be located between or within the intensities of the support member 202 . FIG. 3A also illustrates the struts or members (i.e., the extension member) on the proximal and distal portions 204 , 206 as being tapered. Because the proximal and distal portions 204 , 206 expand significantly, there is a propensity for the composition to tear at these locations. The tapering configuration is helpful to prevent tearing of the composition 212 during expansion as it allows for more material between adjacent struts.
The variation of the support member 202 illustrated in FIG. 3A includes control segments 210 which permit the support member 200 to assume a desired shape upon deployment. As will be described herein, the control segments 210 limit expansion of a portion of the implant (in this case the mid portion 208 ) as well as enable the implant to expand in a uniform manner. Although FIG. 3A illustrates the entire implant 200 as being covered by the composition 212 , it is noted that the composition 212 may alternatively extend over portions of the support member 202 .
FIG. 3B illustrates a side view of the implant 200 after expansion. In this variation, the control segments 210 restrain expansion at the mid portion 208 . Because the proximal and distal portions 204 , 206 are not restrained, upon expansion, the implant 200 forms a grommet shape as the control segments 210 unfold.
FIG. 3C illustrates a front view of an expanded implant 200 . FIG. 3C shows the passageway having a hexagonal cross section. The cross-section, however, is not limited to such a shape. The cross section may be circular, oval, rectangular, elliptical, or any other multi-faceted or curved shape. Because of its shape, the implant 200 will have a variable diameter. The inner diameter (D 1 ) of the center section will be a minimum expanded diameter and the diameter of the implant at the expanded ends (D 2 ) will be a maximum expanded diameter. The inner diameter (D 1 ) when deployed, may range from 1 to 10 mm and perhaps, from 2 to 5 mm.
The variation of the implant 200 shown in FIGS. 3A-3C illustrate an additional feature of implants of the present invention. In some variations of the invention, implants 200 have a sufficiently small delivery state diameter so that they are delivered to the channel having a sufficiently small diameter profile but a relatively large axial length. Upon expansion, the implant's 200 minimum (internal) diameter is greater than or equal to its axial expanded length. This particular configuration provides several benefits. During deployment having a sufficient axial length permits proper centering of the implant 200 when inserted into the collateral channel, where improper centering could result in a inadequate placement about the airway walls. Upon expansion, as the implant 200 decreases in length it is able to grommet about the airway walls, thereby minimizing the amount of the structure that extends into the airway lumen. Simultaneously, maximizing the minimum internal expanded diameter (e.g., the diameter of the implant at the mid portion 208 ) allows for an implant that permits a sufficient amount of airflow.
FIGS. 4A-4C illustrate additional variations of implants 200 of the present invention. It is noted that in FIG. 4A , as in many additional figures below, the composition is not illustrated for sake of clarity. FIG. 4A shows a side view of a implant 200 in an un-deployed state. The variation shown in FIG. 4A is similar to that shown in FIG. 3 with the exception of that the proximal and distal portions 204 , 206 are not tapered.
FIG. 4B illustrates a side view of the implant 200 of FIG. 4A when expanded. As shown, when viewed from the side, the opposing ends of the implant 200 may have a V, U, or similar shape. In some variations, the angles A 1 , A 2 may vary and may range from, for example, 30 to 150 degrees, 45 to 135 degrees and perhaps from 30 to 90 degrees. Moreover, the angle A 1 may be different than angle A 2 . Additionally, the angle corresponding to each proximal extension member may be different or identical to that of another proximal extension member. Likewise, the angle corresponding to each distal extension member may be different or identical to that of another distal extension member. FIG. 4B also illustrates the implant 200 having a length L that decreases upon expansion of the implant 200 .
The length of the implants of the present invention will depend upon their intended site of implantation. Variations of implants may have lengths ranging from between 2-20 mm. Furthermore, although the figures illustrate the proximal and distal portions of the implant as being symmetric about its center, the implant is not limited to such a configuration.
Furthermore, the implant of the present invention may have any number of extension members on each end device. The number of extension members on each end may range from 2-10. Also, the number of proximal extension members may differ from the number of distal extension members for a particular implant. The extension members may be symmetrical or non-symmetrical about the center section. The proximal and distal extension members may also be arranged in an in-line pattern or an alternating pattern. The extension members or the center section may also contain barbs or other similar configurations to increase adhesion between the implant and the tissue. The extension members may also have openings to permit tissue in-growth for improved retention.
Control Members:
Variations of the implant 200 , as seen in shown in FIGS. 3-6 also includes diametric-control segments, tethers, or leashes 210 to control and limit the expansion of the a portion of the implant 200 when expanded. The shape of the center-control segment 210 typically bends, when the implant radially expands, until it is substantially straight or unfolded. Such a center-control segment 210 may be circular or annular shaped in its folded or unexpanded shape. However, its shape may vary widely and it may have, for example, an arcuate, semi-circular, v-shape, u-shape, s-shape, sinusoidal shape, or other type of shape which limits the expansion of the implant upon unfolding.
The control members 210 assist the implant 200 in assuming a uniform non-cylindrical expanded shape. For example, as a balloon expands the implant 200 there will be variation in the amounts of expansion of various cells (i.e., where a cell is typically defined by an area surrounded by a number of joined struts—as an example refer to FIG. 4C , the shaded portion representing the cell 216 ) of the implant 200 . If one cell expands at an increased amount relative to the remaining cells, once the control member 210 fully unfolds, the cell will be unable to further expand. Thus, the expansion force, as applied by the balloon, is re-directed to a remaining part of the implant 200 . It should be noted that while the control members substantially straighten, there may be a residual bend or “kink” in the control member when expanded.
Typically, one end of the control segment 210 is attached or joined to one location (e.g., a first rib) and the other end of the center-control segment is connected to a second location (e.g., a rib adjacent or opposite to the first rib). However, in alternate variations, the center-control segments may have other constructs. For example, the center-control segments may connect adjacent or non-adjacent center section members. Further, each center-control segment may connect one or more ribs together. The center-control segments may further be doubled up or reinforced with ancillary control segments to provide added control over the expansion of the center section. The ancillary control segments may be different or identical to the primary control segments.
Referring back to FIG. 3B , which illustrates the implant 200 in its deployed configuration, the center-control segments 210 may bend, unfold, straighten, or otherwise deform until they maximize their length (i.e., unfold to become substantially straight) such as the center-control segments 210 shown in FIG. 3B . However, as discussed above, the invention is not so limited and other types of center-control segments may be employed.
As shown in FIGS. 5-6 , control segments 210 may also be used to join and limit the expansion of various portions of the implant 200 . For example, in FIGS. 5A-5C , control segments may be placed elsewhere on the implant 200 . For example, FIG. 5A illustrates control segments 210 located in an alternating pattern at the mid portion 208 of the implant 200 . The implant 200 also includes additional control segments 214 located on an end of the implant 200 . As shown in FIG. 5B , upon expansion of the implant 200 the end control segments 214 cause the respective end portion to form an angle A 2 that is different from an angle A 1 at the opposite unrestrained end.
FIG. 6A illustrates an implant 200 similar to that of FIG. 3 with additional control segments 214 located at both ends of the implant 200 . FIG. 6B illustrates the implant 200 of 6 A in an expanded state. Although the control segments are illustrated to have equal lengths, any length may be selected. For example, adjacent control segments may have different lengths, or opposing control segments (e.g., those located on opposing ends) may have different lengths.
FIG. 7A illustrates another variation of the invention. Like previous variations of the implant 200 (e.g., FIGS. 3-6 ), the support member 202 may comprise a plurality of members forming a number of cells 216 where each cell 216 is joined to an adjacent cell at the mid portion 208 and the proximal and distal portions are unconnected. The cells 216 are located in a circumferential manner about an axis of the implant and further include at least one control member 210 having a serpentine configuration. Upon expansion of the cell, the control member 210 straightens or unfolds to limit expansion of the cell 216 . For illustrative purposes, the composition is not illustrated in FIGS. 7A and 7B .
The variation of FIGS. 7A and 7B differ from previously described implants as the proximal 204 and distal 206 portions are of different sizes. The larger sized portion 206 may be useful in separating parenchymal tissue or providing a larger anchoring structure when implanted (as shown in FIG. 7B .)
FIG. 7C illustrates the implant 200 of FIGS. 7A and 7B having a composition 218 as described herein. As illustrated, variations of the invention include composition 218 that are only placed over a portion of the implant 200 .
In any variation of the invention, the control segments, as with other components of the implant, may be added or mounted to the implant or alternatively, they may be integral with the implant. That is, the control segments may be part of the implant rather than separately joined to the implant with adhesives or welding, for example. The control segments may also be mounted exteriorly or interiorly to the members to be linked. Additionally, sections of the implant may be removed to allow areas of the implant to deform more readily. These weakened areas provide another approach to control the final shape of the deployed implant. Details for creating and utilizing weakened sections to control the final shape of the deployed implant may be found in U.S. Pat. No. 09/947,144 filed on Sep. 4, 2001 which is hereby incorporated by reference in its entirety.
The implant described herein may be manufactured by a variety of manufacturing processes including but not limited to laser cutting, chemical etching, punching, stamping, etc. For example, the implant may be formed from a tube that is slit to form extension members and a center section between the members. One variation of the implant may be constructed from a metal tube, such as stainless steel, 316L stainless steel, titanium, tantalum, titanium alloy, nitinol, MP35N (a nickel—cobalt—chromium—molybdenum alloy), etc. Also, the implant may be formed from a rigid or elastomeric material that is formable into the configurations described herein. Also, the implant may be formed from a cylinder with the passageway being formed through the implant. The implant may also be formed from a sheet of material in which a specific pattern is cut. The cut sheet may then be rolled and formed into a tube. The materials used for the implant can be those described above as well as a polymeric material, a biostable or implantable material, a material with rigid properties, a material with elastomeric properties, or a combination thereof. If the implant is a polymeric elastic tube (e.g. a thermoplastic elastomer), the implant may be extruded and cut to size, injection molded, or otherwise formed.
Additionally, the implants described herein may be comprised of a shape memory alloy, a super-elastic alloy (e.g., a NiTi alloy), a shape memory polymer, or a shape memory composite material. The implant may be constructed to have a natural self-assuming deployed configuration, but is restrained in a pre-deployed configuration. As such, removal of the restraints (e.g., a sheath) causes the implant to assume the deployed configuration. A implant of this type could be, but is not limited to being, comprised from an elastic polymeric material, or shape memory material such as a shape memory alloy. It is also contemplated that the implant could comprise a shape memory alloy such that, upon reaching a particular temperature (e.g., 98.5° F.), it assumes a deployed configuration.
Also, the implant described herein may be formed of a plastically deformable material such that the implant is expanded and plastically deforms into a deployed configuration. The implant may be expanded into its expanded state by a variety of devices such as, for example, a balloon catheter.
The implant's surface may be modified to affect tissue growth or adhesion. For example, an implant may comprise a smooth surface finish in the range of 0.1 micrometer to 0.01 micrometer. Such a finish may serve to prevent the implant from being ejected or occluded by tissue overgrowth. On the other hand, the surface may be roughened or porous. The implant may also comprise various coatings and polymeric layers as discussed below.
Composition
As discussed above, the implants of the present invention may include a composition or polymeric layer that includes a bio-active substance or combination of bioactive substances. One purpose of the composition is to assist in modifying the healing response as a result of the trauma to lung tissue resulting from creation of the collateral channel. The composition may also serve other purposes as well. For example, the composition may assist in controlling of bacteria, prevent irritation of the tissue near the implant, or may carry additional bio-active substances.
The term lung tissue is intended to include the tissue lining the airway, the tissue beneath the lining, and the tissue within the lung but exterior to the airway (e.g., lung parenchyma.) In modifying the healing response it is fundamentally desirable to further the patency of the channel to allow sufficient flow of trapped gasses through the implant into the airways. A discussion of the bio-active substances is found below.
FIGS. 3A and 3B illustrate an example an implant 200 having a composition 212 . The composition may comprise a polymeric layer which acts as a carrier for various bioactive or other agents as described herein. Alternatively, or in combination, the polymeric layer may function as a tissue barrier to inhibit growth of tissue into the conduit/implant. In an additional variation, the support member may be fabricated from a polymeric material having the bio-active substance incorporated directly therein. The composition 212 prevents tissue in-growth from occluding the collateral channel or passage of the implant 200 . The polymeric layer 212 may coaxially cover the center section from one end to the other or it may only cover one or more regions of the implant 200 . The composition 212 may completely or partially cover the implant 200 . The composition 212 may be located about an exterior of the implant's surface, about an interior of the implant's surface.
Alternatively, or in combination, as shown in FIGS. 8A and 8B , the composition 212 may be located within an opening or pocket 220 in the support structure 202 of the implant. In such a case, the pocket 220 will have a barrier (e.g., polymeric or other porous material) that either degrades to allow the composition or bioactive substance to be delivered from the implant, or acts as a diffusible barrier to deliver the composition or bioactive substance.
The composition should be selected to accommodate the significant expansion of the implant. Examples of such polymers include, but are not limited to, thermoplastic polymers, thermoset polymers, acrylate polymers, a blend of acrylate-methacrylate polymers, silicone elastomers, urethane elastomers, ethylene vinyl acetate polymers, polyethylene, polypropylene, PLA-PGA, PLA, PGA, polyortho-ester, polycapralactone, polyester, hydrogels, polystyrene, co-polymers of styrene-isobutylene-styrene, and combinations or blends thereof.
Examples of bioabsorbable polymers include but are not limited to poly(L-lactic acid), polycaprolactone, poly(lactide-co-glycolide), poly(hydroxybutyrate), poly(hydroxybutyrate-co-valerate), polydioxanone, polyorthoester, polyanhydride, poly(glycolic acid), poly(D,L-lactic acid), poly(glycolic acid-co-trimethylene carbonate), polyphosphoester, polyphosphoester urethane, poly(amino acids), cyanoacrylates, poly(trimethylene carbonate), poly(iminocarbonate), copoly(ether-esters) (e.g., PEO/PLA), polyalkylene oxalates, polyphosphazenes and biomolecules such as fibrin, fibrinogen, cellulose, starch, collagen and hyaluronic acid. Also, biostable polymers with a relatively low chronic tissue response such as polyurethanes, silicones, fluorosilicones, and polyesters could be used. Also, hydrogels may be used to carry the drug.
Examples of other types of polymers that may be useful include but are not limited to polyolefins, polyisobutylene and ethylene-alphaolefin copolymers; acrylic polymers and copolymers, vinyl halide polymers and copolymers, such as polyvinyl chloride; polyvinyl ethers, such as polyvinyl methyl ether; polyvinylidene halides, such as polyvinylidene fluoride and polyvinylidene chloride; polyacrylonitrile, polyvinyl ketones; polyvinyl aromatics, such as polystyrene, polyvinyl esters, such as polyvinyl acetate; copolymers of vinyl monomers with each other and olefins, such as ethylene-methyl methacrylate copolymers, acrylonitrile-styrene copolymers, ABS resins, and ethylene-vinyl acetate copolymers; polyamides, such as Nylon 66 and polycaprolactam; alkyd resins, polycarbonates; polyoxymethylenes; polyimides; polyethers; epoxy resins, polyurethanes; rayon; rayon triacetate; cellulose, cellulose acetate, cellulose butyrate; cellulose acetate butyrate; cellophane; cellulose nitrate; cellulose propionate; cellulose ethers; and carboxymethyl cellulose. It may be possible to dissolve and cure (or polymerize) these polymers on the implant so that they do not leach into the tissue and cause any adverse effects on the tissue.
The coatings may be applied, for example, by either painting, dip coating, molding, spin-coating, transfer molding or liquid injection molding. Alternatively, the polymeric layer may be a tube of a material and the tube is placed either over and/or within the implant. The polymeric layer may then be bonded, crimped, heated, melted, shrink fitted or fused to the implant. The polymeric layer may also be tied to the implant with a filament of, for example, a suture material.
Still other techniques for attaching the polymeric layer include: solvent swelling applications and extrusion processes; wrapping a sheet of material about the implant, or placing a tube of the material about the implant and securing the tube to the implant. The polymeric layer may be secured on the interior of the implant by positioning a sheet or tube of material on the inside of the center section and securing the material therein.
The composition may also be formed of a fine mesh with a porosity or treatment such that tissue may not penetrate the pores. For example, a ChronoFlex™ DACRON® or TEFLON® mesh having a pore size of 100-300 microns may be saturated with collagen or another biocompatible substance. This construct may form a suitable polymeric layer. The mesh may be coaxially attached to a frame such as the open frame structures disclosed above. Still other suitable frames include a continuous spiral metallic or polymeric element.
Bioactive Substances:
As discussed above, the bio-active substance or combination of bioactive substances is selected to assists in modifying the healing response as a result of the trauma to the lung tissue resulting from creation of the collateral channel. As noted above, the term lung tissue is intended to include the tissue lining the airway, the tissue beneath the lining, and the tissue within the lung but exterior to the airway (e.g., lung parenchyma.) The purpose of modifying the healing response is to further extend the patency of the channel or implant to increase the duration which trapped gasses may exit through the implant into the airways. The term antiproliferative agent is intended to include those bioactive substances that directly modify the healing response described herein.
The bioactive substances are intended to interact with the tissue of the surgically created channels and in particular, lung tissue. These substances may interact with the tissue in a number of ways. They may, for example, 1.) accelerate cell proliferation or wound healing to epithelialize or scar the walls of the surgically-created channel to maintain its patent shape or 2.) the substances may inhibit or halt tissue growth when a channel is surgically created through an airway wall such that occlusion of the channel due to tissue overgrowth is prevented. Additionally, other bioactive agents may inhibit wound healing such that the injury site (e.g., the channel or opening) does not heal leaving the injury site open and/or inhibit infection (e.g., reduce bacteria) such that excessive wound healing does not occur which may lead to excessive tissue growth at the channel thereby blocking the passageway.
A variety of bioactive substances may be used alone or in combination with the devices described herein. Examples of bioactive substances include, but are not limited to, antimetabolites, antithrobotics, anticoagulants, antiplatelet agents, thorombolytics, antiproliferatives, antinflammatories, agents that inhibit hyperplasia and in particular restenosis, smooth muscle cell inhibitors, growth factors, growth factor inhibitors, cell adhesion inhibitors, cell adhesion promoters and drugs that may enhance the formation of healthy neointimal tissue, including endothelial cell regeneration. The positive action may come from inhibiting particular cells (e.g., smooth muscle cells) or tissue formation (e.g., fibromuscular tissue) while encouraging different cell migration (e.g., endothelium, epithelium) and tissue formation (neointimal tissue).
Still other bioactive agents include but are not limited to analgesics, anticonvulsives, anti-infectives (e.g., antibiotics, antimicrobials), antineoplastics, H2 antagonists (Histamine 2 antagonists), steroids, non-steroidal anti-inflammatories, hormones, immunomodulators, mast cell stabilizers, nucleoside analogues, respiratory agents, antihypertensives, antihistamines, ACE inhibitors, cell growth factors, nerve growth factors, anti-angiogenic agents or angiogenesis inhibitors (e.g., endostatins or angiostatins), tissue irritants (e.g., a compound comprising talc), poisons (e.g., arsenic), cytotoxic agents (e.g., a compound that can cause cell death), various metals (silver, aluminum, zinc, platinum, arsenic, etc.), epithelial growth factors or a combination of any of the agents disclosed herein.
Examples of agents include pyrolitic carbon, titanium-nitride-oxide, taxanes, fibrinogen, collagen, thrombin, phosphorylcholine, heparin, rapamycin, radioactive 188Re and 32P, silver nitrate, dactinomycin, sirolimus, everolimus, Abt-578, tacrolimus, camptothecin, etoposide, vincristine, mitomycin, fluorouracil, or cell adhesion peptides. Taxanes include, for example, paclitaxel, 10-deacetyltaxol, 7-epi-10-deacetyltaxol, 7-xylosyl-10-deacetyltaxol, 7-epi-taxol, cephalomannine, baccatin III, baccatin V, 10-deacetylbaccatin III, 7-epi-10-deacetylbaccatin III, docetaxel.
Of course, bioactive materials having other functions can also be successfully delivered in accordance with the present invention. For example, an antiproliferative agent such as methotrexate will inhibit over-proliferation of smooth muscle cells and thus inhibit restenosis. The antiproliferative is desirably supplied for this purpose until the tissue has properly healed. Additionally, localized delivery of an antiproliferative agent is also useful for the treatment of a variety of malignant conditions characterized by highly vascular growth. In such cases, an implant such as a implant could be placed in the surgically created channel to provide a means of delivering a relatively high dose of the antiproliferative agent directly to the target area. A vasodilator such as a calcium channel blocker or a nitrate may also be delivered to the target site. The agent may further be a curative, a pre-operative debulker reducing the size of the growth, or a palliative which eases the symptoms of the disease. For example, tamoxifen citrate, Taxol® or derivatives thereof Proscar®, Hytrin®, or Eulexin® may be applied to the target site as described herein.
Variations of the invention may also include fibrinolytics such as tPA, streptokinase, or urokinase, etc. Such fibrinolytics prevent or reduce the accumulation of fibrin within the opening. Accumulation of fibrin in the opening may result from inflammation of the tissue. The fibrin may form a structure which makes it easier for tissue to grow into the opening using the fibrin structure as a framework. Use of fibrinolytics, either topically, locally, or on the implant, serves to remove or hinder the network of fibrin from forming within the opening (or implant) and therefore aids in modifying the healing response.
In the event that poisonous and toxic compounds are delivered, they should be controlled so that inadvertent death of tissue does not occur. The poisonous agent should be delivered locally or only be effective locally. One method for delivering the bioactive agent locally is to associate the bioactive agent with an implant. For example, the implants described herein may include a bioactive substance or medicine deposited onto the interior, the exterior, or both the interior and exterior surfaces of the implant. The bioactive substance may remain on the implant so that it does not leach. Cells that grow into the surgically created channel contact the poison and die. Alternatively, the bioactive agent may be configured to gradually elute as discussed below.
When used in the lungs, the implant modifies the healing response of the lung tissue (e.g., at the site of newly created hole/channel).for a sufficient time until the healing response of the lung tissue subsides or reduces such that the hole/channel becomes a persistent air path. For example, the implant and bioactive substance will modify the healing response for a sufficient time until the healing response is reduced and, from a visual observation, the body treats the opening essentially as a natural airway passage rather than as an injury to the airway wall.
To illustrate the above, FIGS. 11A-11B show histology from animal models. The histology is a cross sectional slice of the airway wall 110 and lung parenchyma 116 . In each slide, the collateral channel 112 was created in the airway wall 110 and extended into the lung parenchyma 116 . The implant (which was removed for histology and is not shown) was placed in the channel 112 so as to create an airflow path (as demonstrated by the arrows 114 ) from the lung parenchyma 116 through the airway wall 110 .
FIG. 11A illustrates a histology sample from a site two weeks subsequent to the creation of a channel and implantation with a device. In this site, the device included a polymeric coating but no bio-active substance. This site was also given a single local treatment of a bioactive substance (mitomycin) subsequent to creation of the channel 112 . As shown, two weeks subsequent to the procedure, the healing process of the lung tissue already caused a considerable amount of fibrosis 120 between the channel 112 and lung parenchyma 116 . From the figure, the fibrosis appears as a darker tissue that is adjacent to the lung parenchyma 116 . The presence of this fibrosis 120 strongly suggests that air would not be able to flow from the lung parenchyma 116 through the channel 112 .
FIG. 11B illustrates a histology sample from a site 1 8 weeks subsequent to the creation of a channel and implantation with an implant of the present invention (an example of which is discussed below.) As evident from the figure, the channel 112 remained significantly unobstructed with only a minimal discontinuous layer of fibrosis 120 .
In one variation of the invention which modifies the healing response as describe above, the implant provides a steady release rate of bio-active substance as well as has a sufficient amount of available bio-active substance to modify the healing response of the lung tissue. As noted herein, the term lung tissue is intended to include the tissue lining the airway, the tissue beneath the lining, and the tissue within the lung but exterior to the airway (e.g., lung parenchyma.) Such a delivery profile allows for a concentration gradient of drug to build in these tissues adjacent to the delivery site of the implant.
It is believed that forming the concentration gradient affects the healing response of the lung tissue so that the implant does not become occluded as a result of the healing response. Because the implant is often placed in the airway wall it is exposed to the healing process of the multiple tissues. Providing a sufficient amount of bio-active substance allows for the formation of a concentration of the bio-active substance across these various tissues. In one variation of the invention it is believed that the fluids from these tissues enter into the composition layer of the device. The fluids then combine with the bio-active substances and migrate out of the composition layer to settle into the lung tissue. A concentration gradient forms when the drug ‘saturates’ local tissue and migrates beyond the saturated tissues. Furthermore, by providing a sufficient delivery rate, the healing response may be affected or suppressed during the critical time immediately after the wounding caused by creation of the collateral channel when the healing response is greatest.
To select a proper combination of drug and polymer, it is believed that the solubility parameter of the polymer must be matched with the bio-active substance to provide an acceptable slow elution rate from the polymer. Next, the polymer itself must be selected to have the proper attributes, such as a proper diffusion coefficient (to slow fluid entering and departing from the implant), and proper mechanical expansion properties (to allow for the significant expansion of the polymer to accommodate formation of the grommet shape.)
The solubility parameter is defined as the square root of the cohesive energy of the molecules in a compound. The level of control that a polymer has over the elution of a drug is the difference between the solubility parameters of the polymer and the solubility parameter of the drug. To select a polymer with the approximate diffusion a polymer with a high internal density could be selected to be less permeable to a complex molecule such as paclitaxel. Using a polymer with high internal density also accommodated the significant expansion required of the polymer to form the structure necessary to grommet about the airway wall. An example of the polymer selection is found below.
It is also important to note that paclitaxel is a taxane that is regarded as a microtubule stabilizer. The benefits of a microtubule stabilizing substance for use in vascular drug eluting stents is discussed, for example, in U.S. Pat. No. 5,616,608 to Kinsella et al. This type of drug operates to enhance microtubule polymerization which inhibits cell replication by stabilizing microtubules in spindles which block cell division. In contrast to the vascular applications, the implant for use in the present invention may use microtubule stabilizing substances such as taxanes (e.g., paclitaxel) as well as those microtubule destabilizing substances that are believed to promote microtubule disassembly in preventing cell replication. Such destabilizing substances include, but are not limited to vincristine, vinblastine, podophylotoxin, estramustine, noscapine, griseofulvin, dicoumarol, a vinca alkaloid, and a combination thereof.
Additionally, the exterior surface of the implant may be treated via etching processes or with electrical charge to encourage binding of the bioactive substances to the implant. The exterior surface may also be roughened to enhance binding of the medicine to the surface as discussed in U.S. patent application Publication No. 2002/0098278. See also U.S. patent application Publication Nos. 2002/0071902, 2002/0127327 and U.S. Pat. No. 5,824,048 which discuss various techniques for coating medical implants.
Although the implant may comprise a frame or body with a bioactive matrix disposed or otherwise associated therewith, the invention is not so limited. In one variation, the support member is formed from a polymer and the composition is joined to the polymeric support member. Alternatively, the bioactive substances may be placed directly onto the polymeric support member.
Various additional substances may be used incorporated into the device to reduce an adverse reaction resulting from possible contact with the implant and the airway wall. Adverse reactions include, but are not limited to, granulation, swelling, and mucus overproduction. These substance may may also be inhaled, injected, orally applied, topically applied, or carried by the implant. These substances may include anti-inflammatory, infection-fighting substances, steroids, mucalytics, enzymes, and wound healing-accelerating substances. Examples of these substances include but are not limited to, acetylcysteine, albuterol sulfate, ipratropium bromide, dornase alfa, and corticosteroids.
As noted above, conventional vascular drug eluting devices are not designed for exposure multiple tissue environments. Moreover, those devices are placed in an environment where a constant flow of blood creates an environment requiring a different delivery mechanism and rate. As noted herein, experiments with conventional coronary drug eluting implants demonstrated that such devices were unsuitable.
FIG. 12 illustrates data from a pre-clinical animal model evaluating the wound healing response, under pre-clinical protocol (QT-305), using an implant w/o any antiproliferative substance, a paclitaxel coronary Stent (manufactured by Boston Scientific under the name Taxus®), and a sirolimus coronary stent (manufactured by Johnson & Johnson under the name Cypher®). In comparison, experiments using implants according to the present invention, QT-345 and QT-362 were conducted. The implant w/o any antiproliferative substance, the paclitaxel coronary stent, and the sirolimus coronary stent reduced to at least 50% patency without stabilization (i.e., the determination was made that 100% closure would occur.) The chart indicates closure of these devices given a criteria that at least half of the implanted devices closed with tissue and the trend indicated that full closure of the devices would occur. In contrast, the implants according to the present invention maintained 88% patency of the openings @ 12 weeks (QT-362) and 69% patency @ 18 weeks (QT-345). In both of these latter cases, repeated inspection determined that the healing response (as evidenced by the closure rate) of the implants stabilized. Furthermore, for QT-362, 2 specimens maintained 100% patency while 1 speciment maintained 75% patency. For QT-345, no decline in patency occurred for the last 6 weeks of the trial.
It is important to note that, to obtain data and histology, applicants terminated QT-304 at 7 weeks (42 days), QT-362 at 12 weeks, and QT-345 at 18 weeks. Yet, based on the trend and closure of the devices, full closure would have occurred soon after 7 weeks for all devices in QT-304. In contrast, based on the stabilization of both the trend and relative patency of the devices in QT-362 and QT-345, patency of the devices in these trials would have extended well beyond the respective 12 and 18 weeks. In the above protocols, patency of the implants were determined visually using a bronchoscope advanced to the implant site.
Visualization Feature
As discussed above, when placed into an airway wall, the implant of the present invention is usually placed using a bronchoscope under direct visualization. In such a procedure, the direct visualization only permits viewing of the interior of the airway and care must be taken to place the implant such that during expansion, the implant properly deploys about the airway wall. Also, care must be taken not to advance the implant/balloon catheter too far into the opening into the airway wall. Improper advancing of the implant/balloon could potentially result in a pneumothorax or pneumomediastinum.
To address the above problem, as illustrated in previous figures, the implant 200 may also include a visualization mark 218 . The visualization marker 218 is visually apparent during a procedure and gives the medical practitioner an indication when the implant/balloon is advanced to the proper location. In this manner, the visualization mark 218 facilitates alignment and deployment of the implants into collateral channels.
The visualization mark 218 may be a ring of biocompatible polymer and may be selected to provide contrast so that it may be identified as the medical practitioner views the device through a endoscope or bronchoscope. For example, the bronchoscope will usually contain a light-source that illuminates the target area. Therefore, the visualization mark may be something that reflects or refracts the light in a different manner from the remainder of the implant. In one variation, the visualization mark may be the same color as the remainder of the device, or partially transparent, or entirely transparent, but is identifiable because the mark reflects or refracts light differently than the remainder of the device. Also, the visualization feature may protrude from the center section or it may be an indentation(s). The visualization mark may also be a ring, groove or any other physical feature on the implant. Moreover, the visualization feature may be continuous or comprise discrete segments (e.g., dots or line segments).
The visualization feature may be made using a number of techniques. In one example, the mark is a ring formed of silicone and is white. The polymeric ring may be spun onto the polymeric layer. For example, a clear silicone barrier may be coated onto the implant such that it coaxially covers the implant. Next, a thin ring of white material such as a metal oxide suspended in clear silicone may be spun onto the silicone coating. Finally, another coating of clear silicone may be applied to coat the white layer. The implant thus may include upwards of 1-3 layers including a polymeric layer, a visualization mark layer, and a clear outer covering. In another example the mark is a ring formed of silicone and is black. In another example the mark is a ring formed by suspending gold particulates in the polymer as shown in FIG. 9A .
The shape of the visualization mark is not limited to a thin ring. The visualization mark may be large, for example, and cover an entire half of the implant as shown in FIG. 9B . The visualization mark may, for example, be a white coating disposed on the proximal or distal half of the implant. The visualization mark thus may extend from an end of the extension members to the center section of the implant. As explained in more detail below, when such a device is deposited into a channel created in lung tissue, the physician may observe when one-half of the implant extends into the channel. This allows the physician to properly actuate or deploy the implant to secure the implant in the tissue wall.
In most variations of the invention, the visualization mark is made to stand out when viewed with, for example, an endoscope. The implants may also have additional imaging enhancing additives to increase non-direct imaging, such as fluoroscopic or radioscopic viewingIt is also contemplated that other elements of the implant can include visualization features such as but not limited to the extension members, polymeric layer, control segments, etc.
In some variations of the invention, it was found that incorporation of a bioactive or other substance into the coating caused a coloration effect in the composition layer (e.g., the polymer turns white). This coloration obscures the support member structure in the layer making it difficult to identify the edges and center of the support member or implant. As discussed herein, placement of the implant may depend upon positioning the center of the implant within the opening in tissue. If the support member structure is identifiable, then one is able to visually identify the center of the implant. When the composition colors obscures the support member or renders the implant otherwise opaque, it may become difficult to properly place the device. This may be especially true when the composition layer extends continuously over the support member.
Additionally, the coloration may render the visualization mark difficult to identify especially under direct visualization (e.g., using a endoscope) In some cases it was undesirable to simply add additional substances on or in the composition layer for marking because such substances could possibly interfere with the implant's ability to deliver the substance as desired. To address these issues, a variation of the invention includes a delivery device for delivering an expandable implant (such as those described herein and in the cases referenced herein), where the delivery device includes an expandable member having an expandable implant located about the expandable member. Where the implant and the expandable member are of different visually identifiable colors or shades such that the distinction is easy to identify under endoscopic or bronchoscopic viewing.
In one example, as shown in FIG. 9C , a balloon catheter has a colored sleeve 306 located about the balloon. The sleeve 306 comprises a visually identifiable color where selection of the colors should ease identification of the implant in an endoscopic visualization system (e.g., blue or a similar color that is not naturally occurring within the body.) The implant is placed about the sleeve 306 where the proximal and distal areas of the implant would be identifiable by the difference in color. Such a system allows a medical practitioner to place the implant 200 properly by using the boundary of the implant 200 to guide placement in the tissue wall. The sleeve 306 may be fashioned from any expandable material, such as a polymer. Optionally, the sleeve 306 may also provide an elastic force to return the balloon to a reduced profile after expansion of the balloon. Such a system allows for identification without affecting the properties of the implant.
It should be noted that variations of the invention include coloring the balloon itself, or other expandable member, a color that meets the above criteria.
In another variation, the visualization mark may comprise providing a contrast between the implant and a delivery catheter. In one example the implant appears mostly white and while mounted on a contrasting color inflation balloon. In this example the implant would be placed over a blue deflated balloon catheter. The proximal and distal areas of the implant would be flanked by the deflated blue balloon, thus giving the appearance of a distinct distal and proximal end of the implant. This would allow a physician to place the implant properly by using the blue flanks as a guide for placing the central white portion in the tissue wall. Similarly, a colored flexible sheath covering the balloon would also suffice.
It is noted that while the visualization features described above are suitable for use with the implants described herein, the inventive features are not limited as such. The features may be incorporated into any system where placement of an implant under direct visualization requires clear identification of the implant regardless of whether the implant is opaque or colored.
Valves and Barriers Within Implants
The implants may further comprise various structures deposited within the passageway. For example, as shown in FIG. 9 , an implant may include a valve 224 . The valve 224 may be positioned such that it permits expiration of gas from lung tissue but prevents gas from entering the tissue. The valve 224 may be placed anywhere within the passageway of the implant. The valve 224 may also be used as bacterial in-flow protection for the lungs. The valve 224 may also be used in combination with a bioactive or biostable polymeric layer/matrix and the polymeric layer may be disposed coaxially about the implant. Various types of one way valves may be used as is known to those of skill in the art.
One example of the one-way valve 224 is a valve as shown in FIG. 10A . The geometry of the valve is such that when air is passed through the valve 224 the bill members deflect. When air places pressure on the closed side the geometry of the bills place a force onto the opening preventing air from flowing through.
Additionally, a valve could be used to prevent fluid such as mucus from flowing into the passage and into the parenchyma. Such a valve could be configured and could operate similarly to the one described above for gas flow.
FIG. 10B illustrates another variation of the invention 200 having a barrier which may serve as an anti-bacterial barrier, or to preserve sterility of the parenchymal tissue adjacent to the implant.
The above illustrations are examples of the invention described herein. Because of the scope of the invention, it is specifically contemplated that combinations of aspects of specific embodiments or combinations of the specific embodiments themselves are within the scope of this disclosure.
EXAMPLE
Implant
Implants comprising stainless steel mesh frame fully encapsulated with a composition comprising silicone (as described below) and paclitaxel were implanted in several canine models. Visual observation indicated that, on average, the passage through the implants of the present invention remained unobstructed and were associated with significantly reduced fibrotic and inflammatory responses, in canine models, at a considerably higher rate than an implant without any drug adjunct or coronary drug eluting stents (as shown in FIG. 12 ).
The composition comprised approximately a 9% paclitaxel to silicone ratio with approximately 400 micrograms of paclitaxel per implant. Measurements found that approximately 30% of the paclitaxel released after 60 days. In general, for implants with the paclitaxel/silicone composition, observations of chronic inflammation, epithelial metaplasia and fibrosis were all very mild.
For paclitaxel as the bioactive substance, polymers with solubility parameters between 5-25 (MPa) ^½ were believed to provide sufficient elution rates. The polymer used in the example device has good diffusivity for lipophilic drug (such as paclitaxel) because the side methyl group on the silicone may be substituted with more lipophilic hydrocarbon molecules containing vinyl group or groups in addition polymerization by platinum catalyst.
The composition for the example may be as follow: polymer part: polydimethylsiloxane, vinyldimethyl terminated, any viscosity; and/or polydimethylsiloxane, vinylmonomethyl terminated, any viscosity. The cross-linker part: polydimethylsiloxane, any viscosity; and or polymonomethylsiloxane, any viscosity. Platinum catalyst part and/or cross-linker part: platinum; and/or platinum-divinyltetramethyldisiloxane complex in xylene, 2-3% Pt; and/or platinum-divinyltetramethyldisiloxane complex in vinyl terminated polydimethylsiloxane, 2-3% Pt; and/or platinum- divinyltetramethyldisiloxane complex in vinyl terminated polydimethylsiloxane, ˜1% Pt; platinum-Cyclovinylmethylsiloxane complex, 2-3% Pt in cyclic vinyl methyl siloxane.
These components may be combined in different ratios to make the polymer. The hydrocarbon side chain off the silicone back bone makes this polymer system unique and may result in a “zero-order”-like release profile. The amount of vinyl siloxane cross-linker may determine the rate of the drug release and diffusivity of the polymer to the drug. There are other types of polydimethylsiloxanes such as: trimethylsiloxy terminated polydimethylsiloxane in various viscosities, (48-96%) dimethyl (4-52%) diphenylsiloxane copolymer in various viscosities, dimethylsiloxane-ethylene oxide copolymer, dimethyl diphenylsiloxane copolymer, polymethylhydrosiloxane, trimethylsilyl terminated at various viscosities, (30-55%) methyldro- (45-70%) dimethylsiloxane copolymer at various viscosities, polymethylphenylsiloxane, polydimethylsiloxane silanol terminated at various viscosities, polydimethylsiloxane aminopropyldimethyl terminated at various viscosities. For paclitaxel a release profile was found to be acceptable with a polymer system consisting of polydimethylsiloxane vinyl terminated at various viscosity and a range of platinum-mono, di, tri and/or tetramethyldisiloxane complex.
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This is directed to methods and devices suited for maintaining an opening in a wall of a body organ for an extended period. More particularly devices and methods are directed maintaining patency of channels that alter gaseous flow within a lung to improve the expiration cycle of, for instance, an individual having chronic obstructive pulmonary disease.
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RELATED APPLICATION
[0001] This application claims priority to U.S. provisional patent application serial No. 60/452694, filed Mar. 6, 2003 with the United States Patent and Trademark Office, which is co-pending.
FIELD OF THE INVENTION
[0002] This invention relates to the field of scanning microscopy where a specimen is scanned using non-raster, continuous-spiral patterns with particular applications in laser scanning confocal microscope systems as well as beam projection systems.
BACKGROUND OF THE INVENTION
[0003] In optical scanning microscopy, a specimen is scanned with a probe by moving a specimen relative to a stationary beam or by moving a beam relative to a stationary specimen. Alternatively, a spinning disk containing an array of apertures can be placed between the light source and the specimen so that regions of the specimen are illuminated in a patterned and sequential manner. One objective of laser scanning confocal microscopy is to realize diffraction limited spatial resolution through the use of strategically placed apertures. The general properties of optical scanning microscope systems are considered in detail in: Theory and Practice of Scanning Optical Microscopy, Tony Wilson and Colin Sheppard (Academic Press, New York, 1984); Confocal Microscopy, edited by Tony Wilson (Academic Press, New York, 1990); and the Handbook of Biological Confocal Microscopy, edited by James B. Pawley (Plenum Press, New York, 1990) and articles referenced therein.
[0004] In a number of instances, such as applications involving confocal microscopy, movement of the specimen relative to a fixed illumination source has proven too slow. Therefore, it has become customary to scan a stationary specimen with an illumination light, typically a laser beam, to increase scan rates. Movement of the illumination light along X and Y axes in the plane orthogonal to the optical (Z) axis has most commonly been accomplished using mirrors displaced in space by mechanical devices, such as closed loop and resonant galvanometers. Light that interacts with the sample (by reflection, refraction, fluorescence, etc.) is collected in a serial fashion (i.e. one point at a time) and reconstructed within a computer's memory in order to form an image. The typical pattern to perform this operation is in the form of a raster pattern or 2-dimensional grid produced by rapidly scanning along a straight line in one axis (X direction), then moving the beam one grid location in the orthogonal axis (Y direction), followed by a scan along a parallel straight line in the X axis (in either the forward or reverse direction). Repeated application of this sequence allows the construction of a two-dimensional grid or raster-scanned image of a rectangular field of view. Such an image can readily be viewed on any device organized as a two-dimensional grid display such as a computer screen or television.
[0005] An inefficiency of the current technique is caused by the fact that beam-directing devices with inertia cannot instantaneously start or stop their movements. At the end of each line segment, the beam must be directed to retrace or turn around in order to initiate the scanning of a new line. During this time, no useful data are collected. This retrace or turn around time ultimately limits the temporal resolution (i.e. the number of images that can be collected per unit time). The greatest scan rates achieved with this approach have yielded acquisition rates on the order of 30 frames/sec for images containing 512×512 pixels or less. Higher rates can be achieved by decreasing the dimensions of the scanned region. However, even if spatial resolution is compromised by reducing the number of points in each dimension, turn around time severely limits the maximum temporal resolution that can be attained. The ultimate compromise in spatial resolution is the so-called “line scan” in which a beam is simply directed back and forth along a single line. Even during line scans, a significant time is spent in the “turn around” mode.
[0006] In another approach for high rate scanning confocal microscopy, acousto-optical beam deflector (AOD) devices, which do not have any moving mechanical parts, have been implemented as beam-steering devices to increase scan speeds. However, this approach is limited by the small deflection angles and the optical properties of AOD devices. In particular, light at different wavelengths is deflected at different angles. Consequently, it is difficult to illuminate the same spot in the specimen simultaneously with different wavelengths of light, and in the case of fluorescence microscopy, light coming from the specimen does not move along the same path as light directed toward the specimen after passing through the AOD. As a consequence, AOD devices are typically not placed in the path of light coming from the specimen and it is not possible to focus light emanating from the image plane in the specimen at a pinhole placed in front of the detector, as is required for true confocal microscopy. Instead, light is often passed through a slit, which permits more out-of-focus light to reach the detector. In this approach, optical performance is sacrificed for speed.
[0007] A number of applications, including the observation of any process where changes occur over the period of less than I second, would benefit from faster scan speeds than have been achieved to date. In addition, processes that utilize a scanned beam to affect a surface in a spatially organized manner, such as high resolution lithography or image projection systems, would benefit from faster scan rates. Therefore, there is a need to increase the rates at which specimens and/or surfaces are scanned without sacrificing imaging performance such as spatial resolution.
PRIOR ART
[0008] U.S. Pat. Nos. 6,606,153 and 6,271,916 to Marxer et al. describe a system for surface inspection in which an object is moved in a spiral pattern. The purpose for this movement is to minimize the distance traveled when inspecting circular wafers and to simplify the optical arrangement to detect scattered light. However, the system is not designed for gathering images at high frame rates and, in general, any system that moves an object solely by moving a stage results in scanning that is considerably slower than one that involves steering a beam.
SUMMARY OF THE INVENTION
[0009] The present invention utilizes non-raster scanning patterns to perform rapid probe steering and data collection within imaging devices such as scanning microscopes or beam projection systems such as those used to perform maskless lithography. By using waveforms to direct probe-steering devices in each spatial dimension that are primarily sinusoidal in nature, continuous spiral scanning patterns are generated with a number of advantages. An object of the present invention is to optimize the rate of scanning and/or data collection by increasing the number of data points and/or the number of frames projected or acquired per unit time. In confocal microscopy applications, these high scan rates can be attained without sacrificing the ability to achieve diffraction-limited spatial resolution. The present invention also produces smooth movements to maximize performance and reduce wear and tear on electromechanical scanning devices. The present invention also allows for software-controlled location (i.e. panning), magnification (i.e. zoom), spatial resolution and temporal resolution. By using software algorithms and position feedback signals to determine probe location and orientation, the present invention also optimizes the spatial accuracy of the assignment of pixel locations. The present invention also allows the user to select from a continuous scale between temporal versus spatial resolutions. The present invention also facilitates automated, intelligent probe-steering control in a repeated fashion since the start and end points of each scan are near the same location.
[0010] In an embodiment of the present invention, the scanning pattern utilizes an Archimedes' spiral that begins at a central location and spirals out to a desired radius. The beam direction is then turned around and the spiral is connected in a continuous fashion to a second Archimedes' spiral that spirals inward, filling the gap approximately midway between lines generated by the first spiral. The pattern terminates at the central location where the process can be repeated without interruption in the gathering of data. In an alternative embodiment, the scanning pattern utilizes an Archimedes' spiral that spirals out to a specified radius. The pattern then, without changing direction, continuously spirals inward to the center where the sequence can be re-initiated. For maximum temporal resolution during imaging, data gathered during the outward and inward spirals can be used to generate separate frames or images. The outcome is a class of spiral scanning patterns that minimize accelerations needed to produce scanned images and generate serial data streams in which little or no time is lost projecting to, or collecting from, unwanted regions. In embodiments, the present invention can incorporate substantially rectangular spiral patterns, where portions of the spiral pattern are distorted to provide a larger useable area than a round spiral pattern.
[0011] Techniques of the present invention can be applied to a variety of other projection or probe devices where beam-steering and/or scanning is performed in a point-by-point (i.e. serial) fashion. In applications such as maskless lithography or image projection systems, the beam can be both rapidly steered and modulated in intensity. In other embodiments, such as in laser- scanning confocal microscopes or scanning probe microscopes, the beam of energy or particles can be made to spiral during data collection. In yet another embodiment, the stage is maintained stationary and a mechanical probe is moved using spiral patterns. In another embodiment, the beam or probe remains stationary and the stage affixed to the sample is moved in a spiral pattern. Embodiments of the present invention combine of these controls in different spatial dimensions.
[0012] Other features and advantages of the present invention will be realized from reading the following detailed description, when considered in conjunction with the accompanying figures, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 shows a moderate spatial resolution spiral pattern with approximately 1000 points and a single turnaround region where filled diamond symbols represent the locations of individual samples collected at a constant temporal rate;
[0014] [0014]FIGS. 2A and 2B show X and Y control signals used to generate the spiral in FIG. 1;
[0015] [0015]FIG. 3A-3C show an alternative continuous spiral patterns with no turnaround region where filled diamond symbols represent the locations of sample points;
[0016] [0016]FIGS. 4A and 4B show X and Y control signals used to generate the spiral in FIG. 3;
[0017] [0017]FIG. 5 shows the sample locations of a spiral data acquisition sequence;
[0018] [0018]FIG. 6 shows an image of a fluorescent pollen grain generated by mapping spiral data points of FIG. 5 to a raster image;
[0019] [0019]FIGS. 7A and 7B show images of fluorescent pollen grains collected using higher temporal resolution (10 spiral rotations, FIG. 7A) versus higher spatial resolution (40 spiral rotations, FIG. 7B);
[0020] [0020]FIG. 8 illustrates a non-raster scanning pattern having rounded corners;
[0021] [0021]FIGS. 9A and 9B illustrate x and y control signals for generating the scanning pattern shown in FIG. 8;
[0022] [0022]FIGS. 10A and 10B show the overall amplitudes of X and Y control signals;
[0023] [0023]FIGS. 11A and 11B show acceleration of X and Y control signals;
[0024] [0024]FIGS. 12A and 12B illustrate rectangular areas covered by round versus square spiral patterns;
[0025] [0025]FIG. 13 shows in block diagram form a general hardware arrangement and flow of information during spiral imaging; and
[0026] [0026]FIG. 14 shows in flow diagram form an execution sequence for data acquisition and display in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The primary factor that limits the rate at which beam-steering devices can operate is the amount of force required to generate movement. Movement can be computed from a=f/m, where f is the applied force, m is the mass of the moving object (e.g. mirror and any attachment components) and a is acceleration (second time derivative of displacement). Force can be generated by electrical energy to produce displacement in electromechanical devices such as galvanometers. A maximal rate of movement arises because of limitations in the ability to both generate and dissipate electrical power within the small volumes occupied by such beam-steering devices. If attempts are made to expand the size of beam-steering devices, additional limits on the mass or complexity of linkages between the force generating device and the mirror assembly at high displacement rates are imposed due to friction and inertia. In order to keep peak forces low, accelerations (in each dimension, including angular acceleration) need to be minimized. An optimum waveform to keep peak accelerations low is a sinusoid.
[0028] In addition to using sinusoidal waveforms to minimize acceleration, many electromechanical and other steering devices such as mirrors can be designed to operate efficiently with sinusoidal control signals. This arises particularly when inertial forces are related to acceleration as described above and restoring forces are related to displacement, generating a relation that can be expressed as a second order differential equation. By taking advantage of resonance characteristics in the frequency domain, performance of such devices can be greatly extended over higher frequencies using sinusoidal waveforms.
[0029] If sinusoidal waveforms are used to direct both X and Y movements in a scanning process, elliptical patterns are formed as characterized by Lissajous patterns. If the same frequency is used to control X and Y movements with a phase difference between the sinusoids of 90°, a circle is produced. In order to produce a pattern of nearly sinusoidal waveforms in which a two-dimensional area is scanned, the radius of the circle can be made to vary continuously, but slowly. In Cartesian (x,y) coordinates this can be expressed as x=a·t·sin(t) and y=a·t·cos(t), where “a” is a constant that controls how rapidly the pattern spirals away from or toward the central location, and t is the independent variable (i.e. time in this case). In polar coordinates (r, θ), this can be expressed simply as r=a·θ. The pattern generated is a referred to as an Archimedean spiral.
[0030] There are several ways in which spiral patterns can be employed in order to efficiently scan a two dimensional field of view. Most differences among patterns arise in the manner in which sequential spirals are combined to produce continuous waveforms and uniform spatial coverage while simultaneously minimizing accelerations (particularly peak acceleration). One example of a coupled spiral pattern is shown in FIG. 1, in which there is an outward spiral, followed by an inward spiral midway between the line segments generated by the outward spiral (mathematically performed by offsetting the outward spiral one-half rotation compared to the inward spiral). The two spirals are connected by a single turn-around region where peak accelerations are generated. In comparison, commonly employed raster scans require two turnaround regions per line segment where a typical image might consist of approximately 500 lines (1,000 turnarounds/frame). The spiral pattern illustrated in FIG. 1 generates a single turnaround per frame. In FIG. 1, samples are collected when the beam is located at the positions represented by the filled diamond symbols. Except for the turnaround region 10 , the spatial area covered during each sample period is approximately the same throughout the field of view. Sample areas are also distributed uniformly throughout the roughly circular field of view. Together, these attributes produce one objective of the present invention: uniform coverage of the field of view with equal beam dwell time in each region. In confocal microscopy applications, uneven dwell times could cause non-uniform photo-bleaching of a specimen; and in lithography applications could cause non-uniform chemical properties of a photo-resistive coating.
[0031] [0031]FIGS. 2A and 2B illustrate the X and Y control signals used to generate the spiral in FIG. 1. These typically are voltages (or currents) generated by a digital-to-analog interface within a computer and applied to electromechanical beam-steering devices. Except for the turnaround region at the mid-point of the traces, waveforms consist of slowly varying, amplitude- and frequency-modulated sinusoidal waveforms.
[0032] Significant accelerations can develop in turnaround regions. In order to keep forces pointed inward (i.e. toward the central location), reducing the tendency for scanning devices to “run away” due to outward acceleration, it is preferable to generate the outermost spiral first, followed by the innermost spiral. The region of the turnaround region 10 (see FIG. 1) is then generated by predominantly inward-pointing forces, reducing chances for loss of control of the beam-steering device. Another method to reduce peak acceleration is to smooth (i.e. low pass filter) each of the X and Y waveforms in this transition zone. This becomes particularly important at higher image frame rates. A small amount of smoothing has been applied to the spirals in FIG. 1 and FIG. 2 as revealed by the closer spatial separation between sample points in the turnaround region. Differences in the inward versus the outward beam paths of the spirals can differ slightly due to the forces involved in accelerating some galvanic scanning devices. Multiplication of the “a” term by a small correction factor (i.e. close to 1) for either the inward or outward spiral can be used to correct such differences.
[0033] [0033]FIGS. 3A-3C shows an alternative continuous spiral pattern in which there are no turnaround regions. The scanning pattern spirals out to a specified radius and, without changing direction, continuously spirals inward to the center where the sequence can be re-initiated. Separate images can be generated from the inward and outward spirals (FIGS. 3A and 3B). This pattern and sequence is optimum for the highest frame rates. A minor disadvantage of this method is that the positions of the spiral data set for all even numbered frames differ somewhat from sample positions for odd numbered frames. This can be avoided by computing a single frame from the combination of inward and outward spiral samples (FIG. 3C) at the expense of halving the maximum frame rate.
[0034] [0034]FIGS. 4A and 4B, respectively, show the X and Y control signals used to generate the spiral pattern illustrated in FIG. 3. Control signals typically consist of slowly varying, amplitude- and frequency-modulated sinusoidal waveforms optimized for driving beam-steering devices at high frequencies.
[0035] In most cases (except in turnaround regions), it is desirable to have a uniform distance between sample points along the spirals. In scanning microscopes, this distance corresponds to one axis of an area scanned during a sample period. The dimension of the other axis of the scanned area is governed by the size of the illuminating spot (which is largely dictated by the numerical aperture of the objective lens and the point spread function of the illumination system. An analytic solution to compute uniform distance along the spiral is mathematically difficult. Integration of the distance along a spiral was only partially solved by Archimedes (the reason for the namesake) more than 2 centuries ago and remains not fully resolved today. However, numerically it is possible to compute distances, Δd, between adjacent sample points as:
Δd={square root}{square root over (( x i −x i-1 ) 2 +( y i −y i-1 ) 2 )} (1)
[0036] If t is the independent variable and coordinate (x i-1 ,y i-1 ) has been computed as the t i-1 sample point along the spiral, then the next value t i at coordinate (x i ,y i ) can be computed by a successive approximation scheme. By starting at value t i-1 and initially choosing a temporary t value that is always greater than the desired separation, a range can be established. An example of a simple formula for the increment, Δt=t i −t i-1 , that is approximately double the actual increment, is:
Δ t = ( 0.4 t i - 1 + 0.1 + 0.4 ) · Δ d ( 2 )
[0037] where t i-1 is expressed in rotations and Δd is the desired separation distance. A value of t midway between the two end-points of the range can then be tested using the formula for distance above. The range can be divided in half, based on whether the distance is greater than or less than the desired separation. This binary-search process can be repeated until a desired accuracy is achieved.
[0038] In some spiral projection and imaging applications (e.g. maskless lithography) it is desirable to control beam intensity at each sample location. Beam modulation can be performed in a variety of ways (e.g. shutter, AOD) where electronic modulation of modem solid state lasers provides an ideal method for pattern projection. Modulation can be on/off or in a continuous (i.e. analog) mode to produce precise intensity control. By separately modulating and combining multiple beams with different wavelengths, it is also possible to project multi-colored displays. Data acquisition at each spiral location can also involve simultaneously acquiring multiple display images. Data acquisition can include intensity values at different wavelengths (e.g. using optical filters) or some other attribute of the acquired signals (e.g. polarization properties, time delay between excitation and emission during fluorescence lifetime measurements).
[0039] A practical consideration in order to generate images (e.g. on a computer screen) arises from the fact that sampled data from spiral patterns are generally not aligned with the two-dimensional grid or “raster” structure of most display devices. The requirement to map samples collected in a spiral pattern to a raster space is illustrated in FIG. 5. In this case, a fluorescently- labeled pollen grain (FIG. 6) was sampled at the spiral locations represented by filled diamonds 20 in FIG. 5.
[0040] One method to translate between the spiral data set and a two-dimensional grid of pixels appropriate for display devices such as computer monitors and television screens is to use a weighted average of nearest sample points. This can be implemented by finding the “n” nearest sampled (i.e. spiral) data points to each two-dimensional display pixel. By weighting the spiral data points (e.g. inversely proportional) to the distance between the location of the spiral point and the location of the display pixel an accurate representation of the spiral data with smooth transitions in the grid display can be generated. Proper weighting also includes ensuring that the sum of the weighting factors at each location is equal to 1, or some constant value if contrast gain is desired. For example, we have found that using 4-5 nearest points produces adequate images. The mapping of data samples collected at locations 20 in FIG. 5 to raster pixels illustrated in FIG. 6 was performed using this method.
[0041] A second general method to map a spiral data set to a two-dimensional display is by finding the “n” nearest two-dimensional display pixels to each sampled (i.e. spiral) data point. As in the first scheme, the influence of each newly acquired sample on nearby raster pixels can be weighted (e.g. inversely proportional) to the distance between the location of the spiral point and the location of the display pixel. In addition, the time since pixels were last updated can be taken into account. An advantage of this scheme is that most of the computation required to produce raster images can be performed one point at a time, as each sample is acquired.
[0042] A significant advantage of schemes to map spiral data to raster images is the fact that the number of “spiral” data points sampled can be independent of the number of display pixels. If high temporal resolution (i.e. a high frame rate) is desired, then a small number of data points along the spiral pattern can produce a roughly uniform distribution of samples within an approximately circular field of view. If high spatial resolution is desired, then more spirals as well as more data points along the spirals can be selected. When tracking rapid dynamic behaviors or making comparisons with spatial-temporal mathematical models, the spiral pattern can be used to select just enough spatial resolution while maximizing temporal resolution. The number of sample points per image and frame rate can be chosen to be any values on a continuous scale (i.e. single points can be added or subtracted). Maximum values are governed only by sinusoidal scanning frequency and signal gathering limitations, not by the characteristics of display devices.
[0043] As an example using a spiral pattern with a scanning confocal microscope, if (in order to gather enough photons) each sample required a dwell time of 0.5 microseconds and 2000 samples were needed for adequate spatial resolution, then a frame rate of 1000 frames/second could be achieved. Even higher frames rates can be chosen completely under software control (i.e. with no modifications to hardware). Maximal two-dimensional scan rates using raster (i.e. grid) patterns are generally more than an order of magnitude slower in today's microscopes.
[0044] Another significant advantage of the spiral method is the use of the actual position feedback signal from the electromechanical scanning device to dictate the (x,y) position of each sample collected. This is particularly important at higher frame rates when there are larger differences between command voltages and actual position (as measured using a position sensor). Any changes in the performance of scanning devices, such as those that often occur running at different frequencies or due to changes in temperature or wear, can be bypassed using the position feedback signal. Corrections can also be included for spatial aberrations generated by lenses or other components of the beam pathways. Using the spiral method with position feedback, there is no longer a requirement to have precise control over the time or locations of data samples to correspond to exact grid positions. Every position within every frame is determined (and can be adjusted on a continuous scale) on a sample-by-sample basis. Consequently, it is not necessary to generate a pixel clock signal to control data acquisition, nor is it necessary to discard data obtained during periods of nonlinear velocities, such as occur during the turn-around intervals of a raster scanning system.
[0045] The spiral pattern approach allows magnification (i.e. by controlling the spiral radius), X-Y location (i.e. by adding offsets), spatial resolution (i.e. number of samples per spiral and number of spirals) and temporal resolution (i.e. by controlling the number of samples and sample rate) to all be implemented under software control. Switching any of these characteristics can be performed rapidly; for example, to “zoom in” during the tracking of quickly moving or dynamically changing (or combinations of both) objects within a field of view. The ability to acquire images at a high frame rate and/or to adjust spatial resolution within selected regions of a field of view is a crucial element of imaging systems designed to track high velocity missiles or dynamically changing particles. As an example, FIGS. 7A and 7B illustrate images that have been collected using different spiral resolutions and different frame rates. A decreased number of spirals allows higher frame rates to be achieved (FIG. 7A) whereas an increased number of spirals generates higher spatial resolution within each image (FIG. 7B).
[0046] Various non-raster patterns can be used in alternative embodiments of the present invention. For example, if a more rectangular field-of-view is desired (because of the shape of a particular specimen or field-of-view compatibility with other analysis software), the p (or power) term in equation 3 below, can be set to a value between 0 and 1.
x=a·t ·sin p ( t )
y=a·t ·cos p ( t ) (3)
[0047] The pattern at p=0 is an expanding square and p=1 has been used to compute the rounded patterns in FIGS. 3A-3C. Intermediate “square spiral” patterns with p=0.7 and 0.6 are shown in FIGS. 8 and 12B. Both x andy accelerations (related to Δ(Δx) and Δ(Δy), respectively, see FIG. 12B) increase somewhat in regions near the rounded corners, but in may cases, these can be maintained within the performance specifications of beam steering devices.
[0048] [0048]FIG. 8 shows an outward spiral (inward spiral removed for clarity) where sine and cosine terms are raised to the power 0.7. Individual x andy control signals are shown in FIGS. 9A and 9B. The pattern maintains uniform spacing, but fills in the corners of a square field-of-view. Because of the uniform distance between samples, the overall amplitudes of Δx and Δy (FIGS. 10A and 10B) are independent of frequency. In this class of patterns, there is an increased (but manageable, particularly in the region of the outer spirals) acceleration (i.e. proportional to Δ(Δx) and Δ(Δx), shown in FIGS. 11A and 11B) in the corner regions.
[0049] [0049]FIGS. 12A and 12B illustrate useable rectangular areas covered by round (FIG. 12A) versus “square” (FIG. 12B) spiral patterns. Both of the spiral patterns of FIGS. 12 A and 12 B)contains 18 revolutions reaching the same radius. The square spiral of FIG. 12B was computed using p=0.6. Dashed-lines enclose areas where nearest sample point estimates of intensity can reasonably be computed for all pixels within the region. In this example, the useable rectangular area of the square spiral in FIG. 12B is 30% greater than the round spiral in FIG. 12A.
[0050] [0050]FIG. 13 illustrates an exemplary, overall arrangement of hardware and flow of data during spiral imaging. Embodiments utilizing the hardware arrangement shown in FIG. 13 can include confocal laser-scanning microscopes, near field microscopes, and atomic force microscopes. In an embodiment, spiral patterns are computed and sent to a scan device via digital-to-analog converter 100 . Optionally, the actual position coordinates of the scanning device can be fed back to the computer via an analog-to-digital converter 102 for use in generating display images. Scan device 104 moves a probe, such as a beam and/or the sample 108 according to the computed spiral command signals. Signals collected from the sample (e.g. light) are collected by computer 106 using counters 110 (e.g. photon counting) and/or analog-to-digital conversion 102 . The automated scheme can be implemented in a variety of imaging devices that are capable of deflecting a beam or probe, or moving a stage using spiral patterns. Intensity (e.g. light) signals are registered with the position coordinates (either command or feedback) to generate raw data sets for storage and/or display. Raw spiral data sets can be displayed on a raster terminal using a weighed averaging scheme, as described above. Images, displayed 112 either singly or as a video sequences, show a roughly circular (reflecting the spiral pattern) field of view.
[0051] [0051]FIG. 14 shows an overall flow diagram of an algorithm capable of generating spiral control signals, acquiring/storing spiral image data and displaying spiral data on a conventional (raster) monitor. The algorithm can use different techniques (as described above) to map spiral data to raster images depending on the need for high display frame rates (e.g. during on-line monitoring) or for image accuracy (e.g. during off-line display).
[0052] In the case of optical microscopy applications, the spiral approach can be used for fluorescence imaging involving single photon activation, where descanning of the collected light is required for confocal imaging, or using multi-photon activation where descanning of the emitted light is not necessary. Spiral movement can be implemented using a number of beam-steering devices such as closed-loop galvanometers coupled to mirrors, piezoelectric actuated dual axis mirrors, and single- and dual-axis MEMS (microelectromechanical system) micro-mirrors. In each case, the sinusoidal control waveforms allow the rate and accuracy of beam-steering to be improved.
[0053] While a method and apparatus for performing imaging using continuous, non-raster scanning patterns have been illustrated and described in detail, many modifications can be made to embodiments of the present invention without departing from the spirit thereof
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A method and apparatus for performing data collection within a device is disclosed. A device steers a scanning probe in a continuous, non-raster pattern across a specimen. The specimen is supported by a stage, and data is collected in response to interaction between the probe and the specimen to form a data set. Spiral scanning patterns without turnaround regions are utilized in embodiments of the present invention, both with and without rounded corners in the scanning patterns.
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BACKGROUND OF THE INVENTION
It is desired to provide a metal detector that is capable of imaging the metal on persons or objects passing through a spatial plane, providing location, shape, and mass of the metal objects.
In the standard metal detectors most commonly used today, a passive ferromagnetic device measures attenuations in the earth's magnetic field created by the presence of a metallic object. A disadvantage of this current device is that the sensor is incapable of giving the precise location of the metallic object. Furthermore, information pertaining to the shape and mass of the object is not available when using the current metal detection devices. The inability to provide a more precise location and information about metallic objects detected requires more intrusive detection means such as a hand-held metal detection wand or a physical search.
Another disadvantage of the current metal detection systems is that only one person or object may be scanned at any given time. This limitation hinders pedestrian traffic and is thought to be intrusive.
SUMMARY OF THE INVENTION
This invention describes an imaging metal detector used to generate two or three dimensional images of metallic objects within a given imaged plane (i.e., the two-dimensional plane to be scanned for metallic objects). This imaged plane may contain several objects simultaneously. The present invention provides the precise location of all metallic or electrically conductive or dielectric objects, their shape, their mass, and the type of metal or conductors contained within those objects. The invention may be operated using low frequency electromagnetic radiation, similar to that of a 60 Hz house current, and thus, is intrinsically safe for the subjects being scanned. Further, the use of low frequency electromagnetic radiation simplifies the electronics because diffraction effects are minimal. This simplification allows for rapid imaging calculations.
The present invention comprises a sensor ring consisting of a plurality of sensors wrapped around ferrite stubs mounted on a ferrite loop. The ferrite loop is arranged to substantially surround the imaged plane. Each sensor is switchably coupled to a transmitter and a receiver allowing the sensor to act as either a transmitter or receiver of a magnetic signal. Alternatively, separate transmit and receive sensors may be used. A computer is coupled to the receiver for sending a receive address code and to the transmitter for sending a transmit address code. The transmitter and receiver then activate the corresponding sensors for receipt and transmission of the magnetic beam. The computer is programmed to: provide transmit address codes to the transmitter and receive address codes to the receiver, accept image data from the receiver, and to process the image data and generate a two-dimensional metal image indicating the distribution of metal in the imaged plane.
The generated metal image may be displayed on a video monitor. Also, a photographic camera may be utilized to provide a video image of the imaged plane for overlay with the generated metal image.
The method of detecting the presence and distribution of metal in an imaged plane consists of utilizing the above described apparatus in the following manner:
transmitting a signal from at least one sensor and receiving the attenuated signal at least one other sensor, the receiving sensor providing information representative of the attenuated signal (e.g. raw voltages) to the computer;
repeating the transmitting and receiving step using a different transmitter sensor until a sufficient number of attenuated signals have been calculated to generate an image of the metal contained in the imaged plane; and
generating an image of the metal contained in the imaged plane from the information provided to the computer.
The generating step may be carried out as follows:
calibrating sensors by:
zeroing the raw voltages with respect to reference voltages taken with no metal in said imaged plane by subtracting the reference voltages from the raw voltages;
converting zeroed voltages to decibels relative to the reference voltage; and
correcting for the signal gain caused by the position of the sensor which provided the raw voltage to derive calibrated voltages;
calculating a raw image by:
averaging the calibrated voltages corresponding to all scan lines that pass through a given pixel for each pixel; and
calculating the back calculated voltage at the receiver sensors corresponding to the raw image by determining what each sensor would measure for the raw image;
optimizing the raw image to approximately match the calibrated voltages by:
dividing the calibrated voltage by the back calculated voltage for each scan line to derive a scaling constant for each scan line; and
multiplying the product of the scaling constants corresponding to the scan lines which pass through a given pixel by the average of the calibrated voltages for that given pixel to derive an optimized voltage; and
comparing the product of the scaling constants to one:
if the product is within a preselected threshold of one, then the metal image is output;
otherwise, the raw voltage is set equal to the optimized voltage and repeating the optimizing step until the product is within the preselected threshold.
Alternatively, the computer may be further programmed to compare the generated metal image to a set of metal images corresponding to a variety of weapons and other threatening objects. If a match is found, the operator can be alerted by an alarm, the image may be highlighted on the screen, or other appropriate action may be taken as deemed necessary.
Also, the imaged plane may be scanned consecutively several times as the objects moves through the imaged plane, and the generated two-dimensional metal images may be placed together to form a three-dimensional image.
Further, the imaged plane may be scanned at several different frequencies. The generated multi-frequency profile of the object may be used to identify the type of metal detected by comparison to known profiles. It is also possible to calculate the mass of the metallic object if a three-dimensional image is generated in conjunction with the profile. Further, the metal image profile may be overlaid on a photographic or x-ray image.
It will be apparent that a person of skill in the art, having the benefit of this disclosure of this invention, may conceive of numerous other applications for which this invention will be beneficial. Nothing in this disclosure limits the application of the invention herein to the embodiments and the applications expressly described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited advantages and features of the present invention, as well as others which will become apparent, are attained and can be understood in detail, a more particular description of the invention summarized above may be had by reference to a preferred embodiment thereof which was illustrated in the appended drawings, which drawings form a part of this specification.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a schematic drawing of an imaging metal detector according to this invention.
FIG. 2 is a block diagram of one embodiment of the hardware for the imaging metal detector according to a preferred embodiment.
FIG. 3 is a block diagram of one embodiment of the hardware for the imaging metal detector according to a preferred embodiment.
FIG. 4 is a block diagram of one embodiment of the software of the imaging metal detector according to a preferred embodiment.
FIG. 5 is a flow chart of one embodiment of the software of the imaging metal detector according to a preferred embodiment.
FIGS. 6a-11 are diagrams of an example run of the flow chart in FIG. 5. These diagrams do not contain realistic numbers and are for illustrative purposes only.
FIG. 12 is an example of a metal image generated by an imaging metal detector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an imaging metal detector that exemplifies a preferred embodiment of this invention. A sensor ring (10) surrounds the imaged plane (20) which contains the metallic or electrically conductive object (30) desired to be located and analyzed. Alternatively, the sensor ring may be "U" shaped (omitting the lower portion of the loop), if the imaged plane is narrow in dimension as, for example, in a narrow doorway.
The sensor ring (10) is comprised of a ferrite loop (12) with sensors (14) mounted at spaced intervals on the loop. The ferrite loop (12) consists of a rubber ring loaded with ferrite powder or a series of ferrite rods placed end-to-end, and substantially surrounds the imaged plane (20). The entire sensor ring (10) may be covered with molding for a more architecturally aesthetic appearance and to reduce the intrusive appearance of the imaging metal detector. The sensors are ferrite stubs with 30-50 turn coils wrapped around them and are mounted with their central axis pointing into the loop. These sensors are clipped onto the ferrite loop and switchably connected to a transmitter and a receiver. The number and spacing of the sensors may be adjusted according to the desired amount of detail in the resultant metal image. It is found that for a 5.5'×7' ferrite loop a 1" spacing of sensors is adequate and provides a 60×84 pixel image. A 1/8" spacing of sensors in the same loop would provide a 528×672 pixel image.
The transmitter (40) has multiple outputs (42) which are connected to each sensor (14). Each sensor (14) is also connected to one input (54) of the receiver (50). In turn, the receiver (50) and the transmitter (40) are connected to a computer (60) by input ports (44 & 54) and an output port (52).
The transmitter (40) receives a transmit address code (46) from the computer (60) which corresponds to a transmit sensor (14). The transmitter (40) then sends a sinusoidal activation signal to the transmit sensor (14) having the corresponding address code (46). The preferred frequency range of the activation signal is 5-85 kHz. The most preferable frequency is around 80 kHz because this avoids local broadcast bands and senses most common metals. The frequency range is limited by the principal dimension of the loop. In a preferred embodiment, the wavelength should be at least ten times larger than the longest loop dimension to minimize diffraction effects. In a more preferred embodiment, the wavelength is at least twenty times larger than the longest dimension. The transmitter may be operated at as high as 20 volts, but about 2.5 volts is preferred.
Likewise, the receiver(s) (50) accepts one or more receive address code(s) (56) from the computer (60) and sends an activation signal to the corresponding receive sensor(s). The receiver (50) has a series of inputs (54) for receiving attenuated signal measurements from receive sensors (14) and a receive address code (56) from the computer (60), and one output (52) for sending metal image data (58) to the computer (60). The receiver may be a high Q op amp or a digital signal processor.
The transmit sensor (14) then generates a electromagnetic field. This magnetic field will be attenuated by the metallic object (30) blocking the magnetic field. Alternatively, several transmit sensors may be activated simultaneously provided they are phase coherent. This alternative allows for faster scanning times, but requires a more complex algorithm as feedback may become a problem. This attenuated signal is then received by one or more receive sensors (14). The receive sensors then send signals back to the receiver (50) which in turn provides metal image data representative of the attenuated signal to the computer (58).
The sensors may be switchably connected to the transmitter and receiver, so that each sensor may be used to either transmit or receive the magnetic signal. Alternatively, sensors may be used solely for either transmitting or receiving.
The computer (60) then calculates the degree of signal attenuation corresponding to each receive address code (56). This procedure is repeated using a variety of transmit sensors and receive sensors until a sufficient number of attenuated signals have been calculated to generate an image (62) of the metallic object (30) in desired detail. This requires about 1/6 as many readings as desired pixels.
Alternative embodiments of the present invention is indicated in FIG. 1 by dashed lines. In one alternative embodiment, the metal image (62) which is generated by the computer (60) may be displayed on a monitor (70).
In another alternative embodiment of the present invention, a photographic camera (80) may record a video image (82) of the image plane (20) and send this video image (82) to the monitor (70) via the computer (60). The metal image (62) may then be overlaid onto the video image (82).
In another alternative embodiment, several images may be generated as the object passes through the imaged plane. These two-dimensional images may then be placed together to generate a three-dimensional image.
In another embodiment, the object may be generated at various frequencies. From these scans a multi-frequency profile of the metal may be generated and used to identify the type of metal. This information may be overlaid or used in conjunction with a photographic image, x-ray image, or three-dimensional image. Note that if one were to obtain a three-dimensional image and metal image profile, one could calculate the mass of the object.
FIG. 2 depicts one embodiment of the hardware for an imaging metal detector according to a preferred embodiment. The computer (60) sends a transmit address code (46) to the transmitter (40) which then activates the addressed transmit sensor (14). The computer (60) also sends one or more receive address codes (56) to the receiver (50) which then activates the addressed receive sensors (14).
The receive sensors (14) accept the attenuated electromagnetic signal from the transmit sensor (14) and relay signals back to the receiver (50) which in turn sends a signal representative of the attenuated signals to the computer (60).
This process of transmitting and receiving electromagnetic signals across the imaged plane is repeated until a sufficient amount of information is gathered to generate a metal image. In one alternative embodiment, the computer (60) relays the metal image (62) to a monitor (70). In another alternative embodiment, a photographic camera (80) relays video image data (82) of the imaged plane to the computer (60) which may then send a video image (64) to the monitor (70) for overlay with the metal image (62).
FIG. 3 depicts one embodiment of the hardware for the imaging metal detector according to a preferred embodiment. This embodiment includes a transmitter MUX (45) and receiver MUX (55) for accepting address codes (46 and 56, respectively) from the computer (60).
Also, depicted in this alternative embodiment is a frame grabber card (84) for holding video image data (82) from the photographic camera (80) and relaying it to the computer (60).
Lastly, the alternative embodiment shown includes an A/D convertor (65) for converting the analog signals from the receiver to digital codes for the computer (60).
Alternatively, as in a previous embodiment, a monitor (70) may be used to display the video image (64) and the metal image (62).
FIG. 4 is a block diagram of one embodiment of the software for the imaging metal detector. The metal image data (58) is received by the image software (100), and a metal image is generated which may then be displayed on a monitor (70).
In one alternative embodiment, a photographic camera (80) (not shown) may send video data (82) to the image software (100) which then generates a video image and sends it to the monitor (70). The imaging software may then overlay the video image with the metal image.
In yet another alternative embodiment of the present invention, the metal image data (58), in addition to being sent to imaging software (100), is sent to comparison software (120) which compares the metal image data to a set of threat-match images (110). The threat-match images (110) are a catalog of metal image data for a variety of known weapons or other objects desired to be located. If the comparison software (120) finds a threat-match it then signals the imaging software (100) and an appropriate action may be taken (e.g. sound an alarm, display information known about the particular weapon, overlay the video image with an image of the known weapon on the monitor (70), etc.).
FIG. 5 is a flow chart for one embodiment of the software for the imaging metal detector according to a preferred embodiment. The software performs several functions. First, it calibrates the voltages received from the sensors with objects in the imaged plane relative to those received when no items are in the imaged planed. This is done by receiving the raw voltages, V R , from the receiving sensors (510) and subtracting the reference voltages, V 0 , obtained when no items were present in the imaged plane (520) and converting to Db (i.e. 10 log (V R -V 0 ) /V 0 !=V c (Db)). Lastly, the voltages are calibrated to correct for the position of the particular sensor in the loop (530). That is, the position of a given sensor causes differences in the signal gain which is corrected in this step. These calibration steps (i.e. 510-530) are carried out for each scan to obtain the corresponding calibrated voltages, V c '.
In practice one way of correcting for signal gain due to position of a sensor is to suspend a piece of metal into the imaged plane and scan it. The metal is then rastered to each pixel and scanned. The measurements should be equal at all sensors. To the extent the measurements differ due to the location of given sensors, a map can be generated with correction factors.
Second, the software generates a metal image from the metal image data sent by the receiver. In generating a metal image, an approximation (i.e. numerical method) is used rather than a closed form solution because the number of sensors multiplied by the numbers of scans is usually less than the number of pixels. For example, a 100×100 sensor array would yield 100 known from a horizontal scan, 100 known from a vertical scan, 200 known from a 45 degree diagonal scan, and 10,000 pixels to solve for. Thus, there are more unknowns than equations. The ratio of the number of unknowns to the number of equations which will form a reasonable image is dependent upon the complexity of the image and the particular application. It has been found that for a normal sparsely populated image, up to a six to one ratio will give a good image. For more complex images or for application requiring higher resolutions, the ratio will approach one.
One way of quickly generating the metal image, is to first calculate a raw image, and then, apply a correction factor to produce a more detailed image. In calculating a raw image, first the calibrated voltages, V c ', corresponding to a given pixel are averaged together (540) for each pixel. The back calculated voltage, V B , corresponding to the raw image is then calculated for each sensor (550). That is, the Db attenuation which would be expected to be received by a given sensor based upon the raw image is determined. This is done by adding the V c ' values for each scan line. The calibrated voltage V c ' (i.e. from 530) is divided by the back calculated voltage (i.e. from 550) for each scan line to arrive at a scaling constant, k, (560) corresponding to that scan line (i.e. k=V c '/V B ). This scaling constant, k, is then multiplied by the voltage average, AVG(V c '), for each pixel on that scan line (i.e. from 540) which results in an optimized voltage, V OPT , at the sensor for that scan line (i.e. V OPT =k 1 k 2 k 3 . . . k n AVG (V c ')) (570). Thus, each pixel is multiplied by the correction factors from the several scan lines which intersect it. If the resulting signal, V OPT , at the pixel is positive, the signal is set to the null signal (i.e. if V OPT >0, then V OPT =0) (580-590). If the product of the scaling factors (i.e. k 1 , 2 k 3 . . . k n ) is within a preselected threshold value, then the image is output (600-620). Otherwise, a raw image is once again recalculated (i.e. return to 550) using the V OPT values (630) (i.e. AVG(V c '=V OPT )). This is repeated until the product of scaling factors is smaller than the threshold. Although, the threshold value will vary, depending upon the a number of factors, a threshold value which results in about 10 iterations is generally sufficient for most common applications. The resulting image shows metal and RF absorbing material images with a pixel size equal to the sensor spacing.
In an alternative embodiment (not shown), image recognition programs can be used to determine if a metal image matches a known set of threat objects (e.g., knives, handguns, rifles, etc). When matches are found, those objects can be enhanced for the operator, an alarm can be sounded, etc.
Also, a video image may be overlaid onto the metal image to facilitate locating the metallic object in relation to nonmetallic objects and allowing human discrimination of objects based upon their physical location.
There are an infinite number of possible algorithms for generating an image from data received from the sensors. Obviously, any number of scans may be taken in any number of directions. Multiple transmission and receptions may take place simultaneously if the transmissions are in phase. There are a variety of different ways to calibrate the raw voltages. Likewise, there are a variety of ways to generate a raw image. Rather than averaging voltages to generate a raw image, numerous formulations and methods could be employed for a more accurate raw image. The method depicted in FIG. 5 is just one example among many of ways to generate an image from the attenuation data collected.
FIGS. 6a-11 depict a made up example which traces the flowchart of FIG. 5. This example does not use realistic numbers and is intended solely for illustrative purposes. These figures depict an imaged space with 4 sensors running horizontally at the bottom of the space (labeled 1, 2, 3, and i), 4 sensors running vertically on the left side of the space (labeled 1, 2, 3, and j), and one sensor at the intersection of the axes. For clarity, only a small portion of the imaged space is shown. Each intersection in the imaged space represents a pixel. The four dots contained among the pixels (labeled -10, -7, -1, and -3, in FIG. 6a) represent metallic or conductive objects in the imaged plane, and the number adjacent to them in parenthesis represents the amount of attenuation encountered at each point.
FIG. 6a is a depiction of a horizontal and vertical scan of the imaged space. The numbers to the right of the plane are the voltages measured from the horizontal scan (i.e. 90, 93, 96, and 100). Likewise, the numbers at the top of the plane are the voltages measured from the vertical scan (i.e. 89, 93, 100, and 97). FIG. 6b is similar to FIG. 6a, but the scan is taken diagonally. Thus, FIGS. 6a and 6b correspond to block 510 of FIG. 5.
FIGS. 7a and 7b depict the raw voltages being calibrated in the horizontal and vertical directions and the diagonal direction, respectively. For simplicity, it was assumed that no correction was necessary for gain due to sensor location (i.e. V c '=V 0 ). Thus, these figures correspond to blocks 520 and 530 of FIG. 5.
FIG. 8 depicts an averaging of calibrated voltages for each pixel which corresponds to block 540 in FIG. 5.
As, in block 550 of FIG. 5, the back voltages are then calculated as depicted in FIGS. 9a and 9b. The back voltages, V B , are calculated by adding the average calibrated voltages, AVG (V c '), along a given scan line.
Scaling factors, k n , are then determined for each given scan line by dividing the calibrated voltage by the back calculated voltage (i.e. k n =V c '/V B ), as depicted in FIGS. 10a and 10b. Thus, these figures correspond to block 560 in FIG. 5.
Next, the optimized voltage, V OPT , is calculated for each pixel as the product of the scaling factors, k, and the average calibrated voltage, V c ' (i.e. V OPT =k 1 k 2 k 3 AVG(V c ')) which is depicted in FIG. 11. In this example, three scans (i.e. horizontal, vertical, and diagonal) were taken, and thus, each pixel will have three scaling factors corresponding to these scan lines. Thus, FIG. 11 corresponds to block 570 in FIG. 5.
This completes the first iteration.
This example illustrates one of many methods which could be used to generate a metal image from the attenuation measurements gathered. Any number of scans in any number of directions could be used. Further, a wide variety of scaling factors could be devised to weight the various measurements. Any number of numerical methods could be employed to estimate a solution to the equations generated. Lastly, a closed solution can be obtained by taking a larger number of scans.
FIG. 12 is an example of a metal image generated by an imaging metal detector. A 5.5'×7' ferrite loop was used having sensors mounted to it at 1" intervals. The loop consisted of 0.188 diameter×0.375" length, type 33 ferrites bonded together end-to-end. The transmit sensors consisted of 50 wraps of wire around a 0.75" long ferrite rod, and the receive sensors consisted of 50 wraps of wire on a 1.5" long ferrite rod. Accuracy of up to 1" was achieved which provided a 66×84 pixel image.
The transmitter was operated at 83 kHz with a 20 volt peak-to-peak input.
The receiver was a two-stage amplifier, the first having a low pass filter, the second having a band pass filter with a Q of 10.
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This invention relates to the field of metal detectors. More particularly, it relates to an imaging metal detector for imaging the metal on subjects passing through a spatial plane providing the specific location, shape and mass of the metal object. This invention makes use of an array of active sensors to transmit and receive magnetic beams and a computer for generating an image of the metal object based upon the data received from the sensors. Through the use of this invention it is possible to scan several subjects at the same time and generate a two- or three-dimensional image of any metal object on the subject as well as precise location, mass and type of metal contained in the object.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention provides a vehicle suspension system employing a beam mounted for pivoting movement to a hanger and connected securely to a vehicle axle where the beam is constructed with a laterally widening base as it extends longitudinally from the pivot mounting to the vehicle axle and with an axle shell securing the beam to the axle where the shell connection to the axle reduces stress on the vehicle axle.
(2) Description of the Related Art
In the design of vehicle suspension system beams of the type having a pivot mounting to a hanger member suspended beneath a vehicle chassis at one end, and a connection to a lateral vehicle axle and a spring means spanning between the beam and the vehicle chassis at an opposite end, it is desirable to reduce the weight of the beam without reducing its capacity to support vehicle loads. With the beam being a major component in most suspension systems, reduction of the beam's weight results in a significant reduction in the overall weight of the suspension system. However, in designing suspension beams to reduce their weight, care must be taken to avoid creating stress concentration areas in the beam itself or in its rigid connection to the vehicle axle. Difficulties are frequently encountered in the design of the connection between the beam and the vehicle axle where stresses are often concentrated. Load stresses due to vehicle load exerted on the beam and cyclic stresses exerted on the beam while the vehicle is operated over the road can be concentrated at the connection of the beam to the axle. Where the connection of the beam to the axle is a rigid, weld connection, the concentration of stresses on the weld can result in the weld's failure, causing the axle to separate from the beam and causing substantial damage to the vehicle.
SUMMARY OF THE INVENTION
The present invention provides a unique beam design of reduced weight with a specialized weld connection to a vehicle axle that reduces stress concentrations and distributes load and cyclic stresses through the construction of the beam, thereby enhancing the fatigue life and safety of the axle attachment to the beam. The reduced weight of the beam reduces the overall weight of the suspension system employing the beam, and thereby reduces the overall weight of the vehicle supported by the suspension system. While the novel construction of the beam minimizes its weight, it also provides a rigid weld connection between the beam and vehicle axle with an extended fatigue life. The construction of the beam may be employed in both an overslung and underslung axle connection with only minor modifications made to the beam to accommodate an air spring connection in both instances.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and features of the present invention are revealed in the following detailed description of the preferred embodiment of the invention and in the drawing figures wherein:
FIG. 1 is a side elevation view of the beam of the present invention in an illustrative operative environment;
FIG. 2 is a top plan view of the beam shown in FIG. 1 viewed from the line 2--2 of FIG. 1;
FIG. 3 is a perspective view of the axle shell removed from the beam;
FIG. 4 is a side elevation view of the beam shown in FIG. 2;
FIG. 5 is an end elevation view of the beam from the line 5--5 of FIG. 4;
FIG. 6 is a cross section of the beam viewed from the line 6--6 of FIG. 4; and
FIG. 7 is a side elevation view of the beam of the invention employed in an underslung attachment to a vehicle axle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows one illustration of an operative environment of the suspension system beam 10 of the present invention. It should be understood that the environment shown in FIG. 1 is provided to illustrate only one potential use of the beam 10, and that the beam 10 may be employed in a variety of different types of vehicle suspension systems having constructions differing from that shown in FIG. 1. The suspension system construction shown, apart from the beam 10 of the invention, is for the most part conventional. The system is shown attached to the underside of a vehicle chassis 12 and comprises a hanger 14 supporting a pivot bushing assembly 16, a shock absorber 18, a vehicle axle 20 and an air spring 22 connected between the beam 10 and the underside of the chassis 12. In the operative environment shown, the beam 10 is connected to the axle 20 in an overslung fashion. It should be understood that the beam 10 of the present invention has a construction that may be employed in both overslung and underslung connections to a vehicle axle without substantial modification to the beam itself. With this in mind, the use of terms such as "upward", "downward", "top" and "bottom" in the description of the beam to follow are not intended to have any limiting effect on the claimed subject matter. These terms are used solely to describe the beam in referring to the orientation of the beam shown in the drawing figures. Where the beam of the invention is employed connected to a vehicle axle in an underslung fashion, the terms "upward", "downward", "top" and "bottom" should be interpreted as having their opposite meanings. It is reemphasized that the beam 10 of the present invention in the description to follow is described as being connected to a vehicle axle in an overslung fashion to simplify the description of the invention. The orientational terms employed in the description of the invention and in the claims are not intended to be limiting as the beam 10 of the invention is equally well suited for use in overslung and underslung connections to vehicle axles. In FIG. 1, only one suspension system employing the beam 10 of the invention is shown, it being understood that a like suspension system employing the same beam 10 of the invention is positioned on an opposite lateral side of the vehicle as is conventional.
FIG. 2 shows the beam 10 removed from the suspension system of FIG. 1 to better illustrate the novel construction of the beam. Generally, the beam is constructed of a generally cylindrical sleeve 26, a U-shaped channel 28, a top panel 30 and a curved axle shell 32. Also shown in FIG. 1 is an air spring support bracket 34, the configuration of which changes depending on whether the beam 10 is employed in an overslung or underslung attachment to the vehicle axle. As set forth earlier, the bracket 34 shown in FIG. 2 is for use of the beam 10 in an overslung attachment to a vehicle axle.
The cylindrical sleeve 26 is configured to receive a conventional pivot bushing assembly within a center bore 36 of the sleeve having a lateral center axis 38. The sleeve is described as being generally cylindrical herein because the sleeve itself is not a complete cylinder but has a gap 40 formed therethrough. The gap 40 is provided to enable the sleeve to be deformed and enlarged to facilitate the insertion of the pivot bushing assembly into the sleeve center bore 36. A pair of opposed flanges 42, 44 project radially from the opposite sides of the gap 40 and extend laterally across the exterior surface of the sleeve. The flanges 42, 44 are reinforced by pluralities of gussets 46, 48, respectively, secured between the flanges and the exterior surface 50 of the sleeve. A plurality of holes are provided through the flanges 42, 44 for receipt of threaded fasteners that are tightened down to close the sleeve 26 around the pivot bushing providing a secure connection between the sleeve interior surface 52 and the exterior surface of a pivot bushing in attaching the beam 10 to a pivot bushing assembly suspended by a hanger 14 from a vehicle chassis.
Variations of the generally cylindrical sleeve 26 may be employed with the beam 10 without departing from the intended scope of the invention as defined by the claims. For example, the sleeve may be provided in two semicircular sections that are connected together over a pivot bushing assembly by threaded fasteners, thereby attaching the beam to the pivot bushing. Other types of generally cylindrical sleeves providing an attachment of a suspension system beam to a pivot bushing assembly are known in the prior art and it is intended herein that the description of the generally cylindrical sleeve 26 should also cover other known sleeve constructions apart from that shown in the drawings.
The channel 28 has longitudinally opposite first 56 and second 58 ends with a longitudinal length of the channel extending therebetween. The channel 28 has a generally U-shaped cross section comprised of a pair of laterally spaced side panels 60, 62 integrally connected to a bottom panel 64. The lateral spacing of the side panels 60, 62 provides an opening at the top of the channel. The first end 56 of the channel is formed by arcuate configurations of the left hand ends of the side panels 60, 62 and a substantially straight left hand end of the bottom panel 64, all of which fit flush against the sleeve exterior surface 50 and are welded thereto. The reinforcing sleeve gussets 48 are also welded to the bottom panel 64. As the side panels 60, 62 of the channel extend longitudinally from the first end 56 of the channel to the second end 58 they increase vertically in size. The additional material in the area of the channel second end 58 provides additional strength to the channel side panels 60, 62 adjacent their connection to the vehicle axle yet to be described. As the bottom panel 64 of the channel extends longitudinally from the channel first end 56 to the second end 58 it also increases in its lateral width. The increased lateral width of the channel bottom panel 64 at the channel second end 58 over the width of the bottom panel at the channel first end 56 enhances the strength of the bottom panel adjacent its connection to the vehicle axle yet to be described.
The specific configuration of the bottom panel 64 is also designed to enhance the strength of the bottom panel and thereby enhance the overall strength of the channel 28. As shown in the drawing figures, a pair of laterally spaced, longitudinally extending bends 66, 68 are formed in the bottom panel 64. The bends 66, 68 extend the entire length of the bottom panel between the channel first and second ends 56, 58. The bends divide the bottom panel 64 into three longitudinally extending sections. A center section 70 is oriented at an angle to the lateral side sections 72, 74 on opposite sides of the respective bends 66, 68. The relative angles between the center section 70 and the side sections 72, 74 enhance the strength of the bottom panel 64 over prior art beam bottom panels that are substantially flat along their longitudinal lengths.
The increasing lateral width of the bottom panel 64 as it extends from the channel first end 56 to the channel second end 58 also causes the lateral spacing between the side panels 60, 62 to increase as they extend longitudinally from the channel first end 56 to the channel second end 58. The increased lateral spacing between the channel side panels 60, 62 at the channel second end 58 over the lateral spacing between the side panels at the channel first end 56 provides a stronger and more stable connection of the beam to the vehicle axle as will be described.
The axle shell 32 of the beam 10 is specifically designed to minimize stress concentrations in the beam connection to a vehicle axle. The shell 32 is constructed having a generally curved configuration with opposite interior 78 and exterior 80 surfaces, the configuration being bounded by laterally opposite lateral edges 82, 84 of the shell and longitudinally opposite weld edges 86, 88 of the shell. Each of the shell lateral edges 82, 84 flare laterally outward as they extend longitudinally toward the weld edges 86, 88 at the opposite longitudinal ends of the shell. At the junctures of the lateral edges 82, 84 with the weld edges 86, 88 blunt ends 90 are formed to avoid stress concentrations at the juncture of the lateral and weld edges. The projecting tips formed at the blunt ends 90 of the axle shell are more flexible than the remaining construction of the shell and their flexibility distributes stress away from the tips and up the lateral sides of the shell.
Each of the weld edges 86, 88 are given nonlinear configurations. What is meant by nonlinear is that the weld edges 86, 88 are configured to be nonparallel to the axis A of the lateral vehicle axle 20 to which the axle shell 32 is to be joined. The weld edges 86, 88 and welds 76 may have a convex configuration with a continuous curved edge between the blunt ends 90, or a more angular configuration such as that shown in the drawing figures where opposite end portions of the weld edges taper upward toward the blunt ends 90 from an intermediate portion of the weld edges. It should be understood that by describing the weld edges 86, 88 as being nonparallel to the axis of the vehicle lateral axle, various nonlinear configurations of the weld edges similar to the generally convex configuration of the weld edges shown in the drawing figures are intended to be included. Together, the concave configuration of the axle shell lateral edges 82, 84 extending laterally outward beyond the lateral spacing of the beam side panel 60, 62, the blunt ends 90 formed at the junctures of the lateral edges 82, 84 to the opposite ends of the weld edges 86, 88, and the nonparallel, convex configuration of the weld edges 86, 88 all contribute to reducing stress concentrations in the axle shell 32 and the vehicle axle connected to the shell, and in the distribution of vehicle load stresses and operation cyclic stresses throughout the construction of the axle shell 32 and the beam 10.
Although the axle shell 32 is described as having a generally curved configuration and is shown configured to receive a vehicle axle 20 having a circular cross section, it should be understood that the configuration of the shell 32 may be modified to accommodate the receipt of a vehicle axle having a rectangular or other geometric cross section within the curvature of the interior surface 78.
The channel side panels 60, 62 at the second end of the channel 58 are given curved configurations complementary to the curvature of the shell exterior surface 80. The axle shell 32 is connected to the channel second end 58 by welds along the curved configurations of the side panels 60, 62 at the channel second end 58 and along the bottom panel 64 at the channel second end 58. In assembling the beam 10 to a vehicle axle 20, the axle 20 is received within the curvature defined by the shell interior surface 78 and welds 76 between the axle shell 32 and the vehicle axle 20 are provided solely along the weld edges 86, 88 of the axle shell. The welds 76 extend laterally along the weld edges 86, 88 beyond opposite lateral sides of an intermediate portion 92 of the axle shell. The curved configuration of the axle shell weld edges 86, 88 and the resulting curved configuration of the weld line joining the weld edges 86, 88 to the vehicle axle 20, together with the specific configuration of the axle shell prevents stress concentrations at the blunt ends 90 of the shell and distributes vehicle load stress and operation cyclic stress over the weld lines, thereby enhancing the fatigue life and safety of the beam 10.
The top panel 30 has longitudinally opposite first 94 and second 96 ends and a longitudinal length between its opposite ends. The top panel 30 is secured to the top edges of the channel side panels 60, 62 along the entire longitudinal length of these top edges and follows the configuration of the side panel top edges. The first end 94 of the top panel is welded to the exterior surface 50 of the sleeve. A pair of lateral bends 98, 100 are formed in the top panel 30 where it changes its longitudinal direction in following the top edges of the side panels 60, 62. The top panel diverges vertically away from the bottom panel as it extends from the sleeve 26 to the first bend 98. From the first bend 98 to the second bend 100, the top panel extends longitudinally, generally parallel with the channel bottom panel 64. From the second bend 100, the top panel converges toward the channel bottom panel 64 as it extends longitudinally to the top panel second end 96 which is welded to the exterior surface of the axle shell 32. In following the top edges of the channel side panels 60, 62 as they extend from the sleeve 26 to the axle shell 32, the lateral width of the top panel 30 increases. The increased lateral width of the top panel second end 96 over the lateral width of the top panel first end 94 enhances the structural strength of the top panel adjacent its connection to the vehicle axle 20.
A shock absorber bracket 104 is secured to one of the channel side panels 60 by welds. The construction of the bracket 104 is conventional and is not described in detail.
The air spring bracket 34 is secured to the channel second end 58 across the exterior surface of the axle shell 32 and the beam top panel 30. The spring bracket 34 is comprised of a top plate 108 supported by a U-shaped gusset 110 connected between an underside of the top plate 108 and the exterior surfaces of the axle shell 32 and the beam top panel 30. A plurality of holes 112 are provided through the top plate 108 to secure a conventional air spring thereto.
FIG. 7 shows the suspension beam of the present invention in an operative environment where the beam is connected in an underslung fashion to a vehicle axle. The component parts of the beam are substantially identical to the previously described embodiment and are labeled with the same reference numbers as the first described embodiment followed by a prime ('). Apart from slight variations in the shapes of the component parts, the construction of the underslung beam shown in FIG. 7 is substantially identical to that of the first described, overslung embodiment of the beam and will not be described here in detail. It should be understood that the description of the first embodiment of the beam is also applicable to the description of the underslung beam shown in FIG. 7 except that the vertical relative positions of component parts of the beam are reversed. Therefore, the top panel 30 of the first described embodiment is equivalent to the panel 30' of the FIG. 7 embodiment except that it is now positioned on the underside of the beam. The channel 28' of the FIG. 7 beam has an inverted-U shaped configuration with an opening between side panels at the bottom of the beam and with the bottom panel 64' positioned on the upper side of the beam. As stated earlier, in the description of the beam 10 of the invention presented herein and in the subject matter of the invention set forth in the claims, the use of the terms "upward", "downward", "top" and "bottom" were employed only to simplify the description of the beam construction and are not intended to be limiting. As shown in the drawing figures, substantially the same construction of the beam 10 of the invention may be employed in an overslung or underslung manner without departing from the intended scope of the subject matter set forth in the claims.
While the present invention has been described by reference to a specific embodiment, it should be understood that modifications and variations of the invention may be constructed without departing from the scope of the invention defined in the following claims.
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A vehicle suspension system comprises a beam mounted for pivoting movement to a hanger and securely to a vehicle axle where the beam is constructed with a laterally widening base as it extends longitudinally from the pivot mounting to the vehicle axle and with an axle shell securing the beam to the axle where the shell connection to the axle reduces stress on the vehicle axle.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
The present patent application is a continuation of U.S. patent application Ser. No. 11/625,556, filed Jan. 22, 2007 now U.S. Pat. No. 7,784,478, which in turn claims the benefit of U.S. Provisional Patent Application Ser. No. 60/760,820, filed Jan. 20, 2006; U.S. Provisional Patent Application Ser. No. 60/837,965, filed Aug. 16, 2006; and U.S. Provisional Patent Application Ser. No. 60/850,930, filed Oct. 11, 2006, the entireties of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates generally to the field of processing flat articles utilizing acoustic energy, and specifically to systems, methods and apparatus that utilize acoustic energy for cleaning flat articles, such as semiconductor wafers.
BACKGROUND OF THE INVENTION
In the field of semiconductor manufacturing, it has been recognized since the beginning of the industry that removing particles from semiconductor wafers during the manufacturing process is a critical requirement to producing quality profitable wafers. While many different systems and methods have been developed over the years to remove particles from semiconductor wafers, many of these systems and methods are undesirable because they damage the wafers. Thus, the removal of particles from wafers, which is often measured in terms of the particle removal efficiency (“PRE”), must be balanced against the amount of damage caused to the wafers by the cleaning method and/or system. It is therefore desirable for a cleaning method or system to be able to break particles free from the delicate semiconductor wafer without resulting in damage to the devices on the wafer surface.
Existing techniques for freeing the particles from the surface of a semiconductor wafer utilize a combination of chemical and mechanical processes. One typical cleaning chemistry used in the art is standard clean 1 (“SC1”), which is a mixture of ammonium hydroxide, hydrogen peroxide, and water. SC1 oxidizes and etches the surface of the wafer. This etching process, known as undercutting, reduces the physical contact area of the wafer surface to which the particle is bound, thus facilitating ease of removal. However, a mechanical process is still required to actually remove the particle from the wafer surface.
For larger particles and for larger devices, scrubbers have historically been used to physically brush the particle off the surface of the wafer. However, as devices shrank in size, scrubbers and other forms of physical cleaning became inadequate because their physical contact with the wafers began to cause catastrophic damage to the smaller/miniaturized devices.
Recently, the application of sonic/acoustical energy to the wafers during chemical processing has replaced physical scrubbing to effectuate particle removal. The terms “acoustical” and “sonic” are used interchangeably throughout this application. The acoustical energy used in substrate processing is generated via a source of acoustical energy, which typically comprises a transducer which is made of piezoelectric crystal. In operation, the transducer is coupled to a power source (i.e. a source of electrical energy). An electrical energy signal (i.e. electricity) is supplied to the transducer. The transducer converts this electrical energy signal into vibrational mechanical energy (i.e. sonic/acoustical energy) which is then transmitted to the substrate(s) being processed. Characteristics of the electrical energy signal, which is typically in a sinusoidal waveform, supplied to the transducer from the power source dictate the characteristics of the acoustical energy generated by the transducer. For example, increasing the frequency and/or power of the electrical energy signal will increase the frequency and/or power of the acoustical energy being generated by the transducer.
Over time, wafer cleaning utilizing acoustical energy became the most effective method of particle removal in semiconductor wet process applications. Acoustical energy has proven to be an effective way to remove particles, but as with any mechanical process, damage is possible and acoustical cleaning is faced with the same damage issues as traditional physical cleaning methods and apparatus. In the past, cleaning systems utilizing acoustical energy were designed to process semiconductor wafers in batches, typically cleaning twenty-five substrates at once. The benefits of batch cleaning became less important as the size of substrates and the effectiveness of single-wafer cleaning systems increased. The greater value per semiconductor wafer and the more delicate nature of the devices resulted in a transition in the industry toward single-wafer processing equipment.
An example of a single-wafer cleaning system that utilizes megasonic energy is disclosed in U.S. Pat. No. 6,039,059 (“Bran”), issued Mar. 21, 2000, and U.S. Pat. No. 7,100,304 (“Lauerhaas et al.”), issued Sep. 5, 2006, the entireties of which are hereby incorporated by reference herein. The single-wafer cleaning system that is the subject of U.S. Pat. No. 6,039,059 and U.S. Pat. No. 7,100,304 is commercialized by Akrion, Inc. of Allentown, Pa. under the name GOLDFINGER®. Other examples of single-wafer cleaners that utilize acoustic energy are disclosed in U.S. Pat. No. 7,145,286 (“Beck et al.”), issued Dec. 5, 2006, U.S. Pat. No. 6,539,952 (“Itzkowitz”), issued Apr. 1, 2003, and United States Patent Application Publication 2006/0278253 (“Verhaverbeke et al.”), published Dec. 14, 2006. In single-wafer acoustic cleaning systems, such as the ones mentioned above, a semiconductor wafer is supported and rotated in horizontal orientation while a film of liquid is applied to one or both sides/surfaces of the wafer. A transducer assembly is positioned adjacent to one or the surfaces of the wafer so that a transmitter portion of the transducer assembly is in contact with the film of liquid by a meniscus of the liquid. The transducer assembly is activated during the rotation of the wafer, thereby subjecting the wafer to the acoustic energy generated by the transducer assembly.
Nonetheless, the industry's transition to the below 100 nm devices has resulted in additional challenges for manufacturers of semiconductor processing equipment. The cleaning process is no different. As a result of the devices becoming more and more miniaturized, cleanliness requirements have also become increasingly important and stringent. When dealing with reduced size devices, the ratio of the size of a contaminant compared to the size of a device is greater, resulting in an increased likelihood that a contaminated device will not function properly. Thus, increasingly stringent cleanliness and PRE requirements are needed. As a result, improved semiconductor wafer processing techniques that reduce the amount and size of the contaminants present during wafer production are highly desired.
As a result of these increasingly stringent cleanliness and PRE requirements, the removal of particles from both sides/surfaces of the wafer have been discovered by the present inventors to be playing an increasingly important role in achieving high yields. In existing single-wafer systems, removal of particles from both surfaces of the semiconductor wafer during a cleaning cycle are achieved by providing a single transducer assembly adjacent to one of the surfaces of the wafer. This transducer assembly is operated at a sufficient power level so that the generated acoustic energy passes through the wafer itself to loosen particles on the opposite surface of the wafer. This basic concept is one of the subject inventions of U.S. Pat. No. 6,039,059. This dual-sided cleaning concept is also shown as being utilized and copied in the system disclosed in United States Patent Application Publication 2006/0278253 (“Verhaverbeke et al.”) with the transducer assembly located adjacent the backside of the wafer.
Despite these advancements in single-wafer systems and methods for cleaning both sides of the wafer, there still remains a need for single-wafer systems that can achieve improved PRE with minimized device damage. Furthermore, the continued miniaturization of devices continues to render existing cleaning systems incapable of achieving an acceptable balance between high PRE and minimized device damage.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a system, apparatus and method for processing flat articles, such as semiconductor wafers, with acoustical energy.
Another object of the present invention is to provide a system, apparatus and method for simultaneously cleaning both surfaces of flat articles, such as semiconductor wafers, with acoustical energy.
Still another object of the present invention is to provide a system, apparatus and method for simultaneously cleaning both surfaces of flat articles, such as semiconductor wafers, with acoustical energy that improves PRE and/or reduces damage to the flat article.
Yet another object of the present invention is to provide a system, apparatus and method for applying acoustical energy to the bottom surface of a rotating flat article.
A further object of the present invention is to provide a system, apparatus and method for simultaneously cleaning both surfaces of flat articles, such as semiconductor wafers, that utilize acoustic energy reflection.
A still further object of the present invention is to provide an apparatus and method that allows existing single-wafer cleaners to be retrofitted to achieve improved cleaning of both surfaces of the wafer.
A yet further object of the present invention is to provide a system, apparatus and method that achieves increased liquid coupling between a transducer assembly and the bottom surface of a flat article.
Yet another object of the present invention is to provide a system, apparatus and method that increases the backside particle removal efficiency in a single-wafer cleaning system without increasing damage to devices located on the topside of the wafer.
Still another object of the present invention is to provide a system, apparatus and method for applying megasonic energy to the backside of a flat article.
These and other objects are met by the present invention, which in one embodiment of the invention can be a system for processing flat articles comprising: a rotatable support for supporting a flat article; a first dispenser for applying liquid to a first surface of a flat article on the rotatable support; a second dispenser for applying liquid to a second surface of a flat article on the rotatable support; a first transducer assembly comprising a first transducer for generating acoustic energy and a first transmitter acoustically coupled to the first transducer, the first transducer assembly positioned so that when the first dispenser applies liquid to the first surface of a flat article on the rotatable support, a first meniscus of liquid is formed between a portion of the first transmitter and the first surface of the flat article; and a second transducer assembly comprising a second transducer for generating acoustic energy and a second transmitter acoustically coupled to the second transducer, the second transducer assembly positioned so that when the second dispenser applies liquid to the second surface of the flat article on the rotatable support, a second meniscus of liquid is formed between a portion of the second transmitter and the second surface of the flat article.
In another embodiment, the invention can be a system for cleaning flat articles comprising: a rotatable support for supporting a flat article; a first transducer assembly comprising a first transducer and a first transmitter acoustically coupled to the first transducer, the first transducer assembly positioned so that a first small gap exists between a portion of the first transmitter and a first surface of a flat article on the rotatable support, a first meniscus of liquid being formed between the portion of the first transmitter and the first surface of the flat article when liquid is applied to the first surface; and a second transducer assembly comprising a second transducer and a second transmitter acoustically coupled to the second transducer, the second transducer assembly positioned so that a second small gap exists between a portion of the second transmitter and a second surface of the flat article on the rotatable support, a second meniscus of liquid being formed between the portion of the second transmitter and the second surface when liquid is applied to the second surface.
In yet another embodiment, the invention can be a system for processing flat articles comprising: a rotatable support for supporting and rotating a flat article in a substantially horizontal orientation; a transducer assembly comprising a transducer for generating acoustic energy, a transmitter acoustically coupled to the first transducer and a dam surrounding at least a portion of a perimeter of the transmitter so as to form a liquid retaining channel between the transmitter and the dam; and the transducer assembly positioned so that apportion of the transmitter is adjacent a bottom surface of a flat article on the rotatable support so that when liquid is applied to the bottom surface of the flat article, a meniscus of liquid is formed between the portion of the transmitter and the bottom surface of the flat article.
In still another embodiment, the invention can be a transducer assembly for mounting beneath a bottom surface of a flat article comprising: a transducer for generating acoustic energy; a transmitter acoustically coupled to the first transducer; and a dam surrounding at least a portion of a perimeter of the transmitter so as to form a liquid retaining channel between the second transmitter and the dam.
In a further embodiment, the invention can be a method of manufacturing a transducer assembly comprising: providing a par-cylindrical transmitter plate; bonding one or more transducers to a convex inner surface of the transmitter plate; connecting a housing to the transmitter to create an assembly having a substantially enclosed cavity in which the one or more transducers are located; and encapsulating the assembly with an inert non-reactive plastic.
In a yet further embodiment, the invention can be a method of processing a flat article comprising: a) supporting a flat article in a substantially horizontal orientation within a gaseous atmosphere, the flat article having a bottom surface and a top surface; b) rotating the flat article while maintaining the substantially horizontal orientation; c) applying a film of liquid to the top surface of the flat article; d) applying a film of liquid on the bottom surface of the flat article; e) applying acoustic energy to the top surface of the flat article via a first transducer assembly comprising a first transducer and a first transmitter, a portion of the first transmitter in contact with the film of liquid on the top surface of the flat article; and f) applying acoustic energy to the bottom surface of the flat article via a second transducer assembly comprising a second transducer and a second transmitter, a portion of the second transmitter in contact with the film of liquid on the bottom surface of the flat article.
In a still further embodiment, the invention can be a system for processing flat articles comprising: a rotatable support for supporting a flat article in a substantially horizontal orientation; a transducer assembly comprising a transducer for generating acoustic energy and a transmitter acoustically coupled to the transducer, the transducer assembly positioned so that a portion of the transmitter is adjacent a top surface of a flat article on the support so that a first meniscus of liquid is formed between the portion of the transmitter and the top surface when liquid is applied to the top surface; and a reflective member positioned so that a portion of the reflective member is adjacent a bottom surface of a flat article on the support so that a second meniscus of liquid is formed between a portion of the reflective member and the bottom surface when liquid is applied to the bottom surface; and the reflective member positioned so that at least a fraction of the acoustic energy that is generated by the first transducer assembly that passes through the flat article is reflected back toward the bottom surface of the flat article.
In yet another embodiment, the invention can be a system for processing flat articles comprising: a rotatable support for supporting a flat article in a gaseous atmosphere; a transducer assembly comprising a transducer and a transmitter bonded to the transducer, the transducer assembly positioned so that a first small gap exists between a portion of the transmitter and a first surface of a flat article on the support so that when liquid is applied to the first surface of the flat article, a first meniscus of liquid is formed between the portion of the transmitter and the first surface of the flat article; a reflective member positioned so that a second small gap exists between a portion of the reflective member and a second surface of a flat article on the support so that when liquid is applied to the second surface of the flat article, a second meniscus of liquid is formed between the portion of the reflective member and the second surface of the flat article; and the reflective member positioned so that at least a fraction of the acoustic energy generated by the first transducer assembly that passes through the flat article is reflected back toward the second surface of the flat article by the reflector member.
In another embodiment, the invention can be a method of processing flat articles comprising: a) supporting a flat article in a substantially horizontal orientation within a gaseous atmosphere, the flat article having a bottom surface and a top surface; b) rotating the flat article while maintaining the substantially horizontal orientation; c) applying a film of liquid to the top surface of the flat article; d) applying a film of liquid on the bottom surface of the flat article; e) applying acoustic energy to the top surface of the flat article via a transducer assembly comprising a transducer and a transmitter, a portion of the transmitter in contact with the film of liquid on the top surface of the flat article; and f) reflecting the acoustic energy generated by the first transducer assembly that passes through the flat article back toward the bottom surface of the flat article via a reflective member that is in contact with the film of liquid on the bottom surface of the flat article.
These and various other advantages and features of novelty that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the general technology, its advantages, and the objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is schematic of an acoustic energy cleaning system according to one embodiment of the present invention.
FIG. 2 is a perspective view of one structural embodiment of the acoustic energy cleaning system of FIG. 1 .
FIG. 3 is a cross-sectional side view of the acoustic energy cleaning system of FIG. 2 .
FIG. 4 is a transducer assembly according to one embodiment of the present invention that is utilized in the acoustic energy cleaning system of FIG. 2 as the bottom-side transducer assembly.
FIG. 5 is a cross-sectional view of the transducer assembly of FIG. 4 along cross-section cut A-A of FIG. 4 .
FIG. 6 is an exploded view of the transducer assembly of FIG. 4 .
FIG. 7 is a schematic of the transducer assembly of FIG. 4 positioned adjacent a bottom surface of a semiconductor wafer according to an embodiment of the present invention wherein the transducer assembly of FIG. 4 is shown in cross-section.
FIG. 8 is a schematic representation of one arrangement of the topside transducer assembly relative to the bottom-side transducer assembly for the acoustic energy cleaning system of FIG. 2 .
FIG. 9 is a cross-sectional view of the schematic representation of the transducer assembly arrangement of FIG. 8 along the cross-section cut B-B of FIG. 8 .
FIG. 10 is a schematic representation of an alternative arrangement of the topside transducer assembly relative to the bottom-side transducer assembly for the acoustic energy cleaning system of FIG. 2 .
FIG. 11 is a cross-sectional view of the schematic representation of the alternative transducer assembly arrangement of FIG. 10 along the cross-section cut C-C of FIG. 8 .
FIG. 12 is schematic of an acoustic energy cleaning system utilizing a reflective member according to one embodiment of the present invention.
FIG. 13 is schematic of an acoustic energy cleaning system utilizing a reflective member according to an alternative embodiment of the present invention.
FIG. 14 shows five alternative embodiments of a transducer assembly that can also act as a reflective member for use in the acoustic energy cleaning system of FIG. 12 .
DESCRIPTION OF THE INVENTION
Referring first to FIG. 1 , a schematic of an acoustic energy cleaning system 1000 (hereinafter referred to as “cleaning system 1000 ”) is illustrated according to one embodiment of the present invention. For ease of discussion the inventive system and methods of the drawings will be discussed in relation to the cleaning of semiconductor wafers. However, the invention is not so limited and can be utilized for any desired wet processing of any flat article.
The cleaning system 1000 generally comprises a top transducer assembly 200 , bottom transducer assembly 300 and a rotatable support 10 for supporting a semiconductor wafer 50 in a substantially horizontal orientation. Preferably, the semiconductor wafer 50 is supported so its top surface 51 is the device side of the wafer 50 while the bottom surface 52 is the non-device side. Of course, the wafer can be supported so that its top surface 51 is the non-device side while the bottom surface 52 is the device side if desired.
The rotatable support 10 is designed to contact and engage only a perimeter of the substrate 50 in performing its support function. However, the exact details of the structure of the rotatable support 10 are not limiting of the present invention and a wide variety of other support structures can be used, such as chucks, support plates, etc. Additionally, while it is preferred that the support structure support and rotate the semiconductor wafer in a substantially horizontal orientation, in other embodiments of the invention, the system may be configured so that the semiconductor wafer is supported in other orientations, such as vertical or at an angle. In such embodiments, the remaining components of the cleaning system 1000 , including the transducer assemblies 200 , 300 , can be correspondingly repositioned in the system so as to be capable of performing the desired functions and/or the necessary relative positioning with respect to other components of the system as discussed below.
The rotary support 10 is operably coupled to a motor 11 to facilitate rotation of the wafer 50 within the horizontal plane of support. The motor 11 is preferably a variable speed motor that can rotate the support 10 at any desired rotational speed ω. The motor 11 is electrically and operably coupled to the controller 12 . The controller 12 controls the operation of the motor 11 , ensuring that the desired rotational speed ω and desired duration of rotation are achieved.
The cleaning system 1000 further comprises a top dispenser 13 and a bottom dispenser 14 . Both the top dispenser 13 and the bottom dispenser 14 are operably and fluidly coupled to a liquid supply subsystem 16 via liquid supply lines 17 , 18 . The liquid supply subsystem 16 is in turn fluidly connected to the liquid reservoir 15 . The liquid supply subsystem 16 controls the supply of liquid to both the top dispenser 13 and the bottom dispenser 14 .
The liquid supply subsystem 16 , which is schematically illustrated as a box for purposes of simplicity, comprises the desired arrangement of all of the necessary pumps, valves, ducts, connectors and sensors for controlling the flow and transmission of the liquid throughout the cleaning system 1000 . The direction of the liquid flow is represented by the arrows on the supply lines 17 , 18 . Those skilled in the art will recognize that the existence, placement and functioning of the various components of the liquid supply subsystem 16 will vary depending upon the needs of the cleaning system 1000 and the processes desired to be carried out thereon, and can be adjusted accordingly. The components of the liquid supply subsystem 16 are operably connected to and controlled by the controller 12 .
The liquid reservoir 15 holds the desired liquid to be supplied to the wafer 50 for the processing that is to be carried out. For cleaning system 1000 , the liquid reservoir 15 will hold a cleaning liquid, such as for example deionized water (“DIW”), standard clean 1 (“SC1”), standard clean 2 (“SC2”), ozonated deionized water (“DIO 3 ”), dilute or ultra-dilute chemicals, and/or combinations thereof. As used herein, the term “liquid” includes at least liquids, liquid-liquid mixtures and liquid-gas mixtures. It is also possible for certain other supercritical and/or dense fluids to qualify as liquids in certain situations.
Furthermore, it is possible to have multiple liquid reservoirs. For example, in some embodiments of the invention, the top dispenser 13 and the bottom dispenser 14 can be operably and fluidly coupled to different liquid reservoirs. This would allow the application of different liquids to the bottom surface 52 and the top surface 51 of the wafer 50 if desired.
The cleaning system 1000 further comprises a gas supply subsystem 19 that is operably and fluidly coupled to a gas source 20 . The gas supply subsystem 19 is operably and fluidly connected to the top transducer assembly 200 via the gas supply line 21 and to the bottom transducer assembly 300 via the gas supply line 22 . The gas supply subsystem 19 , which is schematically illustrated as a box for purposes of simplicity, comprises the desired arrangement of all of the necessary pumps, valves, ducts, connectors and sensors for controlling the flow and transmission of the gas throughout the cleaning system 1000 . The direction of the gas flow is represented by the arrows on the supply lines 21 , 22 . Those skilled in the art will recognize that the existence, placement and functioning of the various components of the gas supply subsystem 19 will vary depending upon the needs of the cleaning system 1000 and the processes desired to be carried out thereon, and can be adjusted accordingly. The components of the gas supply subsystem 19 are operably connected to and controlled by the controller 12 . Thus, the transmission of gas from the gas supply subsystem 19 is based upon signals received from the controller 12 .
As will be described in greater detail below, the gas is supplied to the top and bottom transducer assemblies 200 , 300 to provide cooling and/or purging to the transducers in the assemblies 200 , 300 that convert the electrical energy into the acoustic energy. The gas source 20 preferably holds an inert gas, such as nitrogen, helium, carbon dioxide, etc. However, the invention is not limited to the use of any specific gas. Furthermore, as with the liquids, it is possible to have multiple gas sources. For example, in some embodiments of the invention, the top transducer assembly 200 and the bottom transducer assembly 300 can be operably and fluidly coupled to different gas reservoirs. This would allow the application of different gases as desired.
The cleaning system 1000 further comprises a horizontal actuator 250 that is operably coupled to the top transducer assembly 200 and a vertical actuator 350 that is operably coupled to the bottom transducer assembly 300 . The actuators 250 , 350 are operably coupled to and controlled by the controller 12 . The actuators 250 , 350 can be pneumatic actuators, drive-assembly actuators, or any other style desired to effectuate the necessary movement.
The horizontal actuator 250 can horizontally translate the top transducer assembly 200 between a retracted position and a processing position. When in the retracted position, the top transducer assembly 200 is withdrawn sufficiently away from the rotatable support 10 so that the wafer 50 can be loaded and unloaded without obstruction onto and from the support 10 . When in the processing position, at least a portion of the top transducer assembly 200 is spaced from but sufficiently close to the top surface 51 of the wafer so that when liquid is supplied to the top surface 51 of the wafer 50 , a meniscus of liquid is formed between the top surface 51 or the wafer 50 and that portion of the top transducer assembly 200 . In FIG. 1 , the top transducer assembly 200 is in the processing position.
Similarly, the vertical actuator 350 can vertically translate the bottom transducer assembly 300 between a retracted position and a processing position. For the bottom transducer assembly 300 , the retracted position is a lowered position where the wafer 50 can be safely loaded onto the support 50 without contacting the bottom transducer assembly 300 and/or interfering with other processes that may be carried out on the bottom surface 52 of the wafer 50 that require additional space. When the bottom transducer assembly 300 is in its processing position, at least a portion of the bottom transducer assembly 300 is spaced from but sufficiently close to the bottom surface 52 of the wafer 50 so that when liquid is supplied to the bottom surface 52 of the wafer 50 , a meniscus of liquid is formed between the bottom surface 52 of the wafer 50 and that portion of the top transducer assembly 200 . In FIG. 1 , the bottom transducer assembly 300 is in the processing position.
While the actuators 250 , 350 are exemplified in system 1000 as being horizontal and vertical actuators respectively, in other embodiments of the invention, different styles of actuators can be used in the place of each. For example the actuator operably coupled to the bottom transducer assembly 300 can be a horizontal, vertical, angled translation actuator or a pivotable actuator. The same options exist for the actuator operably coupled to the top transducer assembly 200 .
A position sensor 329 is provided in the cleaning system 1000 so that the position of the bottom transducer assembly 300 can be monitored and controlled effectively. The position sensor 329 measures the distance between the bottom transducer assembly 300 and the bottom surface 52 of the wafer 50 so that the proper distance between the two can be achieved to effectuate the proper processing gap for formation of the liquid meniscus. The position sensor 329 is operably and communicably coupled to the controller 12 . More specifically, the position sensor 329 generates a signal indicative of the measured distance and transmits this signal to the controller 12 for processing. While the sensor 329 is illustrated as being connected to the bottom transducer assembly 300 , it can be mounted almost anywhere in the cleaning system 1000 so long as it can perform its position indicating function.
The cleaning system 1000 also comprises an electrical energy signal source 23 that is operably coupled to the top transducer assembly 200 and the bottom transducer assembly 300 . The electrical energy signal source 23 creates the electrical signal that is transmitted to the transducers (discussed later) in the top transducer assembly 200 and the bottom transducer assembly 300 for conversion into corresponding acoustic energy. The desired electrical signals can be sent to the top and bottom transducer assemblies 200 , 300 concurrently, consecutively and/or in an alternating fashion, depending on the process needs. The electrical energy signal source 23 is operably coupled to and controlled by the controller 12 . As a result, the controller 12 will dictate the frequency, power level, and duration of the acoustic energy generated by the top transducer assembly 200 and the bottom transducer assembly 300 . Preferably, the electrical energy signal source 23 is controlled so that the acoustic energy generated by the top transducer assembly 200 and the bottom transducer assembly 300 has a frequency in the megasonic range.
Depending on system requirements, it may not be desirable to use a single electrical energy signal source to control both the top transducer assembly 200 and the bottom transducer assembly 300 . Thus, in other embodiments of the invention, multiple electrical energy signal sources may be used, one for each transducer assembly.
The controller 12 may be a processor, which can be a suitable microprocessor based programmable logic controller, personal computer, or the like for process control. The controller 12 preferably includes various input/output ports used to provide connections to the various components of the cleaning system 1000 that need to be controlled and/or communicated with. The electrical and/or communication connections are indicated in dotted line in FIG. 1 . The controller 12 also preferably comprises sufficient memory to store process recipes and other data, such as thresholds inputted by an operator, processing times, rotational speeds, processing conditions, processing temperatures, flow rates, desired concentrations, sequence operations, and the like. The controller 12 can communicate with the various components of the cleaning system 1000 to automatically adjust process conditions, such as flow rates, rotational speed, movement of the components of the cleaning system 1000 , etc. as necessary. The type of system controller used for any given system will depend on the exact needs of the system in which it is incorporated.
The top dispenser 13 is positioned and oriented so that when a liquid is flowed therethough, the liquid is applied to the top surface 51 of the substrate 50 . When the substrate 50 is rotating, this liquid forms a layer or film of the liquid across the entirety of the top surface 51 of the substrate 50 . Similarly, the bottom dispenser 14 is positioned and oriented so that when a liquid is flowed therethough, the liquid is applied to the bottom surface 52 of the substrate 50 . When the substrate 50 is rotating, this liquid forms a layer or film of the liquid across the entirety of the bottom surface 52 of the substrate 50 .
The top transducer assembly 200 is positioned so that a small gap exists between a portion of the top transducer assembly 200 and the top surface of the water 50 . This gap is sufficiently small so that when the liquid is applied to the top surface 51 of the wafer 50 , a meniscus of liquid is formed between the top surface 51 of the wafer 50 and the portion of the top transducer assembly 200 . Similarly, the bottom transducer assembly 300 is positioned so that a small gap exists between a portion of the bottom transducer assembly 300 and the bottom surface 52 of the wafer 50 . This gap is sufficiently small so that when the liquid is applied to the bottom surface 52 of the wafer 50 , a meniscus of liquid is formed between the bottom surface 52 of the wafer 50 and the portion of the bottom transducer assembly 300 . The meniscus is not limited to any specific shape.
As will be noted, the top and bottom transducer assemblies 200 , 300 are generically illustrated as boxes. This is done because, in its broadest sense, the invention is not limited to any particular structure, shape and/or assembly arrangement for the transducer assemblies 200 , 300 . For example, any of the transducer assemblies disclosed in U.S. Pat. No. 6,039,059 (“Bran”), issued Mar. 21, 2000, U.S. Pat. No. 7,145,286 (“Beck et al.”), issued Dec. 5, 2006, U.S. Pat. No. 6,539,952 (“Itzkowitz”), issued Apr. 1, 2003, and United States Patent Application Publication 2006/0278253 (“Verhaverbeke et al.”), published Dec. 14, 2006, can be used as the top and/or bottom transducer assembly 200 , 300 . Of course, other styles of transducer assemblies can be used, such as those having an elongated transmitter rod supported at an angle to the surface of the wafer.
Referring now to FIG. 2 , a preferred structural embodiment of the cleaning system 1000 is illustrated. Like numbers are used in FIGS. 2-14 to indicate the corresponding structural manifestation of the schematically illustrated components of FIG. 1 .
In the cleaning system 1000 of FIG. 2 , the top transducer assembly 200 comprises an elongate rod-like transmitter 201 that is acoustically coupled to a transducer 203 (visible in FIG. 3 ) that is located within housing 202 . Many of the details of this style of elongate rod-like transmitter 201 are disclosed in U.S. Pat. No. 6,684,891 (“Bran”), issued Feb. 3, 2004 and United States 6,892,738 (“Bran et al.”), issued May 17, 2005, the entireties of which are hereby incorporated by reference. The top transducer assembly 200 is operably coupled to drive assembly/actuator 250 that can move the rod-like transmitter 201 between a retracted position and a processing position. When the rod-like transmitter 201 is in the retracted position, the rod-like transmitter 201 is located outside of the process bowl 204 so that a wafer 50 can be placed on the rotatable support 10 without obstruction. More specifically, the drive assembly 250 withdraws the rod-like transmitter 201 through an opening in a side wall of the process bowl 204 . When in the processing position, the rod-like transmitter 201 is position directly above the top surface 51 of a wafer 50 on the rotatable support 10 . The rod-like transmitter 201 is in the processing position in FIG. 2 .
The bottom transducer assembly 300 is located at the bottom of the process bowl 204 , at a position below the rotatable support 10 . The bottom transducer assembly 300 comprises a dam 301 , a transmitter 302 and a base 303 . The bottom dispenser 14 is in the form of a plurality of sprayers located within the base 303 itself, rather than a single nozzle dispenser.
Referring now to FIG. 3 , it can be seen that the rotatable support 10 is located within the process bowl 204 . The rotatable support 10 supports a wafer 50 in a substantially horizontal orientation in the gaseous atmosphere of the process bowl 204 , which surrounds the periphery of the wafer 50 . The rotatable support 10 is operably connected to the motor assembly 11 . The motor assembly rotates the wafer about the central axis. The motor assembly 11 can be a direct drive motor or a bearing with offset belt/pulley drive.
The rotatable support 10 supports the wafer 50 at an elevation and position between the elongate rod-like transmitter 201 of the top transducer assembly 200 and the transmitter 302 of the bottom transducer assembly 300 . When the wafer 50 is so supported, the transmitter 201 of the top transducer assembly 200 extends in a substantially parallel orientation over the top surface 51 of the wafer 50 in a close spaced relation. Similarly, the transmitter 302 of the bottom transducer assembly 300 extends in a substantially parallel orientation below the bottom surface 52 of the wafer 50 in a close spaced relation. These close spaced relations are such that when liquid is applied to the top and bottom surfaces 51 , 52 from the dispensers 13 , 14 respectively, meniscuses of liquid are respectively formed between a portion of the transmitter 201 and the top surface 51 of the wafer 50 and between a portion of the transmitter 302 and the bottom surface 52 of the wafer 50 .
The bottom transducer assembly 300 is operably connected to the lifter/actuator 350 . The lifter/actuator 350 can be a pneumatic lifter and can also comprise brackets. The lifter 350 can move the bottom transducer 300 assembly between a processing position and a retracted position. In FIG. 3 , the bottom transducer assembly 300 is in the processing position, which is a raised position in which the transmitter 302 is in the close spaced relation discussed above. When in the retracted position, the bottom transducer assembly 300 is in a lowered position to ensure that the wafer 50 is not damaged during insertion onto the rotatable support 10 .
The transducers 203 , 305 of the top and bottom transducer assemblies 200 , 300 are acoustically coupled to the transmitter 201 , 302 respectively. This can be done through a direct bonding or an indirect bonding that utilizes intermediary transmission layers. The transducers 230 , 305 are operably coupled a source of an electrical energy signal. The transducers 203 , 305 can be a piezoelectric ceramic or crystal, as is well known in the art.
Referring now to FIGS. 4-7 concurrently, the bottom transducer assembly 300 is illustrated removed from the cleaning system 1000 so that its details are visible. It should be understood that the bottom transducer assembly 300 , in of itself, is a novel device that can constitute an embodiment of the invention.
The bottom transducer assembly 300 comprises a base structure 303 , a housing 304 , a transmitter 302 , a transducer 305 and a dam 301 . The base structure 303 is preferably made of PTFE or other non-contaminating material that is suitable rigid. The base structure 303 has a top convex surface that is a generally par-spherical shaped. The base structure 303 connects to and supports the remaining components of the bottom transducer assembly 300 . The base structure 303 also comprises a plurality of liquid dispensing holes/nozzles 14 that are adapted to supply a film of liquid to the bottom surface of a wafer during processing. The holes/nozzles 14 are located on both sides of the transmitter 302 in two separate rows that extend along the length of the transmitter 302 .
The transmitter 302 is a generally par-cylindrical shaped plate having a convex outer surface 306 and a concave inner surface 307 . The transmitter 302 , however, can take on a wide variety of other shapes and sizes. The transmitter 302 can be constructed of any material that transmits acoustic energy generated by the transducer 305 , including without limitation quartz, sapphire, boron nitride, plastic, and metals. One suitable metal is aluminum.
The outer convex surface of the transmitter 302 terminates in an apex 313 . Because the transmitter 302 is a par-cylindrical shape, this apex 313 ( FIG. 7 ) forms an elongate edge along 314 along the length of the transmitter. Of course, as used herein, the term elongate edge is not limited to the apex of an elongated curved surface but also includes, among other things, the meeting of two surfaces. Furthermore, in other embodiments, the transmitter 302 may be spherical in nature, thus, the apex could be a point.
The transducer 305 is a curved plate having a convex upper surface 308 and concave lower surface 309 . The construction of transducers that convert electrical energy into acoustical energy is very well known in the art. The convex surface 308 of the transducer has a curvature that generally corresponds to the curvature of the inner concave surface 307 . The transducer 305 is acoustically coupled to the transmitter 302 so that acoustic energy generated by the transducer 305 propagates through the transmitter 302 and to the wafer 50 . More specifically, the convex upper surface 308 of the transducer 305 is bonded to the concave inner surface 307 of the transmitter. This bonding can be a direct bonding between the surfaces 307 , 308 or can be an indirect bonding utilizing intermediary transmission layers. In other embodiments, the transducers may be flat plates or other shapes. Moreover, while the bottom transducer assembly 300 is illustrated as utilizing a single transducer 305 , a plurality of transducers can be used if desired to create the acoustic energy. Preferably, the transducer 305 is adapted to generate megasonic energy.
The transmitter 302 is connected to the housing 304 so as to form a substantially enclosed space 310 in which the transducer 305 is located. Any suitable means can be used to connect the housing 304 to the transmitter 302 , including adhesion, heat welding, fasteners or a tight-fit assembly. A plurality of openings 311 are provided in the bottom portion of the housing 304 . The openings 311 are provided to allow a gas to be introduced into and/or out of the space 310 so that the transducer 305 can be cooled and/or purged. The openings 311 are operably connected to the gas source 20 as described in FIG. 1 . The housing 304 also comprises an opening 312 for allowing the electrical connections (i.e., wires) that are necessary to power the transducer 305 to pass into the space 310 . This opening 312 can also be used to allow the gas to escape the space 310 . The housing 304 can take on a wide variety of shapes and structures and is not limiting of the present invention. In some embodiments, the housing may be merely a plate or other simple structure.
In order to further protect the wafer 50 from possible contamination, once the transmitter 302 is connected to the housing 304 , the combined assembly may be fully encapsulated with an inert non-contaminating plastic, such as TEFLON® or the like. This also serves to protect the transmitter 302 from chemical attack. When the transmitter 302 is so encapsulated and/or coated, the encapsulation and/or coating is considered part of the transmitter 302 .
Referring exclusively to FIGS. 4 and 7 , the bottom transmitter assembly 300 further comprises a dam 301 that surrounds the periphery/perimeter of the transmitter 302 . The dam 301 forms an upwardly protruding ridge 316 having an angled inner surface 317 , an outer surface 318 and a top edge 319 . The dam 301 forms a liquid retaining channel 315 on both sides of the transmitter 302 . More specifically, the inner surface 317 of the ridge 316 forms a channel/groove with the transmitter 302 . Of course, in some embodiments, the dam 301 could be used to form the channel 315 in other ways and/or through cooperation with other structures.
The dam 301 is a rectangular frame-like structure but can take on other shapes. The dam 301 also does not have to surround the entire periphery of the transmitter 302 but can surround only a small portion if desired. The dam 301 can be constructed of HDPE, PVDF, NPP or any other material. Preferably, the material chosen is chemically resistant and mechanically stable.
The dam 301 is implemented into the bottom transducer assembly 300 to increase the size of the meniscus that couples the transmitter 302 to the bottom surface 52 of the wafer 50 . This facilitates an increased amount of acoustic energy being transmitted to the wafer 50 for improved cleaning. As illustrated in FIG. 7 , without the dam 301 , the meniscus couples only area A of the transmitter 302 to the wafer 50 . However, with the dam 301 , the meniscus coupling area is increased to area B.
Referring now to FIGS. 8-12 , the possibilities for the relative arrangement of the bottom transducer assembly 300 and the top transducer assembly 200 with respect to one another in the cleaning system 1000 will be discussed.
Referring first to FIGS. 8 and 9 , an arrangement is illustrated wherein the transmitter 201 of the top transducer assembly 200 is aligned with and opposes the transmitter 302 of the bottom transducer assembly 300 . A wafer 50 is illustrated as being in between the assemblies 200 , 300 . As liquid 70 is applied to the top surface 51 of the wafer 50 , a meniscus of liquid 72 is formed between a bottom portion 207 of the transmitter 201 of the top transducer assembly 200 and the top surface 51 of the wafer 50 . Similarly, as liquid 70 is applied to the bottom surface 52 of the wafer 50 , a meniscus of liquid 71 is formed between the transmitter 302 of the bottom transducer assembly 300 and the bottom surface 52 of the wafer 50 . As can be seen, the coupled portions of the top transmitter 201 and the bottom transmitter 302 oppose one another in an aligned manner. As a result, it is possible that the acoustic energy is generated by the top and bottom transducer assemblies 200 , 300 and transmitted to the wafer via the meniscuses 71 , 72 can interfere with and/or cancel one another out.
Thus, it may be desirable, in certain instances, to operate the top and bottom transducer assemblies 200 , 300 in an alternating and/or consecutive manner during a wafer cleaning cycle. In other embodiments, one may want to activate the operate the top and bottom transducer assemblies 200 , 300 concurrently if interference is not an issue.
Referring now to FIGS. 10 and 11 concurrently, an alternative relative arrangement of the bottom transducer assembly 300 and the top transducer assembly 200 with respect to one another in the cleaning system 1000 is illustrated. In this embodiment, the transmitters 201 , 302 of the top and bottom transducer assemblies 200 , 300 are not aligned and do not oppose one another. Thus, interference should not be a problem during simultaneous generation and transmission of acoustic energy to the wafer. While the horizontal angle of separation between the top and bottom transmitters 201 , 302 is 90 degrees in the illustration, any other angle can be used, including without limitation 180 degrees, 45 degrees, etc.
It was discovered during the creation of the above described system that improved cleaning results were achieved by just having the bottom transducer assembly 300 present in the cleaning system 1000 and arranged as shown in FIG. 8 , even when not activated (i.e., passive). It was discovered that the transmitter 302 of the bottom transducer assembly 300 was reflecting at least a fraction of the acoustic energy that was generated by the top transducer assembly 200 back toward the bottom surface 51 of the wafer 50 . Therefore, in another aspect, the invention is a novel system that utilizes a passive reflective member coupled to the opposite surface of the wafer than the active transducer assembly.
Referring now to FIG. 12 , a cleaning system 2000 that utilizes a passive backside reflective member 400 is schematically illustrated. The cleaning system 2000 is identical to that of cleaning system 1000 except that the bottom transducer assembly is replaced by a reflective member 400 . In fact, in some embodiments, the reflective member 400 could be a transducer assembly, such as the one described above, that is not activated. However, the reflective member 400 is not so limited and can take on a much broader variety of structures. Thus, a detailed explanation of the cleaning system 2000 will be omitted with the understanding that the description of cleaning system 1000 above will suffice for like parts. Like numbers are used to reference like parts.
The reflective member 400 could be a mere plate or other structure. Preferably, the reflective member 400 is made of a material that has an acoustical impedance value (Za) that is much greater than that of water. In one embodiment, it is preferred that the acoustical impedance value be at least greater than 5.0 Mrayl, such as quartz. It may also be preferred that the reflective member 400 be spaced from the surface of the wafer 50 to which it is fluidly coupled by a distance that is a one-fourth interval of the wavelength of the acoustic energy being generated by the top transducer assembly 200 . In some alternative embodiments the reflective member 400 may be used to absorb the acoustical energy instead of reflecting it.
The reflective member 400 may be made of a variety of materials the selection of which is dependent upon whether or not it is intended to be used as a reflector or an absorber of the acoustical energy. In the embodiment shown in FIGS. 12 and 13 the reflective member 400 is designed to reflect acoustical energy. The reflective member 400 may be made of materials such as quartz, sapphire, silicone carbine, or boron nitride. Should acoustical energy wish to be absorbed the member 400 can be constructed out of PolyVinylidine DiFluoride (PVDF) or polytetrafluoroethylene (PTFE) (Also commonly sold under the trade name TEFLON®). The materials chosen are based upon their respective acoustical impedance (Za). Table 1 (below) provides a list of materials and the Zas associated with them.
TABLE 1
Material
Za
Alumina
40.6
Aluminum rolled
17.33
ARALDITE ® 502/956 20 phe
3.52
ARALDITE ® 502/956 50 phe
4.14
ARALDITE ® 502/956 90 phe
12.81
Beryllium
24.10
Bismuth
21.5
Brass 70 cu 30 Zn
40.6
Brick
7.4
Cadmium
24
Carbon vitreous, sigradur K
7.38
Concrete
8.0
Copper rolled
44.6
Duraluminum 17S
17.63
EPOTEK ® 301
2.85
Fused silica
12.55
Germanium
29.6
Glass pyrex
13.1
Glass quartz
12.1
Glass silica
13
Glucose
5.0
Gold
63.8
Granite
26.8
Indium
18.7
Iron
46.4
Iron cast
33.2
Lead
24.6
Lithium
33.0
Magnesium
10.0
Marble
10.5
Molybdenum
63.1
Nickel
49.5
Paraffin
1.76
Polyester casting resin
2.86
Porcelain
13.5
PVDF
4.2
Quartz × cut
15.3
Rubidium
1.93
Salt crystalline × direction
10.37
Sapphire, aluminum oxide
44.3
SCOTCH ® tape 2.5 mils thick
2.08
Silicon very anisotropic approx
19.7
Silicon carbide
91.8
Silicon nitride
36
Silver
38.0
Steel mild
46.0
Steel stainless
45.7
STYCAST ®
2.64
Tantalum
54.8
TEFLON ®
2.97
Tin
24.2
Titanium
27.3
Tracon
4.82
Tungsten
101.0
Uranium
63.0
Vanadium
36.2
Wood cork
0.12
Wood pine
1.57
Zinc
29.6
Zinc oxide
36.4
Zirconium
30.1
The acoustical impedance Za of a material is defined as the product of the density of that material times the velocity of sound in that material. The units for Za are Mrayl or (kg/m 2 s×10 6 ). Acoustical energy transmission is affected by the differences in the Za of the materials through which the acoustical energy must pass. More specifically, large differences in the Za between adjacent materials through which the acoustical energy must pass results in increased impedance of the acoustical energy.
Due to the acoustical impedance values of the various surfaces of the reflective member 400 , the acoustical energy is effectively transmitted back towards the wafer 50 . This effectively cleans the bottom surface 52 without having to provide additional transducers. As discussed above, the reflective member 400 is made of a material with a Za that is greater than the fluid through which the acoustical energy is transmitted. Preferably the Za should be greater than 5 Mrayl, and more preferably greater than 15 Mrayl, such as quartz. The reflective member 400 may be hollow in order to create an additional transitional space that causes the acoustical energy to be reflected again as it passes through the reflective member 400 . During the cleaning process there may be continuous reflection between the wafer 50 and the reflective member 400 and it may continue until the acoustical energy diminishes in the system.
FIG. 13 shows an alternative embodiment of the passive cleaning system 2000 wherein the reflective member 400 is positioned adjacent the top surface 51 of the wafer 50 rather than the bottom surface 52 . A bottom transducer assembly 300 is used instead of a top transducer assembly 200 . This embodiment operates in much the same fashion as the embodiment shown in FIG. 12 except with the reflective member 400 and the transducer assembly 300 being reversed.
Referring now to FIG. 14 , it has been discovered that it may be preferable to utilize hollow tubular structures as the reflective member 400 . Examples of hollow tubular members 500 A-E are exemplified. The hollow tubular member 500 A-E can be fitted with transducers 305 A-E if desired. The tubular member can be made of quartz, plastic, metals, or other materials. These tubular members 500 A-E will have different effects on the transmission of the acoustical energy. The tubular members 500 A-E modifiers may be cylindrically shaped, triangular shaped, and trapezoidal shaped. It should be understood that other shapes may be used and are not limited to those shown, the selection of the shape may vary depending upon the desired results.
The rounded or angled tubular members 500 A-E also may be used to direct the reflected acoustical energy at lower angles than that which it is at when it is directed at the wafer 50 .
Typically these angles are less than 40°. By reflecting the acoustical energy at a shallow angle, a majority of the acoustical energy will be focused on the bottom surface 52 of the wafer 50 from the top transducer assembly 200 .
It has also been discovered that the placement of the reflective member 400 from the wafer 50 also plays a role in effectively removing particles. The distance, or gaps, between the reflective member 400 , the transducer assembly 200 or 300 and the wafer 50 is determined so as to accommodate the frequency of the wavelength. The equation for the wavelength is:
λ = v ω f ( 1 )
where λ=wavelength of an acoustical wave, v w is the speed of propagation of the wave, and f=frequency of the wave in 1/s=Hz. Odd ¼ wavelength (e.g. ¼, ¾, 1¼) gaps tend to act as matching layers that permit energy to pass into the next media, and even ¼ wavelengths (e.g. 0.5, 1.0, 1.5, 2.0) gaps between the wafer 50 and the reflective member 400 tend to enhance the reflective property at the media interface. For example, in FIG. 12 , the gap between the top transducer assembly 200 and the wafer 50 may be set for 1 and ¼ wavelengths in order to enhance the transmission of the acoustical energy through the cleaning liquid and the wafer 50 . On the opposite side, the gap between the reflective member 400 and the wafer 50 may be set at 1.0 wavelength (i.e. even) in order to enhance the reflection property so as to keep the transmission of acoustical energy directed towards the bottom surface 52 of the wafer 50 . In the example provided, when using water and a frequency of 835 kHz, the 1 and ¼ wavelength, the gap between the transducer assembly 200 and the wafer 50 is approximately 0.087″. The gap between the reflective member 400 and the wafer 50 , the 1.0 wavelength, is approximately 0.070″.
It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A system, apparatus and method for processing flat articles with acoustical energy. The inventive system, apparatus and method can remove particles from both sides of a wafer more efficiently and effectively. In one aspect, the invention is a system and/or method for processing flat articles wherein a liquid is applied to both major surfaces of the flat article. A first transducer assembly is positioned adjacent to a first of the major surfaces of the flat article and a second member is positioned adjacent to a second of the major surfaces. The first transducer assembly generates and transmits acoustical energy to the first major surface of the flat article while the second member either: (1) reflects the acoustical energy generated by the first transducer assembly back to the second major surface of the flat article; and/or (2) generates and transmits acoustical energy to the second major surface of the flat article.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improvement on a motor and/or a generator, and more particularly to the reduction of loss in current in the coils by utilizing a superconducting material in the coils of a motor or a generator.
2. Related Background Art
Motors are employed in rotating parts of VTR's, still video equipments etc. Requirements for the motors are a uniform torque, compactization, improvement in maximum torque, improvement in torque-to-revolution characteristics etc.
For compactization of the motor, the Japanese Laid-Open Patents 57-186940, 57-186941 and 57-186942 disclose a motor coil of printed structure, obtained by etching a copper plate on an insulating substrate, instead of conventional coil composed of a conductor wound on an iron core.
The coil disclosed in the above-mentioned patent references is made very thin by etching the conductor constituting the coil (hereinafter called printed coil), and can provide a flat and compact motor. FIG. 1 shows an example of use of a motor with printed coils in a video cassette recorder.
In FIG. 1, coils 1, 1' formed on a substrate are fixed, through a fixed yoke 5', to a lower drum 6. When said coils, with a current therein, cross the magnetic flux from a magnet 4, a torque is obtained in a rotor equipped with said magnet. A yoke 5 of a magnetic material is provided for preventing the spreading of said magnetic flux and improving the efficiency. Said yoke is connected to an upper drum 3 through a rotary shaft 2 and functions as a rotor. The upper drum is equipped with magnetic heads 7, 7' for magnetoelectrical conversion, and a rotary transformer 8 is mounted on the upper and lower drums for transmitting the signals to or from said magnetic heads. In FIG. 1, the coil motor corresponds to a portion sandwiched between the yokes 5, 5'.
FIG. 3 shows the coil pattern of said motor. The pattern 10 is formed by etching a copper layer of about 100 microns in thickness adhered to a coil substrate 9. The coils thus prepared are superposed in plural layers, such as three or six layers, to obtain a coil unit. The width of coil wiring is represented by W, and the width of groove for forming the coil pattern is represented by ΔW. The value of ΔW should be made as small as possible in order to improve the motor efficiency by reducing the resistance of coils. In an example ΔW=80 μm while W=ca. 400 μm, so that ΔW/W≦0.2. The groove width ΔW is principally determined by the thickness of copper, while W is determined by the number of turns in a spiral coil and the magnitude of inverse electromotive force.
In recent years there has been remarkable progress in the superconducting transition temperature Tc of superconducting ceramics. Already in the ceramics of Y-Sc-Ba-Sr-Cu-M-O (M=metal) family, the superconducting state has been observed from an ultra low temperature state to a high temperature state. This material is applicable to a coil motor, and can achieve a maximum efficiency, utilizing the zero resistance. In fact the zero resistance in the current path drastically improves the resolution-torque characteristic, and provides a several times higher ability for maintaining a constant revolution.
However, the formation of coils with a superconducting material has resulted in various drawbacks which will be explained in the following in relation to FIG. 2, which is a circumferential cross-sectional view, in the vicinity of the center, of the coils shown in FIG. 3 and shows the shape parallel to the direction of rotation. There are shown a permanent magnet 4 magnetized in a direction indicated by an arrow; magnetic yokes 5, 5'; a coil substrate 9; and coil wires 10 perpendicular to the direction of current 11 indicates magnetic flux, while 12 is a symbol indicating the direction of current, and 13 is the groove of a width ΔW.
Firstly, though it has been tried to reduce the width ΔW of the groove, the magnetic flux is concentrated in the grooves 13 because of the perfect diamagnetism of the superconducting material, thus causing increase in the magnetic resistance of the magnet 4 and the yoke 5', decrease of magnetic flux, larger spreading thereof, and eventually decrease of the torque.
Secondly, the increase of the dimension of the current path increases the inductance, thus increasing the inverse electromotive force and giving a large load to the driving circuits
The above-mentioned drawbacks are not limited to a motor but are also encountered in a generator.
FIG. 4 shows a cylindrical coreless motor, of which coils are formed by winding a conductor in cylindrical shape as disclosed in the U.S. Pat. No. 4,327,304.
FIG. 5 is a partial cross-sectional view of the motor shown in FIG. 4. The magnetic flux emerging from the N-pole of a permanent magnet 12 crosses conductors 14, then passes through an external core 16 of a soft magnetic material, again crosses the conductors 14 and reaches the S-pole of the permanent magnet 12. A rotor 22 rotates in a direction 20 by appropriately regulating the direction 18 of the current in the conductors according to the direction of the magnetic flux.
A superconducting material, if employed in the coils of the cylindrical motor as shown in FIG. 4, leads to following drawbacks.
Because of the Meissner effect of the conductors made of the superconducting material, the magnetic flux 26 is unable to penetrate the conductors and assumes a distribution as shown in FIG. 6. As the magnetic flux has to go around the conductors 24, the length of the magnetic flux becomes longer, and the paths of the magnetic flux become narrower. Consequently the cross section of the magnetic flux is reduced to increase the reluctance, thus decreasing the amount of magnetic flux. In this manner the improvement in the efficiency obtained by the use of superconducting material, capable of reducing the resistance of conductors to zero, is eventually cancelled.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide a coil structure for use in an electric equipment involving electromagnetic effect such as motor or generator, capable of preventing the influence of perfect diamagnetism caused by Meissner effect which is encountered when a superconducting material is employed in the coil.
In order to achieve said first object, there are proposed coil structures of planar type and cylindrical type.
A second object of the present invention is to provide a coil made of a superconducting material, formed as a spiral shape and having a suitable relationship between the width of conductor and the gap of conductors for enabling the magnetic flux from the magnetic flux generating means to pass through the spacing between the conductors thereby effectively utilizing the characteristics of the superconducting material, and a motor utilizing such coils.
A third object of the present invention is to provide a cylindrical coil for a cylindrical motor, capable of preventing the influence caused by Meissner effect in case a superconducting material is used for said coil, and a motor utilizing said coils.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 5 illustrate prior arts wherein;
FIG. 1 is a schematic view of a flat motor;
FIG. 2 is a schematic view of paths of magnetic flux;
FIG. 3 is a schematic view of conventional spiral coils;
FIG. 4 is a cross-sectional view of a cylindrical motor;
FIG. 5 is a schematic view of the working principle of a cylindrical motor;
FIG. 6 is a schematic view of paths of magnetic flux in case coils 24 are made of a superconducting material;
FIGS. 7 to 10 illustrate coils of the present invention applied to a flat motor; wherein
FIG. 7 is a schematic view of spiral coils formed on a substrate 28;
FIG. 8A is a schematic view of a motor with fixed coils;
FIG. 8B is a schematic view of a motor with fixed coils;
FIGS. 9A and 9B are schematic view of a motor with rotary coils;
FIG. 10 is a view of an improvement over the spiral coils shown in FIG. 7;
FIGS. 11 to 17 illustrate coils of the present invention applied to a cylindrical motor, wherein
FIG. 11 is a schematic view of a cylindrical motor structure utilizing thin film coils of a superconducting material;
FIGS. 12A and 12B are schematic views of coil structure;
FIG. 13 is a schematic view of a coil of another structure;
FIGS. 14, 15 and 16 are views of variations of the coil structure; and
FIG. 17 is a view of a cylindrical motor of another structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
At first reference is made to FIGS. 7 to 10 for explaining the structure of coils and motor suitable for a flat motor.
FIG. 7 shows a first embodiment of the coils, best representing the features of the present invention, wherein illustrated are a coil substrate 28 and coil patterns 30 of a superconducting material.
The width W of the coil conductor is selected smaller than the gap ΔW of the groove
The coils are prepared in the following manner. At first a silicon wafer of 0.2 mm in thickness is subjected to an insulating treatment by oxidation, as the coil substrate. Then a ceramic thin film of Y-Ba-Cu-O or Y-Sc-Ba-Sr-Cu-Mn-O family is deposited in a thickness of 20 to 50 μm by CVD (chemical vapor deposition), sputtering or electron beam deposition. Subsequently photoresist is coated thereon, subjected to exposure of coil patterns with an exposure apparatus, and is left only in the necessary portions. Then the patterns of superconducting material are left by dry etching such as ion milling, and the coils are completed by removing the remaining photoresist. The coil pattern formation need not necessarily be achieved by dry etching, but can be more efficiently conducted by wet etching with nitric-phosphoric mixed acid if the precision of patterns has enough margin. In this manner there can be obtained spiral coil patterns as shown in FIG. 7.
The dimensions of the coil shown in FIG. 7 are determined according to design specifications of the electric apparatus in which the coils of the present invention are to be employed. As an example, in case of a motor, the width W of the conductors constituting current paths in the radial direction of the coils is selected as 100 μm, and the width ΔW of the gaps between said conductors is selected as 400 μm. In case the coils of the structure shown in FIG. 7 are employed in a flat motor in which the coils are opposed to the permanent magnet in planar manner, said coils may be designed rotative or fixed. FIGS. 8A and 8B show an example of non-rotating coils. There are shown a motor case 32; a rotary shaft 34 rotatably supported by the motor case 32 through a bearing 36; a rotor magnet 38 which is a permanent magnet fixed on the rotary shaft 34; a yoke member 40 fixed to a motor bracket 42 by means of a support member 40A; and coils 44 fixed on the yoke 40.
The coils 44 are composed of a coil substrate 44B (FIG. 8B) on which spiral coil patterns 44B 1 , 44B 2 , . . . are formed. The internal ends 44b 1-1 , 44b 2-1 , . . . of the coil patterns on the coil substrate 44A and the external ends 44b 2-1 , 44b 2-2 , . . . are connected according to the known connecting methods of the motor coils.
The spiral coil patterns 44B 1 , 44B 2 , . . . of the superconducting ceramic material are formed on the coil substrate 44A shown in FIG. 8A, according to a method similar to that explained before in relation to FIG. 7.
The coil patterns 44B 1 , 44B 2 , . . . are formed in a desired number, concentrically with the rotary shaft 34, according to the design specification of the motor.
The motor shown in FIGS. 8A and 8B have non-rotating coils 44, so that the current supply to each coil pattern is controlled by detecting the position of poles of the permanent magnet 38 with a sensor.
FIGS. 9A and 9B illustrate a motor in which the coils of superconducting material rotate together with the rotary shaft.
There are shown a motor case 46; a rotary shaft 48 rotatably supported by a bearing 50; a support-substrate 52 fixed to the rotary shaft 48; coils 54 formed on the support substrate 52; a commutator support member 56 fixed on the rotary shaft 48; a commutator 58; and connection members 60 for connecting the commutator with said coils.
There are further shown a motor bracket 62; a stator yoke 64; a permanent magnet 66 fixed to the stator yoke and positioned opposite said coils 54; and brushes 67 mounted on the bracket 62 and maintained in contact with the commutator 58. FIG. 9B shows the substrate provided with spiral coil patterns.
The coil patterns of the motor with rotating coils shown in FIG. 9A are formed in spiral shape as shown in FIG. 7, and, for achieving current supply to said coils in Y-connection, the internal ends of the coil patterns and the external ends thereof are mutually connected according to the known connecting method.
The spiral coil patterns 66A 1 , 66A 2 , . . . are formed with a superconducting ceramic material on the coil substrate 66A shown in FIG. 9B, in a similar manner as explained before in relation to FIG. 7. The number of the coil patterns 66A 1 , . . . is determined according to the motor design. The coils are concentrically positioned on a plane extending in the radial direction of the rotary shaft and paths for magnetic flux are formed between adjacent concentrically positioned turns of the coils.
An end 66a 1 of the coil pattern 66A 1 and an end 66a 2 of the coil pattern 66A 2 are connected to the commutator, and a connecting circuit pattern not shown is connected to an unrepresented common wiring. The superconducting materials employed in the present invention have been tested in various compositions for determining the temperature conditions realizing the superconducting state, and there have been announced certain compositions capable of showing the superconducting state at temperatures considerably higher than the absolute zero temperature. However there has not been found a superconducting material that will allow to use the motor of the present invention at the temperature of normal ambient condition. It is therefore necessary to cool the coils and/or motor of the present invention. In case of the flat motor shown in FIG. 8A and the cooling is achieved by inserting a Peltier element (not shown) between the fixed yoke 40 and the coils 44.
In case of the motor shown in FIG. 4, the Peltier element not shown is attached to the core 16. It is also possible to supply the coils in the motor with liquid nitrogen.
The motor of the present invention utilizing the coils of a superconducting material provides following advantages:
(1) The area of the conductors showing perfect diamagnetism is reduced, thus reducing the loss in the amount of magnetic flux emerging from the magnet, thus avoiding the loss in torque and efficiency:
(2) The inductance is reduced in comparison with the wider current paths, thus reducing the load on the driving circuit:
(3) A more compact motor structure is made possible by the improved efficiency:
(4) The use of narrower current paths reduces the fetching of the magnetic flux and the loss caused by the movement thereof, observed in the superconducting material of the second kind, thereby enabling to reduce the power consumption; and
(5) The use of narrower current paths allows to increase the limit current density in the superconducting material.
FIG. 10 shows an improvement on the spiral coils shown in FIGS. 7, 9A and 9B, wherein a substrate 70 supports spiral coils 72A 1 , 72A 2 , . . . of a superconducting material, and an arrow a indicates the rotating direction of the coils. A symbol k indicates the length of space of the coil (length of area of the effective magnetic flux), and m indicates the width of uniform magnetization of the permanent magnet.
In the present embodiment the ratio ΔW/W is selected equal to or smaller than 1 in the current paths running perpendicular to the rotating direction A, but the width ΔW' of the grooves is made as small as possible in the current paths (width W') running parallel to the rotating direction. In the present embodiment, following values W=W'=400 μm, ΔW=400 μm and ΔW'=100 μm are selected. Thus the value k increase by the narrowing of the current paths, and the torque increases by the interaction with the magnetic flux density. More specifically, the relation among the torque T, current i and magnetic flux density B is represented by:
T∝k·B·i
so that the torque increase in proportion to the increase of k.
FIGS. 11 to 17 illustrate coils of a superconducting material, adapted for use in a cylindrical motor as shown in FIG. 4.
FIG. 11 is a partial cross-sectional view of the rotor of the present embodiment, wherein same components as those in FIG. 4 are represented by same numbers and will not be explained further. FIGS. 12A and 12B are respectively an external perspective view and a developed view of the rotor shown in FIG. 11
In these drawings, a conductor 14 constituting the coil wire is composed of a metal conductor 76 such as Cu or Al, and a superconducting thin film 78 formed on a face of said metal conductor 76 and composed of one or plural layers of a ceramic material containing rate earth metals or transition metals such as Bi-La-Sr-Cu-O, Y-Ba-Cu-O or La-Ba-Cu-O or a superconducting alloy. Thus, a coil of superconducting material is fixed on a plane of a metal sheet. In addition, the coil of superconducting material is composed of a first metal and is surfacially covered with the second metal. Said superconducting thin film 78 is formed by resistance-heated evaporation, electron beam evaporation, sputtering, electroplating or CVD, and the portions of the metal conductor 76 not provided with the thin film 78 are covered with a masking material or a susceptor to prevent the deposition of the thin film 78.
The coil patterns are determined by thus formed conductor 14, as shown in a developed view in FIG. 12B, and are fixed by filling the gaps of conductors with an insulating adhesive material 80A. Both faces of the coil patterns are then covered with resin 80B. A cylindrical rotor is formed by the coil patterns prepared in this manner.
In the above-explained structure, the conductors 14 are so arranged that the face of the superconducting thin film 78 is substantially parallel to the direction of magnetic flux passing through the rotor as shown in FIG. 11. Consequently the path of magnetic flux is scarcely distorted by the Meissner effect of the superconducting thin film, and the increase of reluctance can be prevented. Therefore the zero resistance in the coils obtained by the use of a superconducting material in the coils of a coreless motor can be directly reflected in the improvement of efficiency.
Also the use of a metal such as Cu or Al in the conductor 76 enables current supply in the coils even when the superconductive thin film 78 is in the normal conducting state, thus enabling rotor rotation in such state. Therefore, in case of using the motor of the present embodiment under a temperature condition capable of realizing the superconducting state, it is rendered possible to maintain the motor in rotation until said temperature condition is reached, thereby preventing the freezing of the motor.
In addition, the metal conductor 76 functions as a current bypass if the superconducting state is locally broken, thereby preventing undesirable influence to the motor caused by a sudden increase in resistance. Thus, the coil of superconducting material constitutes a conductor for current in cooperation with a metal sheet or member while maintaining the conductivity therebetween.
Besides, the thickness t of the superconducting thin film 78 is preferably as small as possible, but a certain thickness is inevitably required in consideration of the maximum necessary current. There is empirically required a relation l>2t, wherein l is the pitch of the conductors
FIG. 13 shows another embodiment of the coil patterns, which are composed of plural conductors 14, in contrast to the pattern shown in FIG. 12B. This embodiment is advantageous in that the rotor can be made thinner, since the conductors do not cross each other. The number of wires or the number of turns shown in FIGS. 12 and 13 is just given as an example and is not limitative.
FIG. 14 is a horizontal cross-sectional view, similar to FIG. 11, showing another embodiment of the conductors. Different from the structure shown in FIG. 11, the superconducting thin film 78 is sandwiched between metal conductors 76. This structure can be realized for example as a clad material obtained by rolling.
The above-explained structure of the conductor 14 prevents the time-dependent change of the superconducting thin film 78 by the presence of covering conductors 76, thus improving the reliability of the conductor 14.
Also the above-explained structure is advantageous because the conductor can be manufactured for example by rooling, without destruction of the superconducting thin film.
FIGS. 15 and 16 are transversal cross-sectional view of another embodiment of the conductor.
In the structure shown in FIG. 15, superconducting thin films 78 are deposited, for example by CVD, on both faces of a metal conductor 76.
In FIG. 16, the superconducting thin films 78 shown in FIG. 15 are protected by Cu plated layers 82.
Presence of two thin films 78 as shown in FIG. 15 or 16 provides a freedom in selecting the amount of current or the thickness of the thin films 78.
FIGS. 11 to 16 have illustrated coils adapted for use in a cylindrical motor with rotating coils as shown in FIG. 4. However the cylindrical motor can be provided with fixed coils and a rotating permanent magnet, as shown in FIG. 17. The coils of the present invention are also applicable to the motor with fixed coils. In FIG. 17, there are shown a motor case 82; a rotary shaft 84 supported by a bearing 86; a rotor yoke 88 fixed to the rotary shaft 84; a rotor magnet 90; and coils fixed on the internal periphery of the motor case. Said coils 92 are composed, as shown in FIGS. 11 to 16, of a metal conductor 76 and a superconducting thin film 78. In case of a motor with fixed coils shown in FIG. 17, a sensor 94 is provided for detecting the magnetic poles of a permanent magnet 90, for controlling the current supply to the coils.
The present invention has been explained by examples of motors, but similar advantages can be obtained when the coils of the present invention are applied to generators.
The advantages of the present invention explained in the foregoing can be summarized as follows:
to prevent loss in torque and efficiency, resulting from the use of superconducting material;
to reduce the inductance, thereby lowering the load of the driving circuit;
to achieve lighter weight and compactization;
to prevent loss in the current supply, resulting from the magnetic flux fetching of the superconducting material;
to increase the limit current density of the superconducting material; and
to increase the torque by varying the groove pitch in the rotation direction and in the radial direction.
In addition, the motor can rotate even in the normal conducting state, and, even when the superconducting state is locally broken, it is possible to prevent rapid heat generation caused by the increase of resistance.
Also the conductors shown in the foregoing embodiments, if the superconducting thin film is positioned parallel to the path of the magnetic flux, can improve the performance of various electric appliances such as transformer, power accumulating inductor, coil etc.
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Coils for electric appliances such as motor or generator are made with a superconducting material, and the width of the coil and the gap between the coils are so adjusted that the passage of magnetic flux generated by a magnetic flux generating member in the electric appliance is not influenced by the magnetic repulsion of the superconducting material.
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FIELD OF INVENTION
The present invention relates to a novel method of isolation and purification of specific proteins from the fermentation broth of the organism Bordatella pertussis, the removal of pyrogenic factors from these proteins, the detoxification of the proteins and the preparation from these purified proteins of a vaccine that is virtually non-toxic, has little or no side effects and confers protection against the disease of pertussis.
BACKGROUND OF THE INVENTION
For infants below the age of 24 months, the disease caused by Bordatella pertussis, pertussis or whooping cough, can be very severe and has a mortality rate of approximately 1%. Over the last fifty years, three types of vaccine have been available for immunization against the disease. The most widely used vaccine, that has been available for the protection of infants against pertussis infection, in combination with tetanus and diphtheria vaccines, is the so-called "whole cell" vaccine, which is available in all developed countries, and many of the Third World countries.
This whole cell pertussis vaccine is prepared by growing known strains of the B.pertussis organism in a defined medium for several hours in a fermentor, until the mixture reaches certain defined parameters. The mixture then is treated with a chemical agent, such as formaldehyde, which kills the organism and detoxifies proteins present in the supernatant and in the organism itself. After allowing the mixture to stand for a specified time to ensure that this detoxification procedure is complete, the cells are separated from the supernatant by passing the mixture through a continuous centrifuge, to provide a packed mass of cells and the supernatant, which is discarded. The cells then are resuspended in a solution of sodium chloride to provide a suspension, that, when diluted to a known strength, usually determined by the opacity of the suspension, and injected subcutaneously, elicits antibodies that are protective against the disease. This "whole cell" vaccine is known for giving minor local reactions at the injection site with occasionally more severe overall reactions, such as elevated temperature and general fretfulness. There has been speculation that the vaccine is responsible for some neurological reactions in infants.
In a second vaccine type, the B.pertussis was grown and detoxified with formaldehyde as before, and then the isolated cells extracted with a concentrated solution of urea. After filtration and dialysis to remove the urea, a mixture of soluble cell wall components is obtained, which, after dilution to a known strength, was in use as a vaccine from 1969 to 1974, but has now been withdrawn because of poor efficacy. More recently, a third vaccine type, commonly called an acellular vaccine, that is in use in Japan and is in clinical trials in a number of other developed countries, is prepared by isolation and purification of constituents of the culture supernatants of B.pertussis after detoxification. Specifically, the constituents called lymphocytosis promoting factor (LPF) also known as pertussis toxin (PT), filamentous hemaglutinin (FHA) and agglutinogens have been isolated and identified. However, because of variations in growth of the organism and the method of isolation, which is non-specific, the composition of the isolated mixture of proteins can vary. At present there is no vaccine in general use and licensed that is completely non-toxic and still gives good protection.
With the growth of the science of immunology over the years, it has been recognized that protective antibodies against a specific disease can be elicited by the administration of specific cellular components of the organism that causes the disease, rather than the whole organism that has been inactivated or has been attenuated to give a non-pathogenic strain. It has been recognized that use of detoxified or attenuated organisms as a vaccine can introduce components that may be damaging to the recipient. With this in mind, a number of efforts have been made to isolate components of the pertussis organism, either from the cell or that have been excreted into the medium, that could have antigenic capabilities, be completely non-toxic and thus could act as vaccines.
As yet there has been no convincing proof that any one particular cell component, by itself, can act as a protective antigen. However, in a number of publications and Patent applications (see, for instance, European Patent Application Nos. 0231083 and 0175841) it has been suggested that a mixture of the purified and detoxified proteins, lymphocytosis promoting factor (LPF) and filamentous hemaglutinin (FHA), can act as a combined antigen and, when administered to a mammal, generate antibodies that confer protection against the disease. In the aforesaid publications various methods have been disclosed for obtaining these proteins in a purified form, and once purified using them in varying proportions as a vaccine.
Although existing technology produces highly purified LPF and FHA, the processes have inherent drawbacks. The affinity chromatographic methods that have been used are effective but conditions of absorption and elution often use materials which are toxic, expensive and/or denature the required proteins. In addition, some of the materials used on affinity columns can be leached into the product under the harsh elution conditions required and, since some of the leached materials are blood derived, may introduce the possibility of blood born diseases or autosensitization. The use of gel filtration materials and hydroxyapatite are acceptable when used by themselves, but give only low purification factors.
The LPF and FHA, which are produced by B.pertussis, also represent a major challenge in the removal of lipopolysaccharides (LPS) as a contaminant. LPS even in nanogram quantities can produce fever and are an undesirable component of any vaccine. The initial concentration of LPS in the fermentation supernatant can be as high as one milligram per milliliter. A number of methods have been used to remove pyrogens from vaccines (see, for instance, U.S. Pat. Nos. 4,000,257 and 4,380,511). Many of these methods are too harsh and result in denaturation of the required proteins. Other methods are ineffective, cumbersome to use and expensive.
Before using the LPF and FHA in a vaccine, these proteins must be detoxified since the LPF in its natural state is highly toxic and small amounts are still present in the purified FHA. This process previously has been achieved by treating the proteins with a chemical agent which induces cross-linking. Traditionally, the agents used have been formaldehyde and glutaraldehyde. The use of formaldehyde and glutaraldehyde can lead to heavy losses due to aggregation and precipitation.
SUMMARY OF INVENTION
In accordance with the present invention, there is provided a novel method for the isolation and purification of the proteinaceous materials LPF and FHA from the growth medium of B.pertussis by adsorption and desorption on various substrates, using a combination of low and high ionic strength solutions. In addition, there is provided an improved method of removing pyrogenic factors, as exemplified by LPS, from the LPF and FHA by washing the adsorbed proteins with a detergent solution. Further, there is provided an improved method for the detoxification of the LPF and FHA, using a cross-linking agent in the presence of an anti-aggregation agent, such that the purified materials can be readily combined into an efficacious vaccine for the prevention of the disease of pertussis.
Accordingly, in one aspect of the present invention, there is provided a method for the isolation and purification of the proteinaceous materials called lymphocytosis promoting factor (LPF) and filamentous hemaglutinin (FHA) from a growth medium in which has been grown the Bordatella pertussis organism. The method comprises contacting the growth medium at low ionic strength with a solid particulate adsorbing medium to selectively adsorb LPF and FHA from the growth medium, and sequentially or simultaneously desorbing the proteinaceous materials by contacting the adsorbing medium with an aqueous medium of high ionic strength.
The isolated LPF and FHA, after further purification and detoxification, can be formulated into a non-toxic vaccine for protection against pertussis.
GENERAL DESCRIPTION OF INVENTION
The inventors have determined that LPF and FHA can be adsorbed preferentially from the filtered growth medium of B.pertussis, at low ionic strength, onto a variety of solid particulate adsorbent materials. After the LPF and FHA are adsorbed from the growth supernatant at low ionic strength onto the substrates, they are desorbed from the adsorbent material using an aqueous solution of high ionic strength.
The high ionic strength desorbing medium is an aqueous solution of a salt and/or buffer. The term "salt solution" used herein refers to all metal or ammonium salts, such as potassium nitrate, sodium chloride and ammonium sulfate, which when dissolved in water, dissociate into their constituent ions, thereby increasing the ionic strength of the solution without significantly changing the pH of the solution. The term "buffer" used herein refers to a chemical compound which, when dissolved in water, dissociates into their constituent ions, thereby increasing the ionic strength of the solution and having buffering capacity.
As used herein, the term "low ionic strength", refers to an aqueous medium having a conductivity of about 11 mS/cm or less, preferably about 4 mS/cm. The unit of measurement mS/cm is millisiemen per centimeter. A siemen (S) is a unit of conductivity and is the equivalent of the inverse of resistance (ohm) and is sometimes designated mho. The term "high ionic strength" as used herein refers to an aqueous medium having a conductivity of greater than about 11 mS/cm and preferably at least about 50 mS/cm.
Solid particulate adsorbent materials useful in the present invention include filter aids, such as Perlite (which is of volcanic ash origin) and Celite (a diatomaceous earth), siliceous materials, such as sand, celluloses, agaroses and gel filtration materials, such as the Sepharoses, the Sephadexes, ultragel and their derivatives.
The variety of matrix materials which have been found useful for the adsorbing medium in the present invention suggests that the characteristics of the matrix material are non-critical but rather it is the property of LPF and FHA that, under low ionic strength conditions, they will bind to a large variety of matrices.
While not wishing to be found by any particular theory to explain the process of the invention, it is thought that, under the initial low ionic strength conditions employed, the LPF and FHA are close to coming out of solution. By passing the solution in contact with insoluble particulate matrices, the particles of the matrix act as nuclei onto which the LPF and FHA can precipitate. Resolubilization for desorbtion then requires a higher ionic strength solution.
After desorption from the absorbing medium by the high ionic strength solution, a mixture of the two proteins is obtained, that can be further separated on other materials, such as hydroxyapatite or other ion-exchange resins, to give the two proteins in high yields and high purity. Alternatively, we have found that separation of FHA and LPF after adsorption onto the adsorbing medium can be obtained by desorbing from the adsorbing medium at differing ionic strengths. To effect preferential elution of LPF from the adsorbing medium, an ionic strength of solution of about 11 mS/cm to about 20 mS/cm is employed. Once the LPF has been eluted, FHA can be eluted at an ionic strength of solution of at least 20 mS/cm, preferably at least about 50 mS/cm.
The ability to effect adsorption at low ionic strength and subsequent elution at high ionic strength of LPF and FHA on conventional gel filtration media and the other non-derivatized adsorbing media used herein is totally unexpected and deviates from the state of the art, where proteins are not adsorbed to gel filtration media and where the protein is continuously eluted from the column under isocratic, i.e., a single buffer, conditions. The gel media have been chosen in previous work because of their very low non-specific protein adsorption, and yet, under the conditions of the invention, they will still adsorb the LPF and FHA very well. It has been shown by the inventors that FHA and LPF can be purified to a greater degree on agarose than derivatized agarose.
The method can be used either as a batch process on the cell free media obtained from the growth of the organism or as a separation method on a chromatography column of the adsorbent. Because of their ease of filtration, their low costs and the accepted employment of filter-aids in the manufacture of pharmaceutical products, the use of the filter-aids is preferable to the use of other materials, such as gel filtration media, and derivatized materials.
The inventors have further found that, if the proteins adsorbed onto the matrices are washed, before elution, with an aqueous non-ionic detergent solution, the LPS in the final product can be reduced by a factor of 10,000 to 100,000, to a concentration of about 1 to about 10 ng/mL. Examples of suitable non-ionic detergent solutions are Triton X-100 in a concentration of about 0.005 to about 5% (v/v), preferably about 0.1 to about 1% (v/v), and Nonidet p40 in a concentration of about 0.0005 to about 0.1% (v/v), preferably about 0.001 to about 0.01% (v/v).
It has also been found by the inventors that the purified LPF and FHA can be detoxified by contact with a cross-linking agent, such as glutaraldehyde and/or formaldehyde in the presence of an anti-aggregation agent, such as glycerol or sucrose, to improve the yield of final product. The anti-aggregation agent is present in a significant proportion during the detoxification operation and prevents the aggregation and precipitation that occurs in the absence of such material. For the detoxification of LPF in the presence of glycerol, glycerol is present in an amount of about 30 to about 80% (v/v), preferably approximately 50%, while for the detoxification of FHA, glycerol is present in an amount of about 10 to about 80% (v/v), preferably approximately 25%. Where sucrose is used as the anti-aggregation agent, the sucrose is present in an amount of about 30 to about 60% (w/v), preferably approximately 40%.
In the present invention, B.pertussis is grown in a fermentor using controlled conditions. Carbon sources and growth factors are supplemented continuously or in batches at various intervals during the fermentation until the two proteins, LPF and FHA, are at the desired level, which can be determined by enzyme linked immunosorbent assay (ELISA). In our invention, the mixture of cells and medium from the fermentor is not inactivated by chemical means immediately after the fermentation is complete, but later in the purification process. The use of chemical detoxification at this stage in the process can lead to aggregation of the proteins and poor separation in the following steps.
The fermentor then is harvested and the majority of the cells removed by continuous centrifugation. The remainder of the cells then can be removed from the supernatant by filtration, using known membrane filters of 0.2 μ pore size, which also sterilizes the solution. In the present invention, it is this supernatant that is retained and processed for isolation and purification of LPF and FHA. After centrifugation and filtration, the supernatant is concentrated, say 10-fold, using membrane filtration, assayed for protein and then diluted until the ionic strength is in the required range. This solution, which contains the LPF and FHA proteins then is treated with the adsorbing medium, either in a batch process or as a chromatographic process. The LPF and FHA, after adsorption onto the adsorbing medium, are washed first with several volumes of a buffer to remove contaminants and then with a solution of a detergent which removes the majority of the lipopolysaccharides (LPS). Further washing removes any traces of the detergent.
The LPF and FHA can be obtained separately from the adsorbent by elution with solutions of stepwise increasing ionic strength or the two proteins can be eluted together using a high ionic strength salt solution. The proteins can be further purified on a chromatography column of a material, such as hydroxyapatite. The proteins are eluted from such a column by using different ionic strengths solutions after prior washing. The separate proteins then are detoxified in the presence of an anti-aggregation agent to result in high yields of detoxified protein. After removal of the additives, the detoxified proteins are sterilized by filtration and, after assay, can be mixed in the required proportion to give a solution that can be used as a vaccine against pertussis.
DESCRIPTION OF PREFERRED EMBODIMENT
The procedure of the invention may be employed to effect large scale separation of LPF and FHA using a chromatographic column of Perlite, which is currently the best mode known to the applicants for effecting separation and recovery of purified LPF and FHA.
Concentrated B.pertussis fermentation broth is diluted to a low ionic strength corresponding to a conductivity of 4mS or less and loaded onto a column of packed Perlite to provide a protein loading of about 1 to about 5 mg, preferably about 2 to about 3 mg per milliliter of packed Perlite. The packed Perlite column usually about 15 to about 18 cm high and about 10 to about 45 cm in diameter.
The dilute fermentation broth is contacted with the Perlite column at a linear flow rate of about 50 to about 200 cm/hr, preferably approximately 100 cm/hr. The proteins which are adsorbed to the Perlite are almost exclusively LPF and FHA with most of the contaminating proteins and LPS passing through the column.
The column then is washed with about 2 to about 10 column volumes of a buffer containing about 10 to about 50 mM, of Tris HCl at pH 8.0. A subsequent wash with an aqueous non-ionic detergent, typically about 5 column volumes of an 0.5% (v/v) Triton X-100 solution in 50 mM Tris HCl buffer at pH 8.0, decreases the LPS content of the proteins by a factor or about 100, for a total decrease in the LPS/LPF ratio of between 10,000 and 100,000. Subsequent washing of the column with further volumes preferably about 5 volumes of buffer, of 50 mM Tris HCl at pH 8.0, removes the non-ionic detergent.
The FHA is eluted from the column by contacting the column with buffer solution, for example, 5 volumes of 50 mM Tris HCl at pH 8.0, containing about 0.1 to about 0.2 mM sodium chloride, preferably about 0.12 mM. The LPF next is eluted from the column by contacting the column with buffer solution, for example, 5 volumes of 50 mM Tris HCl at pH 8.0, containing at least about 0.2M of sodium chloride, preferably about 0.6M.
The eluted solutions are assayed for protein content. By this procedure, LPF and FHA recoveries of approximately 60 to 65% and 65 to 70% respectively of the initial contents of these proteins in the broth have been obtained.
Further purification of LPF and FHA may be effected using a column of packed hydroxyapatite about 5 to about 8 cm in height and about 5 to about 30 cm in diameter. The column is washed and equilibrated prior to use. The eluate containing LPF is applied to the column at a loading of about 0.5 to about 1 mg/ml of packed gel at a linear flow rate of about 15 to about 25 cm/hr to adsorb the LPF therefrom.
The column is washed with a suitable buffer, for example, 5 column volumes of 30 mM potassium phosphate at pH 8.0, following which the LPF is eluted with about 5 to about 10 column volumes of an eluting medium, for example, 75 mM potassium phosphate at pH 8.0, containing about 0.1 to about 0.3M sodium chloride, preferably about 0.225M.
The procedure may be repeated for the FHA-containing eluant, with elution being effected using an aqueous elution medium, for example, 200 mM potassium phosphate at pH 8.0, containing at least about 0.2M sodium chloride, preferably about 0.6M.
In these hydroxyapatite purification procedures, typical recoveries of the pure protein are about 80 to about 100% with the respective proteins having a purity of at least 90%.
Detoxification of the further purified LPF and FHA may be effected in order to provide these materials in a form suitable for formulation as a non-toxic vaccine. It is preferred to effect detoxification of the LPF protein using glutaraldehyde in the presence of glycerol while it is preferred to effect detoxification of the FHA protein using formaldehyde in the presence of glycerol.
The invention is illustrated further by the following Examples.
EXAMPLES
Methods of protein biochemistry, fermentation and assays used but not explicitly described in this disclosure and these Examples are amply reported in the scientific literature and are well within those skilled in the art.
Example 1
This Example illustrates the growth of B.pertussis in fermentors.
Bordatella pertussis was seeded into a fermentor containing 250 L of broth (modified Stainer-Scholte medium). During the period of perfentation, monosodium glutamate (2.18 kg) and the growth factors, glutathione (41 g), ferrous sulphate (2.7 g), calcium chloride (5.5 g), ascorbic acid (109 g), niacin (1.1 g) and cysteine (10.9 g), were added at intervals to increase the yields of LPF. At the end of a 48 hour fermentation period, the broth was run through a continuous centrifuge to remove the majority of the cells. This suspension, which contains both the LPF and FHA in solution, was further clarified by micro-filtration on cellulose acetate membranes (0.22 μm pore size). The sterilized filtrate was concentrated approximately 10-fold using a 20,000 NML membrane and then assayed for protein by the dye-binding method.
Example 2
This Example illustrates the isolation of LPF and FHA on a number of different matrices.
A number of 1 milliliter columns were packed with various matrices and equilibrated with 50 mM Tris HCl at pH 8.0, 10 mM potassium phosphate at pH 8.0 or water. The matrices included Orange A-, Blue A-, Green A-, Red A-agaroses, Blue Sepharose, Blue B-, Reactive Blue 4-, Cibacron Blue 3GA-, Reactive Brown 10-, Reactive Green 19-, Reactive Yellow 86-Sepharose, non-derivatized agarose, Ultragel ACA44, Sephadex G50, Sepharose 6B, Sepharose CL4B, S-Sepharose, Q-Sepharose, cellulose sulphate, QAE-cellulose, CM-cellulose, Perlite and Celite.
B. pertussis culture broth was centrifuged, sterile filtered through a 0.2 u membrane and concentrated approximately 10 fold by ultrafiltration on 20 kD NML membranes. Broth concentrates were diluted with water so that the ionic strength was less than or equal to 4 mS/cm. Samples between 2 to 10 ml were loaded onto the columns by gravity feed and then washed with excess 10 mM potassium phosphate, followed by 50 mM Tris HCl buffer at pH 8.0. Each column was eluted with 50 mM Tris HCl at pH 8.0 containing either 0.6M or 1.0M sodium chloride. Fractions were analysed by absorbance at 280 nm and on SDS-PAGE. All of the matrices were found to adsorb LPF and FHA. The eluted LPF and FHA were found to be highly purified.
In a similar experiment using white quartz sand, a column 1.5 cm in diameter and 18 cm in height was washed and loaded with the same diluted broth concentrate to adsorb LPF and FHA therefrom and washed. The column then was eluted first with 50 mM Tris HCl at pH 8.0 containing 0.1M sodium chloride, followed by Tris buffer containing 1.0M sodium chloride, so as to elute first the LPF and then the FHA. The separately eluted LPF and FHA respectively were found to be highly purified.
Example 3
This Example illustrates the large scale separation of LPF and FHA using a chromatographic column of Perlite.
The broth concentrate, prepared as described in Example 1, was diluted with water to a conductivity of approximately 4 mS/cm, such that the final loading of protein was approximately 3 mg of crude protein per milliliter of packed Perlite. The packed Perlite column was 18 cm high and 10 cm in diameter and was prewashed with 1.4 L of Water for Injection (WFI). The diluted concentrate was applied to the column at a linear flow rate of 100 cm/hr. The proteins bound to the Perlite were almost exclusively LPF and FHA with most of the contaminating protein and lipopolysaccharide (LPS) passing through. The column was washed with 1.4 L of a buffer containing 50 mM Tris HCl at pH 8.0. A subsequent wash with detergent, composed of 1.4 L of a 0.5% (v/v) Triton X-100 solution in 50 mM Tris HCl buffer at pH 8.0, reduced the LPS content by a further factor of 100, for a total reduction in the LPS/LPF ratio of between 10,000 to 100,000. The column then was washed with a further 1.4 L 50 mM Tris HCl at pH 8.0 to remove the Triton X-100. The LPF then was eluted from the column with 50 mM Tris HCl at pH 8.0 containing 0.12 mM sodium chloride. The FHA was eluted from the column using 50 mM Tris HCl at pH 8.0 containing 0.6M sodium chloride. Approximately 1.4 L of each elution buffer was used. The solutions then were assayed for protein content by the dye-binding assay. LPF and FHA recoveries were 60% and 65%, respectively, based on ELISA values.
Example 4
This Example illustrates the batch adsorption of LPF and FHA on Perlite.
B.pertussis broth concentrates (60 ml) were diluted 4-fold with water to a conductivity of approximately 4 mS/cm and Perlite (2g) added. The mixture was rotated slowly at 4° C. for 3 hr. The mixture was vacuum filtered on a sintered glass filter and the residual Perlite was rinsed into the filter with 50 mM Tris HCl at pH 8.0 (20 ml). The Perlite was washed with 4×50 ml of the Tris buffer and then eluted with 3×20 ml of 50 mM Tris HCl at pH 8.0 containing 1.0M sodium chloride. The eluates were pooled and assayed using an ELISA assay. LPF recoveries were calculated to be at least 65%.
EXAMPLE 5
This Example illustrates the further purification of LPF on hydroxyapatite.
Hydroxyapatite was packed into a column 5 to 30 cm diameter and 6 cm height. The column was washed with 200 mM potassium phosphate at pH 8.0, 1M potassium chloride, 0.5% Triton X-100 and equilibrated with 10 mM potassium phosphate at pH 8.0 prior to use. The LPF solution, recovered as described in Example 3, was applied to the column at a loading of approximately 0.5 mg of protein/ml of packed gel at a linear flow rate of approximately 20 cm/hr. The column was washed with 500 ml of 30 mM potassium phosphate at pH 8.0. The LPF was eluted with 1 L of 75 mM potassium phosphate at pH 8.0 containing 0.225M sodium chloride. The resulting LPF was at least 90% pure. The LPF was assayed for protein by the dye binding method. The LPF recovery was approximately 90% for this step.
Example 6
This Example illustrates the further purification of FHA on hydroxyapatite.
The hydroxyapatite was packed and washed in a column of the same size as detailed in Example 5. The FHA fraction from the Perlite separation described in Example 3 was applied to the column at a linear flow rate of 20 cm/hr and a loading of 0.5 mg of protein/ml of packed gel. The column was washed with 500 ml each of 30 mM potassium phosphate at pH 8.0, 30 mM potassium phosphate at pH 8.0 containing 0.5% (v/v) of Triton X-100 and 30 mM potassium phosphate at pH 8.0. Any remaining LPF in the fraction first was eluted with 500 ml of 85 mM potassium phosphate at pH 8.0 and the FHA then was eluted with 200 mM potassium phosphate at pH 8.0 containing 0.6M potassium chloride. The resulting FHA was at least 90% pure. The FHA was assayed for protein by the Lowry method. FHA recovery for this column was approximately 90%.
Example 7
This Example illustrates the detoxification of LPF with glutaraldehyde.
The purified LPF, prepared as described in Example 5, in 75 mM potassium phosphate at pH 8.0 containing 0.22M sodium chloride was diluted with an equal volume of glycerol to a protein concentration of approximately 200 μg/ml. The solution was heated to 37° C. and detoxified by the addition of glutaraldehyde to a final concentration of 0.5% (w/v). The mixture was kept at 37° C. for 4 hr and followed by the addition of aspartic acid (1.5M) to a final concentration of 0.25M. The mixture was incubated at room temperature for 1 and then diafiltered with 10 volumes of 10 mM potassium phosphate at pH 8.0 containing 0.15M sodium chloride to remove both the glycerol and the glutaraldehyde. The LPF toxoid was sterile filtered through a 0.2 u membrane.
Example 8
This Example illustrates the detoxification of FHA with formaldehyde.
The purified FHA, prepared as described in Example 6, in 200 mM potassium phosphate at pH 8.0 containing 0.6M potassium chloride was diluted with glycerol to give a final concentration of 25% V/V. The protein concentrations was approximately 500 μg/ml based on the Lowry protein assay. The FHA solution was heated to 37° C. and a 1.5M solution of L-lysine HCl at pH 8.0 was added to a final concentration of 50 mM. Formaldehyde was added to a final concentration of 0.25% V/V. Detoxification was carried out at 37° C. for a period of 6 weeks. The resulting toxoid was diafiltered against 10 volumes of 10 mM potassium phosphate at pH 8.0 containing 0.5M sodium chloride to remove both the glycerol and the formaldehyde. The toxoid solution was sterile filtered through a 0.2 μ membrane.
Example 9
This Example illustrates the use of detoxified LPF and FHA in producing protective antibodies.
Guinea pigs (SPF) were prescreened for pertussis antibody titres, and only those animals which showed low background titres were used in the experiment.
Animals were injected with 0.5 ml of test material at day zero. Test materials employed in the tests were the purified and detoxified LPF and FHA products produced by the procedures of Examples 7 and 8 respectively ("adsorbed"), LPF and FHA isolated from broth but not processed by the invention ("unadsorbed") and conventional whole cell vaccine.
Four weeks after injection, the animals were bled and the sera tested for PT and FHA antibodies by ELISA. Sera also were tested for CHO antitoxin activity. At day 35, the animals were boosted with the same dose of antigen and finally the animals were bled at day 49 and the sera tested. The results are shown in the following Table I:
TABLE I__________________________________________________________________________IMMUNOGENICITY OF PERTUSSIS TOXOIDIn guinea pigs at 25 ug dose ELISA × 10.sup.-3 CHO LPF FHA Protein Units 1st 2nd 1st 2nd ug 1st 2nd bleed bleed bleed bleed__________________________________________________________________________LPF (unadsorbed) 25 14 640 3 256(adsorbed) 25 433 1664 59 410FHA (unadsorbed) 25 52 33(adsorbed) 25 14 205Whole Cell human 4 30 2 21 4 21(unadsorbed) dose__________________________________________________________________________ All results are reciprocal reactive titres.
The results set forth in the Table indicate that when compared to the conventional whole cell vaccine and unprocessed LPF and FHA proteins, the purified and detoxified LPF and FHA proteins provided by the procedures of the invention give considerably higher antibody titres.
Example 10
This Example illustrates the use of the purified antigens in the mouse protection test.
Taconic mice (15 to 17g) were injected at day zero with 0.5 ml of the test sample intraperitoneally, in three doses. Each dose was injected into 16 mice. At day 14, the mice were challenged with an intracerebral injection of a standard does of B.pertussis. Control mice also were injected at the same time to ascertain the effectiveness of the challenge. Three days after the challenge, the number of animal deaths was recorded every day up to and including day 28. At day 28, paralysed mice and mice with cerebral edema also were recorded as dead.
Results were recorded as ED 50 , which is the dose at which half the mice survive the challenge. This was done using a computer programme after plotting the survivors divided by the total number of mice in each category at each dose.
The result of this experiment showed that the ED 50 of a mixture of LPF and FHA was less than [lug LPF+2 ug FHA], and thus a mixture of the two purified proteins was protective against the disease.
SUMMARY OF DISCLOSURE
In summary of this disclosure, the present invention provides a novel and unexpected method for the separation of proteins from the growth media of B.pertussis that can be used as antigens to elicit protection against the disease of pertussis. The novel method employs a difference in ionic strengths of the solutions from which the proteins are adsorbed and the solutions used to desorb them from the substrate. A further aspect of the invention is the reduction of LPS by washing the adsorbed proteins with a solution of detergent. The use of glycerol or sucrose for preventing protein aggregation during the detoxification process, is an important aspect of the invention since protein aggregation could result in up to 95% of protein losses at the final step of the process. Modifications are possible within the scope of this invention.
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Lymphocytosis promoting factor (LPF) and filamentous hemaglutinin (FHA) are isolated from the growth medium of the Bordatella pertussis organism and purified by selecting adsorbing the LPF and FHA on a selective adsorbing medium, such as filter aids or gel filtration media, at low ionic strength and subsequently removing the adsorbed LPF and FHA at using an aqueous medium of high ionic strength, either simultaneously or sequentially. Prior to desorbtion of the LPF and FHA, the adsorbing medium may be contacted with an aqueous solution of a non-ionic detergent, which enables the LPF and FHA subsequently desorbed to be substantially free from contamination by lipopolysaccharides (LPS). The LPF and FHA may be further purified on hydroxyapatite. The LPF and FHA may be detoxified separately or together by contacting with a cross-linking agent, such as glutaraldehyde or formaldehyde, in the presence of an anti-aggregation agent. The resulting purified and detoxified LPF and FHA may be used to formulate a vaccine against pertussis.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/538,392 filed Apr. 27, 2006, which is an application under Section 371 of International patent application number PCT/US2004/031202 filed Sep. 22, 2004 which in turn claims the benefit under 35 USC §119(e) to U.S. provisional patent application Ser. No. 60/505,392 filed Sep. 23, 2003, the entire contents of all of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates generally to medical devices for measuring levels of glycated albumin in blood from patients with diabetes. More specifically, the present invention uses lateral flow immunochromatography to measure both glycated albumin and total albumin in a single sample. Additionally the present invention provides methods for monitoring levels of glycated albumin in the blood of diabetes patients using a point-of-care assay and medical device.
BACKGROUND OF THE INVENTION
[0003] Diabetes mellitus, or diabetes, is a disease characterized by elevated levels of plasma glucose. Uncontrolled hyperglycemia is associated with increased risk of vascular disease including, nephropathy, neuropathy, retinopathy, hypertension, and death. There are two major forms of diabetes: Type 1 diabetes (or insulin-dependent diabetes) and Type 2 diabetes (or non insulin-dependent diabetes). The American Diabetes Association has estimated that approximately 6% of the world population has diabetes.
[0004] The goal of diabetic therapy is to maintain a normal level of glucose in the blood. The American Diabetic Association has recommended that diabetics monitor their blood glucose level at least three times a day in order to adjust their insulin dosages and/or their eating habits and exercise regimen. However, glucose tests can only measure a point in time result and do not provide an overall assessment of glycemic control over a period of time. The measurement of glycated albumin has proven to be valuable measure of the effectiveness of glycemic control over the preceding 2-3 weeks. The basis for measuring glycated albumin depends on the nonenzymatic glycosylation of albumin and is directly proportional to the level of glucose in plasma over a period of time. The half-life of albumin in plasma is 2-3 weeks and as glycosylation occurs at a constant rate over time the level of glycated albumin provides a measure of the average blood glucose level over the preceding two to three weeks.
[0005] Frequent monitoring of the individual's glycated albumin would provide an accurate assessment of overall effectiveness of glycemic control in the individual.
[0006] Current methodology for performing tests for glycated albumin are complex to perform or require expensive instrumentation and are generally performed in laboratories. It would be advantageous to develop a simplified point-of-care assay that could be utilized in a doctor's office or by the patient and there is intensive research to develop such a test.
[0007] The present invention describes a simplified point-of-care assay that utilizes disposable test strips and a reusable measuring instrument.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to medical devices and methods for monitoring levels of glycated albumin in the blood of diabetes patients using a point-of-care assay and medical device. Specifically, the present invention uses lateral flow immunochromatography to measure both glycated albumin and total albumin in a single sample.
[0009] In an embodiment of the present invention, an immunochromatographic system is provided for measuring glycated albumin in a blood sample comprising a first test strip that measures glycated albumin and a second test strip that measures total albumin; and a measurement device that reads, calculates and displays the result as the percentage of glycated albumin compared to total albumin in the sample.
[0010] In another embodiment of the present invention, the first test strip is comprised of microparticles coated with a first antibody to glycated albumin and an immobilization agent covalently bound to the membrane strip. The immobilization agent is a second antibody to glycated albumin or phenyl boronic acid.
[0011] In alternative embodiments of the present invention the first and second antibodies to glycated albumin are individually monoclonal or polyclonal antibodies. The polyclonal antibodies may be the whole antiserum, the IgG fraction or the purified antibody.
[0012] In an embodiment of the present invention, the microparticles of the first test strip are selected from the group consisting of colloidal gold particles, latex particles, polystyrene particles, acrylic particles or other solid phase microparticles. Additionally the size of the microparticles can vary from approximately 5 nm to approximately 50 nm in diameter.
[0013] In another embodiment of the present invention, the second test strip is comprised of microparticles coated with a first antibody to albumin and an second antibody to albumin covalently bound to the membrane strip.
[0014] In an embodiment of the present invention, the first and second antibodies to albumin are individually monoclonal or polyclonal antibodies. The polyclonal anti-albumin antibodies may be the whole antiserum, the IgG fraction or the purified antibody.
[0015] In an embodiment of the present invention, the microparticles of the second test strip are selected from the group consisting of colloidal gold particles, latex particles, polystyrene particles, acrylic particles or other solid phase microparticles. Additionally the size of the microparticles can vary from approximately 5 nm to approximately 50 nm in diameter.
[0016] In another embodiment of the present invention the microparticles of either of the first or second test strips can have particle size diameters of 10 nm, 20 nm, 30 nm and 40 nm.
[0017] In yet another embodiment of the present invention, the microparticles of either the first or second test strip can either colored or tagged with a fluorescent compound.
[0018] In an embodiment of the present invention, the first test strip and the second test strip may be arranged in parallel; or opposite to each other; or at an angle to each other. Additionally the first test strip and the second test strip are enclosed in a rigid cassette.
[0019] In an embodiment of the present invention the measurement device is a reflectance spectrometer comprising: a reflectance detector for measuring the glycated albumin test result; a reflectance detector for measuring the glycated albumin control band; a reflectance detector for measuring the total albumin test result; a reflectance detector for measuring the total albumin control band; an internal computer chip for measurement and calculation; a liquid crystal display; an external port to transfer data to an external computer and/or printer; a battery and/or an external power source; and a rigid external case with an aperture for inserting the test cassette.
[0020] In an embodiment of the present invention the measurement device is a fluorometer composed comprising: a fluorescence detector for measuring the glycated albumin test result; a fluorescence detector for measuring the glycated albumin control band; a fluorescence detector for measuring the total albumin test result; a fluorescence detector for measuring the total albumin control band; an internal computer chip for measurement and calculation; a liquid crystal display; an external port to transfer data to an external computer and/or printer; a battery and/or an external power source; and a rigid external case with an aperture for inserting the test cassette.
[0021] In another embodiment of the present invention the measurement device further comprises an internal memory chip capable of storing one or more than one test result.
[0022] In yet another embodiment of the present invention, the measurement device can display one or more than one test result on the measurement device's liquid crystal display in numerical format or in graphical format. Additionally the test results can be transferred to an external computer or printer.
[0023] In an embodiment of the present invention, a method of monitoring glycated albumin using a point-of-care assay is provided comprising: depositing a drop of blood into a sample well of an immunochromatography system test cassette; transferring said blood into the sample application pad thereby allowing blood plasma to pass into a first conjugate pad of a first test strip; binding said blood plasma to anti-glycated albumin antibody-coated microparticles in said first conjugate pad; allowing blood plasma-bound anti-glycated albumin antibody-coated microparticles to migrate across said first conjugate pad to a fixed band of membrane-bound anti-glycated albumin antibody; binding said blood plasma-bound anti-glycated albumin antibody-coated microparticles to said membrane bound anti-glycated albumin antibody to form a visible band; inserting said immunochromatography system test casette into a measurement device; and providing numerical results of glycated albumin levels.
[0024] In an embodiment of the present invention, the method of monitoring glycated albumin using a point-of-care assay further comprises: depositing a drop of blood into a sample well of an immunochromatography system cassette; transferring said blood into the sample application pad thereby allowing blood plasma to pass into a second conjugate pad of a second test strip; binding said blood plasma to anti-total albumin antibody-coated microparticles in said second first conjugate pad; allowing blood plasma-bound anti-total albumin antibody-coated microparticles to migrate across said second conjugate pad to a fixed band of membrane-bound anti-total albumin antibody; binding said blood plasma-bound anti-total albumin antibody-coated microparticles to said membrane bound anti-total albumin antibody to form a visible band; inserting said immunochromatography system test cassette into a measurement device; and providing numerical results of total albumin levels.
[0025] In another embodiment of the present invention, a method of monitoring glycated albumin using a point-of-care assay is provided wherein glycated albumin levels and said total albumin levels are used to determine percent glycated albumin.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 depicts a first view of the test strips made in accordance with the teachings of the present invention.
[0027] FIG. 2 depicts a second view of the test strips made in accordance with the teachings of the present invention.
[0028] FIG. 3 depicts a side view of the test strips made in accordance with the teachings of the present invention.
[0029] FIG. 4 depicts a reflectance spectrometer as used with the test strips made in accordance with the methods of the present invention.
[0030] FIG. 4 b depicts a fluorometer as used with the test strips made in accordance with the methods of the present invention.
[0031] FIG. 5 depicts a first view of a test strip cassette made in accordance with the teachings of the present invention.
[0032] FIG. 6 depicts a second view of a test strip cassette made in accordance with the teachings of the present invention.
[0033] FIG. 7 depicts a reflectance spectrometer and test strip as used in accordance with the methods of the present invention.
DESCRIPTION OF THE INVENTION
[0034] This invention utilizes the principle of lateral flow immunochromatography to measure both glycated albumin and total albumin. The patient's blood sample is placed in a test cassette that contains reagents to separate the plasma from the red blood cells and to perform the test. The test cassette is then inserted into a measuring instrument that reads, calculates and reports the result.
[0035] The rapid assay for glycated albumin is an immunochromatographic method that utilizes antibodies to glycated albumin and antibodies to total albumin on test strips. In order to measure the percent of glycated albumin to total albumin, two procedures are involved. The first procedure utilizes an immunochromatographic test strip to measure glycated albumin. The second procedure utilizes an immunochromatographic test strip to measure total albumin. Both strips are contained within a single exterior cassette ( FIG. 1 ) that is inserted into a measuring instrument ( FIG. 7 ) that automatically reads, calculates and displays the result.
[0036] Glycated Albumin Test
[0037] The test strip for measuring glycated albumin is shown in FIGS. 1 and 2 . The test strip consists of a solid phase support ( 1 ), including but not limited to a cellulose nitrate membrane, to which antibody to glycated albumin has been fixed to the solid-phase substrate as a band ( 2 ). A sample application pad ( 3 ) contacts a conjugate pad ( 4 ) containing microparticles coated with anti-glycated albumin antibody. A control band is provided to bind excess unreacted microparticles ( 5 ) and a reservoir pad ( 6 ) is provided at the distal end of the membrane to absorb excess sample fluid. The test strip is enclosed within a rigid cassette containing a sample well and window segments to allow for visualization and measurement of the test result.
[0038] To perform the test a small volume of blood is placed into the sample well. The blood migrates into the sample application pad which filters and binds the red blood cells allowing the plasma to pass through into the conjugate pad where it reacts with the antibody coated microparticles. Any glycated albumin present binds to the anti-glycated albumin antibody-coated microparticles. The microparticles continue to migrate across the cellulose membrane until they come into contact with the fixed band of anti-glycated albumin antibody. Any glycated albumin bound to microparticles becomes bound to the membrane and causes the bound microparticles to form a visible band. The intensity of the band is proportional to the amount of glycated albumin bound to the microparticles. The intensity of the visible band is estimated visually by comparison to a visual standard or measured in an instrument developed for this purpose.
[0039] Total Albumin Test
[0040] The test strip for measuring total albumin is shown in FIGS. 1 and 2 . It consists of a solid phase substrate ( 1 ), including but not limited to a cellulose nitrate membrane ( 1 ) to which antibody to albumin has been fixed as a band ( 7 ). A sample application pad ( 3 ) contacts a conjugate pad ( 8 ) containing microparticles coated with anti-albumin antibody. A control band ( 9 ) is provided to bind excess unreacted microparticles and a reservoir pad ( 6 ) is provided at the distal end of the membrane to absorb excess sample fluid. The test strip is enclosed within a rigid cassette containing a sample well and window segments to allow for visualization and measurement of the test result.
[0041] To perform the test a small volume of blood is placed into the sample well. The blood migrates from the sample application pad which filters and binds the red blood cells allowing the plasma to pass into the conjugate pad where it reacts with the antibody coated microparticles. Any albumin present binds to the anti-albumin antibody coated microparticles. The microparticles continue to migrate across the cellulose membrane until they come into contact with the fixed band of anti-albumin antibody. Any albumin bound to microparticles becomes bound to the membrane and causes the bound microparticles to form a visible band. The intensity of the band is proportional to the amount of albumin bound to the microparticles. The intensity of the visible band is estimated visually by comparison to a visual standard or measured in an instrument developed for this purpose.
[0042] Measuring Instrument
[0043] In one embodiment of this invention, the measuring instrument is a reflectance spectrophotometer that is specifically designed to measure the intensity of the glycated albumin test band on the glycated albumin test strip, the total albumin test band on the total albumin test strip, and to calculate a result from these readings. The instrument has two sets of detectors: one detector set is for measuring glycated albumin and the other detector set is for measuring total albumin. The result is then calculated according to a mathematical algorithm derived from data obtained from measurement of standards of glycated and total albumin. The result is expressed as the percent of glycated albumin compared to total albumin present.
[0044] Alternatively, other methods for measuring the density of the aggregated microparticles may be employed. For example, in another embodiment of the present invention, the measuring instrument may be a fluorometer that measures the fluorescence that is emitted from microroparticles that have been tagged with a fluorescent dye including, but not limited to, fluorescein or rhodamine red. In this embodiment there will be an excitatory beam of light projected onto the test bands and onto the control bands, and the emitted light from each band will be individually read by the corresponding detectors sensitive to the wavelength of the emitted light. The data reduction and reporting of the result will be as described above for the reflectance spectrophotometer.
EXAMPLE 1
Glycated Albumin Test
[0045] A blood sample, such as that obtained from a finger stick, is placed in the sample well and allowed to absorb into the sample application pad. The sample application pad is composed of porous cellulose material but other woven or porous materials including but not limited to glass fibers may be used. The sample application pad has a porosity that does not allow the passage of red blood cells but allows the passage of the plasma. Alternatively, the application pad can be treated with binding agents such as lectins that bind the red blood cells and prevent them from passage through the application membrane.
[0046] The filtered plasma sample then flows into a conjugate pad containing microparticles. The conjugate pad is composed of porous cellulose material but other woven or porous materials such as glass fibers may be used. The microparticles are composed of materials including, but not limited to, colloidal gold, latex particles, acrylic particles or polystyrene particles with diameters that may range from approximately 5 nm to 50 nm. Microparticles composed of other materials may also be employed and are within the scope of this invention. In alternative embodiment of the present invention, colored or fluorescent tagged microparticles can be employed to increase the sensitivity of the system.
[0047] In embodiments of the present invention, the microparticles are coated with either polyclonal or monoclonal antibodies to glycated albumin. The polyclonal anti-glycated albumin antibodies are prepared in immunized animals, including but not limited to rabbits, sheep, goats, or other immunized species of animals, or by monoclonal antibody techniques. Either the whole antiserum, or the IgG purified fraction, or the affinity purified antibody to glycated albumin may be employed. The methods for immunization of animals and the preparation and purification of antibody is performed according to standard laboratory procedures and are known to those skilled in the art.
[0048] Similarly, the methods of developing monoclonal antibodies is performed according to standard laboratory procedures and are known to those skilled in the art. The microparticles may be coated with the antibody by passive adsorption, by chemical conjugation such as covalent binding, or through binding to an intermediate agent such as to Protein A-coated microparticles. The methods for coating microparticles are performed according to standard laboratory procedures and are familiar to those skilled in the art.
[0049] When the test sample comes into contact with the antibody coated microparticles, the antibody will bind any glycated albumin present. The microparticles will continue to migrate across the membrane until they reach the band of anti-glycated albumin antibody fixed to the membrane. Any microparticles containing bound glycated albumin will become bound to the fixed band of anti-glycated albumin antibody to form a visible band.
[0050] Alternatively the membrane may be treated with chemicals known to bind glycated proteins such as phenyl boronic acids which are applied as a band to the membrane strip. Any microparticles containing bound glycated albumin will become bound to the fixed band of phenyl boronic acid to form a visible band. Independent of the method by which the glycated albumin becomes bound to the test strip, the density of the band formed will be directly proportional to the amount of glycated albumin present in the blood sample. The density of the band can be measured using a reflectance spectrometer for colored microparticles or a fluorometer for microparticles tagged with a fluorescent compound. The measurements are used to calculate the percentage of glycated albumin compared to total albumin in the blood sample.
[0051] In order to verify that the test strips are functioning correctly each test strip can additionally have a control band located distal to the test band. For the glycated albumin test strip this control band is composed of antibody directed against the species antibody that was used to coat the microparticles. For example, if rabbit anti-human glycated albumin antibody used to coat the microparticles, then the control band would use another species such as goat or sheep antibodies directed against rabbit IgG immunoglobulin. The antibodies in the control band bind to the excess unreacted antibody-coated microparticles that were not bound to the test band but continued to migrate across the membrane until bound by the control reagent. The intensity of the control band is measured using a reflectance spectrometer or fluorometer and the data is used to determine if the test is performing correctly.
EXAMPLE 2
Total Albumin Test
[0052] A blood sample, such as that obtained from a finger stick, is placed in the sample well and allowed to absorb into the sample application pad. The sample application pad is composed of porous cellulose material but other woven or porous materials, including but not limited to glass fibers may be used. The sample application has a porosity that does not allow the passage of red blood cells but allows the passage of the plasma. Alternatively, the application pad can be treated with binding agents such as lectins that bind the red blood cells and prevent them from passage through the application membrane.
[0053] The filtered plasma sample then flows into a conjugate pad containing microparticles. The conjugate pad is composed of porous cellulose material but other woven or porous materials, including but not limited to glass fibers may be used. The microparticles are composed of materials including, but not limited to, colloidal gold, latex particles, acrylic particles or polystyrene particles with diameters that may range from approximately 5 nm to 50 nm. Microparticles composed of other materials may also be employed and are within the scope of this invention. Colored or fluorescence tagged microparticles may be employed to increase the sensitivity of measurement of the result.
[0054] In embodiments of the present invention, the microparticles are coated with either polyclonal or monoclonal antibodies to glycated albumin. The polyclonal anti-albumin antibodies are prepared in immunized animals including but not limited to rabbits, sheep, goats, or other immunized species of animals, or by monoclonal antibody techniques. Either the whole antiserum, or the IgG purified fraction, or the affinity purified antibody to albumin may be employed. The methods for immunization of animals and the preparation and purification of antibody is performed according to standard laboratory procedures and are known to those skilled in the art. Similarly, the methods of developing monoclonal antibodies are performed according to standard laboratory procedures and are known to those skilled in the art.
[0055] The microparticles may be coated with the antibody by passive adsorption, by chemical conjugation such as covalent binding, or through binding to an intermediate agent such as to Protein A-coated microparticles. The methods for coating microparticles are performed according to standard laboratory procedures and are familiar to those skilled in the art.
[0056] When the test sample comes into contact with the antibody coated microparticles the antibody binds any albumin present. The microparticles continue to migrate across the membrane until they reach the band of anti-albumin antibody fixed to the membrane. Any microparticles containing bound albumin become bound to the fixed band of anti-albumin antibody to form a visible band. The density of the band formed is directly proportional to the amount of albumin present in the blood sample. The density of the band is measured using a reflectance spectrometer for colored microparticles or a fluorometer for microparticles tagged with a fluorescent compound. The measurements are used to calculate the percentage of glycated albumin compared to total albumin in the blood sample.
[0057] In order to verify that the test strips are functioning correctly each test strip has an additional band of fixed reagent located distal to the test band. For the test strip, this control band is composed of antibody directed against the species antibody that was used to coat the microparticles. For example, if rabbit anti-human albumin antibody was used to coat the microparticles then the control band uses another species such as goat or sheep antibodies directed against rabbit IgG immunoglobulin. The antibodies in the control band bind to the excess unreacted antibody coated microparticles that were not bound to the test band but continued to migrate across the membrane until bound by the control reagent. The intensity of the control band is measured using a reflectance spectrometer or fluorometer and the data is used to determine if the test is performing correctly.
EXAMPLE 3
The Measuring Instrument
[0058] The measuring instrument shown in FIG. 4 a is a reflectance spectrometer and is composed of the following components: A detector ( 10 ) calibrated to read the reflectance of the microparticles fixed to the glycated albumin band on the glycated albumin test strip; a detector ( 11 ) calibrated to read the reflectance of the microparticles fixed to the control band on the glycated albumin test strip; a detector ( 12 ) calibrated to read the reflectance of the microparticles fixed to the total albumin band on the total albumin test strip; a detector ( 13 ) calibrated to read the reflectance of the microparticles fixed to the control band on the total albumin test strip; a computing chip and electronic circuitry ( 14 ) to collect the data from the detectors and to calculate the result.
[0059] The calculations are based on a mathematical algorithm and a reference standard curve. The standard curve is derived from value assigned standards and the instrument is precalibrated at the manufacturing facility before it is distributed. The result is expressed as the percent of glycated albumin compared to total albumin and displayed on a liquid crystal display ( 15 ). Successive results obtained over a period of time are stored in the instrument and can be retrieved on demand and displayed in numerical format or in graphical format. Typically, the result will be displayed along with the date of the test. The user may then select to have all the previous stored test results and their date displayed, or have all the results presented as a graph so that any trends can be identified. In order to enter commands to the internal computer the instrument may contain either buttons or a keyboard on its exterior case.
[0060] The results can also be downloaded via an external port to an external computer and/or printed on an external printer ( 16 ). The instrument's electronics are powered by an internal battery ( 17 ) and/or external power source ( 18 ). The components are housed in a rigid exterior case ( 19 ) with a window ( 20 ) for the display monitor and an aperture ( 21 ) for inserting the test cassette.
[0061] Alternatively, the measuring instrument may be a fluorometer ( FIG. 4 b ) that measures the density of aggregated microparticles that have been tagged with a fluorescent dye such fluorescein or rhodamine. The fluorometer is composed of the following components: A detector ( 22 ) calibrated to read the fluorescence of the microparticles fixed to the glycated albumin band on the glycated albumin test strip; a detector ( 23 ) calibrated to read the fluorescence of the microparticles fixed to the control band on the glycated albumin test strip; a detector ( 24 ) calibrated to read the fluorescence of the microparticles fixed to the total albumin band on the total albumin test strip; a detector ( 25 ) calibrated to read the fluorescence of the microparticles fixed to the control band on the total albumin test strip; a computing chip and electronic circuitry ( 26 ) to collect the data from the detectors and to calculate the result. Using fluorescein tagged microparticles as an example, the excitatory beam of light (492 nm wavelength) is projected onto the test bands and onto the control bands, and the emitted light from each band is individually read by the corresponding detectors sensitive to the wavelength (518 nm) of the emitted light. Alternatively, other fluorescent compounds may be used and the wavelength of the exciting beam and the wavelength of the resulting fluorescence to be measured is adjusted accordingly.
[0062] The calculations are based on a mathematical algorithm and a reference standard curve. The standard curve is derived from value assigned standards and the instrument is precalibrated at the manufacturing facility before distribution. The result is expressed as the percent of glycated albumin compared to total albumin and is displayed on a liquid crystal display ( 27 ). Successive results obtained over a period of time are stored in the instrument and can be retrieved on demand and displayed in numerical format or in graphical format. Typically, the result is displayed along with the date of the test. The user may then select to have all the previous stored test results and their date displayed, or have all the results presented as a graph so that any trends can be identified. In order to enter commands to the internal computer the instrument may contain either buttons or a keyboard on its exterior case.
[0063] The results can also be downloaded via an external port to an external computer and/or printed on an external printer ( 28 ). The instrument's electronics are powered by an internal battery ( 29 ) and/or external power source ( 30 ). The components are housed in a rigid exterior case ( 31 ) with a window ( 32 ) for the display monitor and an aperture ( 33 ) for inserting the test cassette.
[0064] In one embodiment of this invention, the test cassette is designed to enclose two test strips arranged in a parallel fashion ( FIG. 1 ) and the sample application well is constructed so that the test sample fluid can migrate across both test strips simultaneously. However, other test cassette configurations may be employed using the same principles described in this invention and are considered to be within the scope of this invention. For example, the sample application well may be centrally located with the glycated albumin test strip and the total albumin test strip pointing outward in a radial direction. FIG. 5 shows the test strips arrangement as diametrically opposite to each other and FIG. 6 shows the test strips to be at an angle to each other. In these examples the test cassette is in the shape of a rectangular or square configuration. The aperture in the measuring instrument for inserting these cassettes is adjusted to accommodate the shape of these cassettes.
[0065] In an embodiment of the present invention, the measuring instrument is a reflectance spectrometer which measures a particular wavelength of the light reflected from the colored microparticles. The amount of reflected light measured at the test band and control band sites is directly proportional to the density of the aggregated microparticles at each site
[0066] Alternatively, a fluorometer may be used as the measuring instrument. In this example, the microparticles are tagged with an internal fluorescent dye such as fluorescein or rhodamine red. The fluorescence-tagged microparticles are excited at one wavelength of light which causes them to fluoresce at a different wavelength of light. The amount of fluorescence measured at the test band and control band sites is directly proportional to the density of the aggregated microparticles at each site.
[0067] In another embodiment of the present invention, the measuring instrument is of small size, compact and lightweight. In general, it is similar in appearance and design to the various handheld glucometers in common usage. Such variations are cosmetic in nature and are considered to be within the scope of this invention.
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A rapid immunochromatographic assay system is provided for measuring the amount of glycated albumin in a blood sample relative to the total level of albumin in the sample. The assay system is comprised of a disposable cassette that contains the test strips and testing reagents, and a measurement device that automatically reads, calculates and displays the test results over a period of time. The test cassette contains two test strips that are used to measure glycated albumin and total albumin respectively. The strips are contiguous beneath the single sample application well so that the same sample is tested simultaneously by both test strips. Part of the sample will migrate thru the glycated albumin test strip where it will react with the glycated albumin test reagents to yield a glycated albumin result, while part of the sample will migrate thru the total albumin test strip where it will react with the total albumin test reagents to yield a total albumin result. The test cassette is placed within a measuring device such as a reflectance spectrometer or fluorometer, that reads, calculates and expresses the result as the percentage of glycated albumin relative to total albumin in the sample. The results of successive testing that are performed over a period of time are stored in the instrument's memory and displayed in a numerical or graphical format so that the individual's glycated albumin levels can be monitored over time.
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BRIEF DESCRIPTIONS OF THE INVENTION
[0001] This invention relates to a quadrupole ion trap and method, and more particularly to an ion trap in which shim electrodes compensate for electric potential faults introduced by apertures drilled into the entrance and exit end caps.
BACKGROUND OF THE INVENTION
[0002] An ion trap, in its most common configuration, is composed of a central ring electrode and two end cap electrodes. Other quadrupole ion trap configurations are described in U.S. Pat. No. 5,420,425. Generally, each electrode has a hyperbolic surface facing an internal volume known as the trapping volume. The trapping volume also serves as an analyzing space in which selected ions are retained and sequentially ejected, based upon their mass and charge. It also serves as a reaction volume, in which fragmentation of charged particles is caused by both collisions and interactions with specific fields. When a radio frequency (RF) voltage is applied between the ring and end cap electrodes, a quadrupolar potential is induced within the trapping volume. Generally, each of the end caps has one or more holes drilled into the center for the purpose of introducing ions or electrons into the trapping volume through the entrance end cap and for ejecting ions from the trapping volume to an external detection system through the exit end cap. Ions introduced into or formed within the trapping volume will or will not have stable trajectories, depending upon their mass, charge, the magnitude and frequency of the applied voltages, and the dimensions and geometry of the three electrodes.
[0003] Quadrupole ion trap potentials deviate from the ideal quadrupolar potential for two reasons: 1) because of holes drilled into the end caps, and 2) because the shapes of the electrodes have finite values. These effects are referred to as electric potential faults.
[0004] The electric potential deviation results in both peak broadening and, in some cases, a shift in measured ion mass from the theoretical mass values. Several schemes have been used and proposed to neutralize electric potential fault effects upon motion of the trapped ions. Franzen et al. U.S. Pat. No. 5,468,958 describes a quadrupole ion trap with switchable multipole fractions, which can be used to correct the electric potential errors due to the finite size of the electrodes.
[0005] Electric potential deviations due to the finite size of the trap electrodes are relatively insignificant compared to the deviations caused by the holes used to inject and eject ions. One method for correcting the deviations due to the holes is to stretch the spacing of the end cap electrodes from the ring electrode beyond the theoretical spacing predicted by solving the equations of motion of charged particles contained within the trapping volume
[0006] A different approach has been taken by Shimadzu Corporation in U.S. Pat. No. 6,087,658, in which they have mechanically modified the end cap electrodes with a bulge at the internal end of each hole. The stated purpose of the bulge is that it corrects the deviation in the electric potential from the pure quadrupole electric potential by controlling the deviation of the electric potential around the central end cap hole.
OBJECTS AND SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a quadrupole ion trap in which electric potential faults are minimized.
[0008] There is provided a quadrupole ion trap of the type including a ring electrode and first and second end cap electrodes which define a trapping volume. The end cap electrodes include central apertures for the injection of ions or electrons into the trapping volume and for the ejection of stored ions during analysis of a sample. Electric potential faults in the RF trapping potential are compensated by shim electrodes carried within the central apertures and electrically insulated from the end cap electrodes.
[0009] In another embodiment of the invention, there is provided a linear quadrupole ion trap with four electrodes, each divided into one or more sections. One or more apertures are provided for ejection of ions during sample analysis. Electric potential faults in the RF trapping potential are compensated by shim electrodes carried within the apertures and electrically insulated from the adjacent electrodes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and other objects of the invention will be more clearly understood from the following description when read in connection with the accompanying drawings of which:
[0011] [0011]FIG. 1 schematically shows a conventional ion trap mass spectrometer.
[0012] [0012]FIG. 2 schematically shows an ion trap mass spectrometer with improved ion trap electrodes.
[0013] [0013]FIG. 3 is a graph of the error of the RF potential within a conventional ion trap generated using the program SIMION 3d Version 6.0
[0014] [0014]FIG. 4 is a graph of the error of the RF potential within a quadrupole ion trap with the shim electrodes having the same RF voltage applied thereto as the corresponding end cap.
[0015] [0015]FIG. 5 is a graph of the error of the RF potential within a quadrupole ion trap, with the shim electrodes having an RF voltage applied thereto which is 9% of the amplitude, but 180 degrees out of phase with the RF potential applied to the ring electrode.
[0016] [0016]FIG. 6 shows a mass spectrometer with a trap in accordance with another embodiment of the invention.
[0017] [0017]FIG. 7 shows an ion trap mass spectrometer in accordance with still another embodiment of the invention.
[0018] [0018]FIG. 8 schematically shows a linear ion trap mass spectrometer with improved ion trap electrodes.
DESCRIPTION OF THE INVENTION
[0019] Referring to FIG. 1, an ion trap mass spectrometer in accordance with the prior art is schematically illustrated. The mass spectrometer includes an ion trap 1 having a ring electrode 12 and end cap electrodes 13 and 14 . The electrode 13 includes an aperture 16 through which electrons formed by the electron gun 17 may be injected into the ion trap volume to ionize a sample. Alternatively, the sample may be ionized externally and the ions injected into the trap through the aperture 16 . In either event, ions of interest are introduced into the trap. The lower end cap 14 includes an aperture 18 , which allows ions to escape the trapping volume 19 of the ion trap. These ions are then detected by the electron multiplier 21 . The output of the electron multiplier is pre-amplified by pre-amplifier 22 and supplied to an associated processor (not shown). A fundamental RF generator 23 applies suitable voltage between the ring electrode 12 and end caps 13 and 14 to generate quadrupole trapping potentials within the ion trap volume 19 . The potentials trap ions over a predetermined mass range of interest. The RF generator is controlled via a computer controller 24 . The end caps are connected to the secondary of a transformer 26 , which applies supplemental or excitation voltages across the end caps. The primary of the transformer 26 is connected to supplemental RF generator 27 . Operation of the supplemental RF generator is controlled by the computer controller 24 .
[0020] In one mode of operation (MS), to determine the mass of ions trapped in the trapping volume by the RF trapping potentials, the supplemental voltage is employed to cause ions having a mass excited by a given frequency of supplemental RF voltage to be ejected from the ion trap through the aperture 18 where they are detected by the electron multiplier 21 . In another mode of operation (MS/MS), the supplemental voltage has a frequency which excites parent ions. The energy applied to the end caps causes a trapped parent ion to undergo collision-induced dissociation (CID) with background neutrals. A second sequential supplemental RF pulse is then applied and the daughter ions of interest are ejected for detection.
[0021] In accordance with the present invention, the ion trap end cap electrodes are modified by providing shim electrodes within the apertures 16 and 18 to compensate for electric potential faults in the quadrupolar ion trap. Referring particularly to FIG. 2, wherein the same reference numbers have been used for like parts, shim electrodes 41 and 42 are associated with the end cap electrodes 13 and 14 , respectively. The shim electrodes include a cylindrical portion 43 , 44 which extend into and are spaced from the apertures 16 and 18 of the end cap electrodes 13 and 14 . The cylindrical shim electrodes include apertures 46 and 47 . Aperture 46 permits the introduction of ions from an ion source or electrons which ionize sample within the trap volume 19 . The aperture 47 permits the ejection of ions from the ion trap into the electron multiplier. In one mode of operation, an RF voltage at the frequency of the fundamental RF trapping voltage and 180 degrees out of phase therewith is applied to the shim electrodes by the shim lens RF generator 48 . In FIG. 2, the end of the cylindrical shim electrode is flush with the inner surface of the end cap electrodes. However, the ends of shim electrodes may extend into the trapping volume, FIG. 6, or may be indented, FIG. 7.
[0022] A computer simulation was carried out using SIMION-3D, Version 6.0 program and the errors of the electric potentials inside a quadrupole ion trap were plotted for three examples: 1) with apertured end cap electrodes only, 2) with apertured end plate electrodes with flush cylindrical shim electrodes, both maintained at the same RF voltage, and 3) with flush shim electrodes with, however, a voltage applied to the shim electrodes 180 degrees out of phase with the RF voltage applied to the ring electrode and having a magnitude less than that of the fundamental RF voltage. The electric potentials inside the ion trap, especially at the region of the holes in the end cap, are shown for a 0.060 in. hole in each end cap without a shim electrode and with a shim electrode having an internal diameter of 0.060 inches and an outer diameter of 0.080 inches placed in each 0.100 in. hole with one end flush with the surface of the end cap. A fundamental RF voltage of approximately 1,000 volts was applied. The shim voltage was between 50 and 100 volts. FIG. 3 shows substantial electric potential faults 51 near the end caps caused by the entrance and exit apertures, FIG. 4 shows little improvement of electric potential faults 52 , but FIG. 5 shows a substantial improvement of electric potential faults 53 . Thus, it is clearly apparent that the shim electrode with a proper voltage has a substantial effect on the configuration of the electric potentials within the ion trap volume 19 .
[0023] We have found that, in certain instances, greater improvement can be achieved by having the shim electrodes extend into the trapping volume beyond the surface of the end cap electrodes as shown at 56 , FIG. 6. In other instances improvements have been found where the ends of the shim electrodes are indented into the end cap electrode hole as shown at 57 , FIG. 7. Thus, the configuration of mechanical modifications with shim electrodes extended, flush or indented, and electrical modifications with a localized quadrupolar potential 180 degrees out of phase with that applied to the ring electrodes have provided substantial improvement of the electric potentials within the trap volume, particularly at the end cap apertures.
[0024] Quadrupole ion traps of other configurations, as described in U.S. Pat. No. 5,420,425, are also susceptible to electric potential faults caused by apertures in the electrodes. One specific configuration, the linear quadrupole ion trap, is shown schematically in cross section in FIG. 8. In this specific configuration, the RF trapping voltage produced by RF generator 23 is applied to only two of the opposed electrodes 61 and 62 . Electrodes 63 and 64 are connected to the secondary of transformer 26 , which applies supplemental or excitation voltages. Electrode 64 includes an aperture 65 normally used for ejection of ions to detector 21 . Electrode 64 is modified by providing a shim electrode 66 connected to the shim lens RF generator 48 to compensate for electric potential faults. The shim electrode includes aperture 67 for ion ejection. It is apparent from the teaching of U.S. Pat. No. 5,240,425 that the elongated electrodes may be curved.
[0025] One can also envision mass shifts which will be compound and shim voltage dependent. By sweeping the shim voltage magnitude while observing mass shifts, compound identity information may be obtained. Thus, it has been illustrated that with a proper combination of shim placement and applied voltage magnitude, mass shifts in compound studies can be reduced to essentially zero.
[0026] The foregoing descriptions of specific embodiments of the present invention are presented for the purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed; obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.
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There is provided a quadrupole ion trap mass spectrometer of the type having a plurality of ring electrodes and defining a trapping volume. The quadrupole potential faults arising from apertures in the electrodes are corrected by an apertured shim electrode placed within and spaced from the walls of the electrode apertures.
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a direct dispensing and self-contained surgical suture package. The package can comprise a first part having a strippable envelope, and a second part self-contained therein.
A direct dispensing and self-contained surgical suture package has been invented. In one embodiment, the package comprises a back panel; at least one side flap foldably connected to the back panel; a label flap foldably connected to the back panel and adjacent to the at least one side flap; and means for self-containing the direct dispensing surgical suture package. In a specific embodiment, the package comprises two opposite side flaps. In another embodiment, the package has a strand flap foldably connected to the back panel and opposite the label flap. In still another embodiment, the package has at least one retention slip contained in the at least one side flap.
In a more specific embodiment, the package comprises a back panel; two opposite side flaps foldably connected to the back panel; a label flap foldably connected to the back panel and adjacent to the side flaps; and means for attaching the label flap to the flaps. In one embodiment, the package has a strand flap foldably connected to the back panel and opposite the label flap. In another embodiment, the package has at least one retention slit contained in at least one side flap.
Another direct dispensing and self-contained surgical suture package has been invented. In this embodiment, the package comprises a first and second part. The first part has a strippable envelope. Self-contained within the first part is the second part. The second part has a back panel; at least one side flap foldably connected to the pack panel; a label flap foldably connected to the back panel and adjacent to the at least one side flap; and a chevron flap foldably connected to the label flap and opposite the back panel. The at least one side flap is folded onto the back panel, the label flap is at least partially folded onto the side flap and the chevron flap is inserted between the side flap and back panel. In a specific embodiment, the package has two opposite side flaps. In another specific embodiment, the package has a strand flap foldably connected to the back panel and opposite the label flap. In a further embodiment, the package has at least one retention slit contained in the at least one side flap.
DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 6 show the folding sequence of the suture package of this invention.
FIG. 1 is a front view of an unfolded suture label with six panels;
FIG. 2 is a front view of FIG. 1 showing the strand cover panel 1 folded onto back panel 2;
FIG. 3 is a front view of FIG. 2 showing the front panel 3 and tuck panel 6 folded onto the back panel 2;
FIG. 4 is a back view of FIG. 3 inverted one hundred and eighty degrees and showing the side panels 4 and 5 folded onto the strand cover panel 1;
FIG. 5 is a back view showing the front panel 3 and tuck panel 6 of FIG. 4 rotated three hundred and sixty degrees, and then folded onto the side panels 4 and 5;
FIG. 6 is a back view of FIG. 5 showing the panel 6 tucked between the side panels 4 and 5, and the strand cover flap 1; and
FIG. 7 is a perspective view showing the preferred loading of the suture package of FIG. 6 into a strippable envelope.
DETAILED DESCRIPTION
The suture label is and remains, before, during, and after suture dispensing, a single piece. The needle of the suture is visible within the label for easy access and removal of the suture from the label. The exposed needle is grasped with the hand or with a needle holder and by pulling gently and evenly, the suture is dispensed.
Referring to FIGS. 1 and 4 to 6, the label is designed to protect the suture strand from being in contact with the needle, therefore preventing the suture strand from being damaged. The needle holding slit(s) 7 located in the side panel 4 can be used to hold either needled or non-needled sutures.
Referring to FIG. 1, the label is manufactured from sterilizable 90 pound offset paper capable of withstanding alcoholic solution, heat, steam, gas or radiation sterilization without adverse affects. The paper may be coated with about 1/2 mil polyethylene so as to make it heat sealable. Such paper is known in the trade, and is readily available. Sealing, if desired, can be accomplished by heat sealing dies, or by ultrasonic means.
Referring to FIG. 6, the self-contained label can be placed into a strippable envelope. The envelope materials, the methods of manufacturing such materials, and the method of loading the label into the envelope are well known in the suture packaging art, e.g. as described in U.S. Pat. No. 4,069,912 FIG. 1 entitled "Suture Package", issued Jan. 24, 1978 to S. Black and D.C. MacRitchie, or U.S. Pat. No. 4,063,638 FIG. 1 entitled "Direct Dispensing Packaging of Surgical Sutures", issued Dec. 20, 1977 to R.K. Marwood. These patents are incorporated by reference. Referring to FIG. 1 of these patents, the strippable envelope 31 is peeled off. The peeling or stripping action is enhanced by the size and shape of the folded label in relation to the envelope 31.
Referring again to FIG. 6 of this invention, the suture label is self-contained. Also, after the suture is dispensed from the label, the label continues to be self-contained and in one piece. Therefore, only the surgical suture needle and/or strand(s), and the self-contained suture label are added to the operating area. Related hazards are thus minimized and accountability is simplified.
FIG. 1 shows a preferred suture label. The label is cut out and scored from a sheet of sterilizable paper which may be coated with polyethylene for heat sealing.
As shown in FIG. 1 to 4, the label consists of a back panel 2. Attached to the back panel is a strand cover panel 1, label cover or front panel 3, tuck panel 6, and side flaps 4 and 5. A retention slit or slits 7 located on the side panel 4 can anchor a needle of an appropriate size and shape in the desired orientation and position between the strand cover flap 1 and the side flaps 4 and 5. For a straight needle of sufficient length, another retention slit or slits 8 located on the other side panel 5 can be used to anchor the pointed end. For a curved needle, the desired orientation is usually such that the arc of travel from the barrel to the point is in a counter clockwise direction. The barrel of the needle protrudes through the retention slit on the panel 4, which is exposed through the round cutout in the panel 3 (shown in FIG. 6) for direct dispensing by hand or by needle holders. Alternatively, the retention slit or slits 7 can be used for a non-needled suture (or sutures).
Referring to FIG. 4, the side panels 4 and are folded onto strand cover panel 1 for the purpose of loading the suture strand (or strands) into the label. In this configuration, the suture strand(s) are loaded into the label between the strand cover panel 1 and back panel 2. The configuration of the strand(s) in the label can be any series of loops or coils that allow the strand(s) to dispense freely from the label without tangling. A preferred strand configuration is that termed a FIG. eight. The loading of a suture strand into a label using the figure eight configuration is known in the prior art.
Referring to FIGS. 4 and 5, the front panel 3 is rotated and then folded onto the side panels 4 and 5. Referring to FIG. 6, the tuck panel 6 is tucked between the side panels 4 and 5, and the strand cover flap 1. In this configuration, the suture package is and remains self-contained and as one piece before, during and after dispensing of the suture.
FIG. 6 shows the label completely assembled, with the tuck panel 6 inserted (tucked) between the side panels 4 and 5, and the strand cover panel 1.
FIG. 7 describes the loading of the self-contained, one piece suture package of FIG. 6 into a strippable envelope 10. The loading of the suture package shown in FIG. 6 into the envelope 10 is known in the prior art, e.g. see the U.S. patents cited above, which are incorporated by reference.
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This invention relates to a direct dispensing and self-contained surgical suture package. The package can comprise a first part having a strippable envelope, and a second part self-contained therein.
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BACKGROUND OF THE INVENTION
The present invention relates to a hinge used in connecting a glass cover to a record player.
BRIEF DESCRIPTION OF THE PRIOR ART
Heretofore, a hinge for a glass cover of a record player has generally consisted of a pair of hinge plates designed to receive the rear end of a glass cover having screw bores so that the glass cover could be tightly fastened to the hinge by means of screws which are fastened across the two hinge plates through the mounting holes of the glass cover so as to sandwich the glass cover between the hinge plates. In this conventional construction, a considerable load is imposed on the area around the mounting holes of the glass cover during repair work or during the opening and closing motion of the glass cover, which can cause breakage. In addition, this conventional construction requires forming mounting holes in the glass cover which is difficult.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a hinge for pivotally securing a glass cover to a record player cabinet which is capable of securing the glass cover to the hinge without using mounting holes in the glass cover. To this end, according to the inventive concept, there is provided a hinge having a cover retainer which has a pair of hinge plates, one of the hinge plates having side plates pivotally secured to a hinge pin and which is provided with a pair of anchoring lugs; while the other hinge plate has one side portion inserted between the side plates of the one hinge plate and, both side portions of the other hinge plate are engaged substantially at the center portion by the anchoring lugs so as to prevent this other hinge plate from rotating away from the one hinge plate. At least one of the pair of hinge plates has screws for securing the rear end portion of the glass cover inserted into the cover retainer. This arrangement permits the glass cover to be secured to the cover retainer of the hinge without the necessity of forming a mounting hole in the glass cover.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a hinge for pivotally securing a cover;
FIG. 2 is a front elevational view of the hinge shown in FIG. 1;
FIG. 3 is a left side elevational view of the hinge shown in FIG. 1;
FIG. 4 is a left side elevational view of the hinge connected between a cabinet and a glass cover; and,
FIG. 5 is an exploded perspective view of the hinge contemplated herein.
DETAILED DESCRIPTION OF THE INVENTION
The best mode for carrying out the invention will be described with reference to the drawings. Referring to FIGS. 1 to 3, a reference numeral 1 denotes a hinge bracket which is formed of an iron sheet bent so that it has a convex shape, comprising a base plate portion 1a, two side plates 1b,1b, attaching plates 1c, 1c and top plate 1d. A hinge pin 8 is attached to the upper end portions of the side plates 1b,1b. The side plates 1b,1b are slightly bent inwards at their mid portions to form a shelf-like portion to hold the top plate 1d. Further, vertical grooves 1e,1e are formed in the side plates 1b,1b. Attaching bores 1f,1f are formed in the attaching plates 1c,1c.
A spring case designated 64 reference numeral 2 is formed also of an iron sheet bent to have a substantially bracket-shaped cross-section and to have a base plate portion 2a, two side plate portions 2b,2b and a bottom plate portion 2c. Guide projections 2d,2d are formed substantially at center portions of the side plate portions 2b,2b so as to project inwards. The lower ends of the side plates 2d,2d are bent slightly inwards to hold the bottom plate 2c.
A hinge bracket 1 is held by the spring case 2. The aforementioned guide grooves 1e,1e receive guide projections 2d,2d of the spring case 2. A friction member 3 such as fibers of the like is inserted between the side plates 1b and 2b at each side through the guide projections 2d,2d. A spring 4 having a tension somewhat smaller than the weight of the glass cover is placed so as to act between the top plate 1d of the hinge bracket 1 and the bottom plate 2c of the spring case 2.
A reference numeral 5 designates a cover retainer formed by a pair of hinge plates 6,7. The front end of the cover retainer 5, when it is not used for securing the cover, is generally biased upwardly through the medium of the spring case 2, by means of the spring 4. In the drawings, however, the cover retainer 5 is illustrated to take a depressed position overcoming the force of the spring 4 to assume a position perpendicular to the hinge bracket 1.
One of the hinge plates in the upper position is formed by a base plate 6a having reinforcement ribs 6c,6c, and two side plates 6b,6b having shelf-like anchoring lugs 6d,6d. A part of the base plate 6a is deflected to project into the space between the side plates 6b,6b to prevent the latter from being bent inwardly.
Another hinge plate 7 is bent at its side surface to have a crank-like shape as shown in FIG. 4 to form an insertible fixing portion 7a and a cover receiving portion 7b. The insertible fixing portion 7a is inserted between the side plate 6b,6b of the hinge plate 6 and is fixed to the inner bottom portion of the base plate portion 6a of the hinge plate 6 by welding or the like measure. The cover receiving portion 7b at about the center portion of the hinge plate 7 is retained by the anchoring lugs 6d,6d and, then, after attaching fixing screws 9,9 to the cover receiving portion 7b, a packing 10 composed of an iron plate 10a and a rubber plate 10b is superimposed on to the iron plate 10a and is placed on the side of the upper surface of the hinge plate 7 opposite to the hinge plate 6.
The side plate portions 6b,6b of the hinge plate 6 formed by the cover retainer 5 are pivotally secured to the hinge pin 8 which is attached to the upper end portions of the side plates 1b,1b of the hinge bracket 1, and is connected also to the side plates 2b,2b of the spring case 2 by means of a pin 11.
The attaching of the glass cover B to the cover retainer 5 is made in the following manner: The rear end portion of the glass cover B is placed between the hinge plate 6 and the packing 10. Thereafter, as the attaching screws 9,9 are tightened, the rear end portion of the glass cover B is pressed against the hinge plate 6 by pressure applied through the packing 10 held by the crank-shaped insertible fixing portion 7a attached to the inside of the base panel 6a of the other hinge plate 6. By this construction, the glass cover B can be secured to the hinge, without being provided with any mounting hole.
As another form of the cover retainer 5, insertible fixing portion 7a of the hinge plate 7 is wound round the hinge pin 8 or, alternatively, the insertible fixing portion is made to contact the hinge pin 8. Such an alternative arrangement provides an equivalent effect to that produced by the described embodiment.
It is possible to secure the rear end of the glass cover B to the cover retainer 5, even if the packing 10 is omitted. However, the use of packing consisting solely of the rubber plate is effective in preventing the withdrawal or dropping of the glass cover B. Further, the composite packing composed of the iron plate 10a and the rubber plate 10b superimposed one on the other effectively distributes the pressure when the fixing screws 9,9 are tightened, so that the glass cover B is protected from local concentration of pressure which might be generated to cause the breakage of the glass cover.
Another advantage is as follows. In the conventional hinge of the kind described, the spring case 2 and the hinge plate 6 are connected to each other by means of eyelets no frictional member nor resilient member is interposed between the overlapping side plates 2b,2b and 6b,6b. According to the invention, the eyelet is substituted by a caulked pin 11 which is inserted through a frictional member 12 such as of fibers and a resilient member 13 such as a spring washer interposed between overlapped portions of the side plates 2b,2b and 6b,6b. At the same time, the head 11a of the pin 11 is caulked at a suitble pressure. As a result, a frictional resistance is caused during the rotation of the hinge plate 6 so that the opening and closing motion of the glass cover B is smooth and an abrupt jumping up of cover glass cover B is avoided even if the force of spring 4 increases.
In the conventional construction, a spring retainer for retaining one end of the spring 4 is separetely suspended in the spring case 2. Alternatively, a spring rod is provided on the bottom plate 2c of the spring case 2 to extend upward through the bottom plate of the hinge bracket 1, and the spring is disposed to act between the bottom plate of the bracket 1 and a spring retainer plate screwed to the upper end of the screw rod. According to the invention, however, the spring 4 is disposed to act between the top plate 1d of the hinge bracket 1 and the bottom plate 2c of the spring case 2 to simplify the construction. This arrangement does not cause undersirable bending of the top plate 1d and the bottom plate 2c bearing the spring force of the spring 4, because the top plate 1d and the bottom plate 2c are held by the shelf-like portion provided on the side plates 1b,1b and the lower ends of the side plates 2b,2b, respectively.
FIG. 4 shows an example of use of the hinge in accordance with the invention. The attaching plates 1c,1c of the hinge bracket 1 are fitted on the upper rear end portion of the cabinet A of an instrument such as a record player or the like, by means of screws 14,14. At the same time, the rear end portion of the glass cover B is secured to the cover retainer 5.
In FIG. 4, the closed condition of glass cover B is represented by full line. In this condition, the spring 4 is in the fully compressed state to press the bottom plate 2c of the spring case 2 downward so as to cause a tendency of counter-clockwise rotation of the hinge plate 6 of the cover retainer 5 to open the glass cover B. However, since the spring force of the spring 4 is overcome by the weight of the glass cover B, the natural opening of the glass cover B is avoided.
Then, as the glass cover B is opened, the cover retainer 5 is rotated counter-clockwise, and the spring case 2 is moved downward as the guide projections 2d,2d are guided by the guide grooves 1e,1e, so as to open the glass cover B. In this condition, the spring 4 is exerting a force to cause a tendency of counter-clockwise rotation of the hinge plate 6 of the cover retainer 5, through the medium of the spring case 2, so that the weight of the glass cover B is nullified by this biasing force to negate the feeling of weight of the glass cover B.
The glass cover B thus opened is stopped as the caulked pin 11 abuts against one side of the upper portions of the side plates 1b,1b of the hinge bracket 1, so that a further movement of the glass cover B in the opening direction does not occur. Thus, the opened glass cover B is maintained by the force of the spring 4.
For closing the glass cover B from the opened condition, the members and parts operate in the reverse manner to the opening operation. In this case, as the glass cover B is not suddenly closed by the spring force of the spring 4 which acts to negate the weight of the glass cover B, the undersirable breakage of the glass cover B is eliminated.
During the opening and closing of the glass cover B, a moderate braking effect is produced by the frictional contact of the resilient member 12 and the frictional member 13 interposed between the side plates 6b,6b of the hinge plate 6 and corresponding side plates 2b,2b of the spring case 2, as well as the friction members 3,3 interposed between the mid portions of side plates 2b,2b of the spring case 2 and the corresponding side plates 1b,1b of the hinge bracket 1. As a result, the opening and closing operation can be made without any jolt or rattle. At the same time, the undesirable jumping up of the cover due to the spring force which becomes annoying in some opening positions of the cover B is avoided. And it is possible to stabilize the glass cover at an intermediate opening angle at which the spring force of the spring 4 and the weightof the glass cover B balance.
The object of the invention can be achieved by adopting other constructions of parts of the hinge besides the cover retainer 5. For instance, it is possible to modify the hinge of the described embodiment by the use of a torsion coiled spring, tensile coil spring and the like, or the hinge can be constructed even without using any spring.
The best mode for carrying out the invention, however, is obtained by applying the cover retainer 5 to the hinge of the above-described construction.
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A hinge arrangement for a record player to properly distribute the load over a glass cover and avoid imposing an unduly large load around the mounting holes. There is provided a cover retainer with a pair of hinge plates having side plate portions which define a receiving space for a pair of anchoring lugs and a hinge pin, on one of said hinge plates. The side portions on the other hinge plate are received by and fixed in said defined space and retained at the center point by the anchoring lugs so as to prevent the other hinge plate from rotating back away from the one hinge plate. Attaching screws are provided on one of said hinge plates for fixing the cover inserted in the cover retainer.
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CLAIM OF PRIORITY
[0001] This application claims the priority of U.S. Ser. No. 61/076,159 filed on Jun. 27, 2008, the contents of which are fully incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to data analysis. More particularly, the present invention relates to an improved system and method for creating pivot tables.
BACKGROUND
[0003] Pivot tables have been provided in numerous spreadsheet programs for several years. A pivot table provides an efficient way to display and summarize data that is included in a database or in the data listing of a spreadsheet by automatically displaying fields of the data in a manner determined by the user and by determining and displaying selected parameters such as the sum, variance, count, standard deviation, etc. of selected data fields. Relatively structured spreadsheets that already have subtotals, data entry cells, and summaries of fields are generally not appropriately expressed using a pivot table. In contrast, any data included in a database that can be queried from within the spreadsheet, or spreadsheet data comprising lists that are not already summarized are ideal candidates for the power of pivot tables.
[0004] The task of comparing standards to actual data (“actuals”) is common in many fields, including medicine, manufacturing, and project financial management. Data related to the reaction of test subjects to medicine or therapies must be compared to standards to determine if the medicine sufficiently treats the condition it was supposed to. In addition, actuals data pertaining to side effects must be compared to standards for allowable side effects, in order to determine if the side effects are not severe enough to outweigh the benefits of the medicine, and allow the medicine to be sold to the public.
[0005] In manufacturing, each manufactured unit has a specification that indicates the desired attributes of the unit (physical dimensions, physical qualities—hardness, softness, springiness, electrical quantities, performance qualities, etc. . . ). The manufactured units must be sampled, and the actual attributes measured, and the actual attributes compared to the specifications.
[0006] In project financial management, the actual costs and revenue incurred on a project must be compared to the budgets, schedules and forecasts for the project.
[0007] In standards vs. actuals analysis, by definition, the standards and actuals are related but dissimilar data. Some attributes may be shared or not shared. There may be a hierarchical parent-child relationship, or there may not be. A very powerful and flexible analysis and reporting tool is needed to compare standards to actuals. In addition, this analysis and reporting tool must be able to analyzed very large amounts of related, but dissimilar data. The additional ability to present graphical representations of the analysis and reporting would be of extreme usefulness.
[0008] Although pivot tables are a very powerful tool for processing and displaying data, they are best suited for accessing data that is in a single table format. Pivot tables can access “multiple consolidation ranges”, but the ranges are not actually separate, dissimilar tables.
[0009] The “single table” data management approach is discussed in U.S. Pat. No. 6,754,666, for use in hierarchical data tables. However, there the “single table approach” was disclosed for use with hierarchical data tables and not disparate data tables as taught in the present invention. Moreover, the '666 patent listed many disadvantages for the “single table” approach. These disadvantages include:
1. Data tables that are very wide, and include a large number of fields, 2. The existence of a lot of wasted space, because the records will be for one of the data sets only, and the schema, or table structure of the single table, will include the fields for all the data sets. 3. Opportunity for errors in the data, because of the large amount of blank cells. It can be difficult to recognize if a cell is blank because it should be, or because the cell is in error. In addition, it may be difficult to determine if an occupied cell should be occupied or blank. 4. It is difficult to dynamically alter the structure of the database once it is populated with data.
[0014] Therefore, it is desirable to have an improved system and method for analyzing data via pivot tables that overcomes the aforementioned limitations.
SUMMARY OF THE INVENTION
[0015] The present invention provides an improved method for analyzing data with a pivot table. In particular, the present invention provides a single table approach that does not rely on any relationships between the tables, so the relationships between the tables can be ignored (for data management purposes), and attention can be placed on analyzing the data only. In particular, the present invention provides a method of combining related but dissimilar data into a single table in order for the data to be accessed by a pivot table.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIGS. 1-4 illustrate an exemplary prior art pivot table process.
[0017] FIG. 5 is a flowchart indicating process steps for performing the method of the present invention.
[0018] FIG. 6 illustrates an exemplary source table.
[0019] FIG. 7 illustrates an exemplary additional source table.
[0020] FIG. 8 illustrates a single table that combines the tables of FIG. 6 and FIG. 7
[0021] FIG. 9A is an exemplary pivot table 900 illustrating an analysis of actuals data.
[0022] FIG. 9B is an exemplary pivot table illustrating a standards-actuals comparison.
[0023] FIG. 10 is an exemplary pivot table illustrating a project management analysis.
DETAILED DESCRIPTION
[0024] To provide a context for the present invention, the basic fundamentals of a pivot table will be briefly explained.
[0025] The invention is a method comprising the steps of creating a single data table from at least two disparate data sets; activating a pivot table function, choosing at least two fields for a pivot table field list and using at least two fields from the pivot table field list to create a pivot table report.
[0026] FIGS. 1-4 show the basic steps of creating a pivot table. In FIG. 1 , a portion of the source data is shown in spreadsheet 102 . The data comprises five columns. Each column represents a different field (e.g. country, salesperson, etc. . . ). Each row represents a tuple of values for the five field set. For example, row 5 represents the tuple <USA, Leverling, 654.06, Jul. 15, 2003, 10251>.
[0027] FIG. 2 shows the pivot table wizard 106 similar to that of MICROSOFT EXCEL. Other spreadsheet programs may have a similar wizard feature. In the wizard, the five fields are shown in the pivot table field list 112 . These fields can be dragged to column region 116 , data region 118 or row region 120 on the pivot table.
[0028] FIG. 3 shows an exemplary pivot table 132 . To form this table, the salesperson field was dragged from the pivot table field list to the row area, and the order amount was dragged from the pivot table field list to the data area.
[0029] FIG. 4 shows some of the various options 136 provided by the pivot table. These options include features such as sum, count, average, maximum, minimum, and product, just to name a few. This is part of what makes pivot tables useful, as a variety of mathematical functions can be quickly applied to the desired data. When drop-down control 139 is selected, it provides the user a means to control which data items are displayed in pivot table 132 . For example, the user can elect to show only a particular salesperson or subset of salespeople shown in table 132 ( FIG. 3 ). In subsequent features of this disclosure, drop-down controls are referred to at various instances. However, for the sake of clarity in the drawings, additional drop-down controls are not indicated with a reference number, but are easily recognizable by the “upside down triangle” with a box.
[0030] FIG. 5 illustrates a flowchart 500 indicated process steps to perform the method of the present invention. In process step 505 , disparate data is examined. For the purposes of this disclosure, disparate data means that, among a plurality of data tables having a plurality of data fields, not all data fields are common across the plurality of data tables.
[0031] In process step 510 , identical fields are identified. These fields can be used as a basis for comparison in standards-actuals analysis. For example, a “part number” field may exist in a standards table that indicates design specifications for a part number, and may also exist in an actuals table that indicates measured dimensions of parts that have been produced.
[0032] In step 515 , comparative fields are identified. These are fields that are not common amongst the source tables that are forming the combined data, but have some semantic relationship. For example, in a standards table, a “design length” field may indicate the desired length of a part, whereas in an actuals table, a “measured length” field may indicate the actual length of a manufactured part. For standards-actuals analysis, it is desired to compare these fields, even though they are non-identical fields.
[0033] In step 518 , disparate data is combined. Identical fields are combined into single fields. Comparative fields remain separate fields.
[0034] In step 520 , a pivot table is created by activating a pivot table function. This may be performed via a “Wizard” application, such as that illustrated in FIGS. 1-4 . The creation of pivot tables via this method is well known in the field of spreadsheets.
[0035] In step 525 at least two fields are selected to create a pivot table report that shows the desired data. The pivot table options ( 136 of FIG. 4 ) can be selected to show the desired information, for example, average, or sum, to name a few.
[0036] FIG. 6 illustrates an exemplary source table 600 that contains standards information. In this example, the standards information is design data for a plurality of different bolts. Column 602 indicates the part number for each bolt type. Column 604 indicates the target design length for each part. Column 606 indicates the target design width for each part. Column 608 indicates the maximum design length. If a manufactured part exceeds the maximum design length then it is “out of specification” and rejected. Column 610 indicates the maximum design width. If a manufactured part exceeds the maximum design width then it is “out of specification” and rejected. Column 612 indicates the minimum design length. If a manufactured part is less than the minimum design length then it is “out of specification” and rejected. Column 614 indicates the minimum design width. If a manufactured part is less than the minimum design width then it is “out of specification” and rejected.
[0037] FIG. 7 indicates an exemplary additional source table 700 that contains actuals information for the parts indicated in FIG. 6 . Column 702 indicates the part number for each bolt. Column 724 is the actual length of a manufactured bolt. Column 726 is the actual width of a manufactured bolt. Column 728 is an indication of if the manufactured bolt is within the design specification limits. Column 730 is a manufacturing lot number. Column 732 indicates a particular production facility. Column 736 indicates a production manager.
[0038] FIG. 8 indicates a single data table 800 that combines the data of the tables of FIG. 6 and FIG. 7 . Therefore, single data table 800 contains data relating to both manufacturing standards as well as data relating to items actually manufactured. Note that, due to the size of the table, the data values are not indicated. However, the column reference numbers refer to those in FIG. 6 and FIG. 7 . Columns 602 and 702 both refer to the leftmost column of table 800 . In this case, columns 602 and 702 represent “identical fields.” That is, the “part number” field is present in both table 600 and table 700 , and represents the identical information for both source tables, and therefore is consolidated in the single data table. The other columns ( 604 , 606 , 608 , 610 , 612 , 614 , 724 , 726 , 728 , 730 , 732 , and 736 ) represent respectively indicated columns from FIG. 6 and FIG. 7 . The group of rows indicated by 834 contains data from table 600 . The group of rows indicated by 838 contains data from table 700 . Note that while for illustration purposes, only a small number for rows are shown, in practice, group of rows 834 and 838 may be populated with hundreds (for example, a single data table populated with 250 data values), or even thousands of data values—limited only by the capability of the spreadsheet program. It is important to note that tables populated with more than 250 data values begin to exceed the limits of human recognition and consequently create a need for the present invention. Thus, while the pivot table approach may be useful for tables having 250 data values or more, the pivot table method disclosed herein may be useful for larger tables populated with 2,500, 250,000 or 250 million values. In addition, the present invention is suitable for use with disparate data tables having from 1 to 100 columns, and from 1 to 1 million rows.
[0039] Also note that the source tables 600 and 700 that are combined in single data table 800 may themselves be spreadsheet tables, but can also be tables residing in a database that is accessible by the spreadsheet program.
[0040] FIG. 9A is an exemplary pivot table 900 illustrating analysis of actuals data. Column 902 represents the indication of standards or actuals data. In this case, the actuals data is selected. Column 904 indicates the production facility. Column 906 indicates the production manager. Column 908 represents the part number. Column 910 shows the average actual length of a particular part (bolt B) by facility and production manager. Column 912 shows the average actual width of a particular part (bolt B) by facility and production manager. Drop-down control 914 allows a user to enable only column 910 , only column 912 , or both columns, as is illustrated here. The user can view a variety of data for analysis. For example, if the user selects the drop-down control of column 908 , data selection box 944 corresponding to the part number field is displayed. Data selection box 944 has show all checkbox 945 , part A checkbox 946 , part B checkbox 948 , and part C checkbox 950 . OK button 952 accepts the options, and Cancel button 954 aborts the operation. In FIG. 9A , the part B checkbox 948 is the only one selected, and hence, only part B is shown in column 908 .
[0041] This technique provides valuable information to a stakeholder in a manufacturing operation. The following list shows just a few examples of such information, other types of information are possible, and within the scope of the present invention.
Indicate trouble with a particular manufacturing facility Indicate trouble with a particular production manager Indicate trouble manufacturing a specific part
[0045] By using the appropriate data selection boxes, the data can be viewed by multiple criteria very quickly, providing important strategic information to a production manager, vice president of operations, or other important stakeholder.
[0046] FIG. 9B is an exemplary pivot table 970 illustrating a standards-actuals comparison. Column 972 represents the part number. Column 974 shows the design (ideal) length for each part. Column 976 shows the design (ideal) width for each part. Columns 974 and 976 represent standards data. Column 978 indicates the count of units that were examined. Column 980 and 982 show the average length and width, respectively, of the manufactured parts. Columns 980 and 982 represent actuals data. Hence, by comparing values in column 974 to values in column 980 , and comparing values in column 976 to values in column 982 , one can quickly compare the standards data to the actuals data, providing useful information for the manufacturing process. Drop-down control 984 allows a user to enable various columns ( 978 , 980 , 982 ) for display. The reader will recognize that the technique shown here can be applied to many other fields besides manufacturing.
[0047] FIG. 10 is an exemplary pivot table 1000 illustrating a project management budget analysis. Column 1002 indicates a desired calendar month. Column 1004 indicates a desired cost type. Column 1006 indicates an employee. Column 1008 indicates an actual labor expense for the month indicated in column 1002 . Column 1010 indicates a budgeted labor expense for the month indicated in column 1002 . Column 1012 indicates a CPI (Cost Performance Index), which is the ratio of budgeted costs to actual costs. Ideally, the CPI should be greater than or equal to one. Column 1012 allows a user to see at a glance that some employees are over budget (when the CPI is less than 1) and some are under budget (where the CPI is greater than 1). However, an additional powerful advantage of this technique is that rows 1014 and 1016 are easily identified has having “missing information.” In particular, the “missing information” is the budgeted data for the employees corresponding to rows 1014 and 1016 (Giambri and Santos, respectively). This quickly highlights that two employees are working on a project for which they were not budgeted. This is only an example of the “missing information” technique, as there are many other applications where the absence of data can highlight an issue warranting further attention or investigation. This technique of identifying one or more rows of the pivot table wherein one or more data values are missing, serves as an error checking routine to identify these errors as early as possible, to minimize their adverse impact to a project.
Disadvantages Avoided
[0048] Many disadvantages have been sited for the “single table” approach. Now that the present invention has been explained in detail, the aforementioned disadvantages to the “single table” approach are restated, followed by a summary of how the present invention overcomes these disadvantages:
[0049] 1. Disadvantage—Data tables that are very wide, and include a large number of fields.
Solution—With modern computer technology, the problems presented by very large data tables are minimized, because of the massive computing power and graphical interface capabilities of modem systems. Thus for example, large scale pivot tables were impractical for PC processors in the 1990's which had limited capabilities to process data efficiently enough to utilize the pivot table approach disclosed herein.
[0051] 2. The existence of a lot of wasted space, because each record will be for one of the data sets only, and the schema, or table structure of the single table, will include the fields for all the data sets. For each record, the fields that do not pertain to that record's data will be empty.
Solution—Again, modern computer technology nullifies the problems presented by processing large amounts of data.
[0053] 3. Opportunity for errors in the data, because of the large amount of blank cells. It can be difficult to recognize if a cell is blank because it should be, or because the cell is in error. In addition, it may be difficult to determine if an occupied cell should be occupied or blank.
Solution—The analytical capabilities of pivot tables allow for quick and easy error detection and error correction in the source data. Example—To check for cells that are occupied in error, bring up a pivot table for each data set, then bring up the fields for the other data sets, in summary. (ex. Set up a pivot table for budgets, then bring up the fields for everything but budgets.) Since the pivot tale is summarizing the data, only a single line has to be reviewed. If any data shows up, it is in error.
[0055] 4. It is difficult to dynamically alter the structure of the database once it is populated with data.
Solution—If the data table is stored as a spreadsheet table, it is relatively easy to alter either the data or the structure of the data table. And considering that the latest version of Excel (Excel 2007) now has one million rows per spreadsheet, (from 65,000 in the earlier version) then the opportunity exists to keep the data in Excel and not store it in a data base. If the data is stored as a database table in a database system like Access or SQL Server, it is more difficult to alter the structure of the populated database. However, instead of dynamically altering the structure of the database, the alternate method of simply recreating the database with an altered structure is easier with pivot tables. Example—A pivot table can be set up that includes an individual total for each dissimilar data set. (It does not matter what the field is, as long as the total includes all the records for an individual data set). Double clicking a total brings the database structure and all the records for that data set into a spreadsheet. The structure of each data set can be altered (the same way) and the data sets can be combined again into a single database table in the original database system (Access, SQL Server, etc.)
[0057] Earlier versions of Excel utilized computer systems having far less capability than current computer systems. For example, the system requirements for Excel 97 were 486 or higher processor (486 processors operated at 33 to 100 MHz); 8 megabytes (MB) of RAM for use on Windows 95; 16 megabytes (MB) of RAM for use on Windows NT; 22-64 MB of hard drive space required; 36 MB required for typical installation.
[0058] In contrast, Excel 2007's system requirements are 500 MHz processor or higher; 256 megabytes (MB) of RAM or higher; 1.5 gigabytes (GB) of hard drive space; (a portion of this disk space will be freed after installation of the original downloaded package is removed from the hard drive).
[0059] The system requirements for the newest Excel version (Excel 2007) include a processor that is 5 to 15 times faster than the processor required for Excel 97. The RAM requirements for Excel 2007 are 16 to 32 times larger than the requirements for Excel 97. The required hard drive space for Excel 2007 is 23 to 68 times larger than the required hard drive space for Excel 97. The minimum system requirements reflect how system capabilities have changed and how more computing power makes possible larger data tables in Excel. It is expected that the data tables of the present invention will be run on systems or their equivalent of a minimum of 500 MHz processor or higher; 256 megabytes (MB) of RAM or higher; 1.5 gigabytes (GB) of hard drive space or greater. equivalent
[0060] Also, it is expected that new versions of Excel are the preferred platform to utilize the present invention. For example, Excel 97 to Excel 2003 are limited to approximately 64,000 rows and 256 columns. Excel 2007 has the capability to over 1 million rows and over 16,000 columns.
[0061] Excel 2007 has (1 million /64K=) 15 times the number of rows and (16,384/256=) 64 times the number of columns of Excel 97. The massive increase of the size of the Excel worksheets from the Excel 97 version to the current Excel 2007 version, and the massive increase in the system requirements for the Excel 2007 version over the Excel 97 version is indicative of the increase in computing and data handling power of modem personal computer systems that makes many of the drawbacks of the single table approach irrelevant.
[0062] The present invention provides powerful methods for data analysis. They provide a means to quickly analyze, and extract key information from large sets of data. This allows important operational decisions to be made quickly. The methods of the present invention can be applied to a variety of application, including, but not limited to, business, manufacturing, project management, engineering, medicine, and logistics, just to name a few.
[0063] It will be understood that the present invention may have various other embodiments. Furthermore, while the form of the invention herein shown and described constitutes a preferred embodiment of the invention, it is not intended to illustrate all possible forms thereof. It will also be understood that the words used are words of description rather than limitation, and that various changes may be made without departing from the spirit and scope of the invention disclosed. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than solely by the examples given.
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A data analysis method is disclosed. The method comprises aggregating related data tables with dissimilar data structures, and combining the tables, and data structures, into a single table that incorporates all the individual data structures. The single table is then analyzed via a pivot table function of a spreadsheet program, such as Microsoft Excel. The method is suited for quickly comparing related but dissimilar sets of data—an important task in virtually every field of human endeavor, from manufacturing to health care to financial services. The present invention provides an improved way to quickly access important strategic information using multiple sources of data.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of application Ser. No. 09/705,484 filed Nov. 3, 2000 entitled, “Thin Film Transistors on Plastic Substrates with Reflective Coatings for Radiation Protection.”
[0002] The United States Government has rights in this invention pursuant to Contract No. W-7405-ENG-48 between the United States Department of Energy and the University of California for the operation of Lawrence Livermore National Laboratory.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to thin film transistors, and more particularly to the formation of silicon based thin film transistors on inexpensive, low-temperature plastic substrates. The present invention relates to a method of fabricating thin film transistors wherein heat sensitive substrates, such as inexpensive and flexible plastic substrates, may be used in place of standard glass, quartz, and silicon wafer-based substrates. A reflective coating for radiation protection of the plastic substrates is utilized during processing. The reflective coating layer is deposited above the plastic substrate to protect it from high intensity irradiation during processing by a laser or other high intensity radiation source.
[0004] Traditional techniques used in manufacturing high-performance polycrystalline silicon (poly-si) thin film transistors require processing temperatures of at least 600° C. This minimum temperature requirement is imposed by silicon crystallization and dopant activation anneals. Processes have recently been developed for crystallizing and doping amorphous silicon on a low cost, so-called low-temperature plastic substrates using a short pulsed high energy source in a selected environment, without heat propagation and build-up in the substrate so as to enable use of plastic substrates incapable of withstanding sustained processing temperatures higher than about 120° C. Such processes are described and claimed in U.S. Pat. No. 5,346,850 issued Sep. 13, 1994, to J. L. Kaschmitter et al. and U.S. Pat. No. 5,817,550 issued Oct. 6, 1998, to P. G. Carey et al., both assigned to the Assignee of the instant application.
[0005] As exemplified by the above-referenced U.S. Pat. No. 5,346,850, high performance polycrystalline silicon devices have been produced at low temperatures (<250° C.). This is accomplished by crystallizing the amorphous silicon layer (and activating dopants) with a short-pulse ultra-violet laser, such as an ArF excimer laser having a wavelength of 308 nm. The extremely short pulse duration (20-50 ns) allows the silicon thin film to melt and recrystallize without damaging the substrate or other layers in the device. Polycrystalline layers produced in this manner provide high carrier mobilities and enhanced dopant concentrations, resulting in better performance.
[0006] The present invention extends the capability of the above-mentioned method and processes for fabricating amorphous and polycrystalline channel silicon thin film transistors at temperatures sufficiently low to prevent damage to low cost, so-called low-temperature plastic substrates. The present invention utilizes a reflective coating for radiation protection of the plastic substrates during processing. A reflective coating layer is deposited above the plastic substrate to protect it from high intensity irradiation during processing by a laser or other high intensity radiation source. The process for fabrication of silicon thin film transistors on low-temperature plastic substrates, the thin film transistor, and the set of thin film transistor substrates for use in manufacturing thin film transistors of the present have different characteristics than existing thin film transistors. They have many and varied uses. For example, plastic displays and microelectronic circuits on flexible, rugged plastic substrates constructed in accordance with the present invention may be used for portable consumer electronics (video cameras, personal digital assistants, cell phones, etc.) or on large-area flat panel displays. Large area plastic displays are in need for high resolution large area flight simulators. Flexible detector arrays have use in radiation (X-ray, gamma-ray) detection. Silicon-on-insulator films may be used in radiation-hardened IC circuits. Many other uses exist and the development of the invention will produce additional uses.
SUMMARY OF THE INVENTION
[0007] The present invention relates to the fabrication of silicon-based thin film transistors (TFT), and more particularly, to a method of fabricating TFT wherein inexpensive and flexible plastic substrates are used in place of standard glass, quartz, and silicon wafer-based substrates. The present invention also relates to the fabrication of silicon-based TFT with plastic substrates utilizing a reflective coating for radiation protection of the plastic substrates during processing. A reflective coating layer is deposited above the plastic substrate to protect it from high intensity irradiation during processing by a laser or other high intensity radiation source.
[0008] The invention provides a method for the formation of TFT on inexpensive plastic substrates. The method of this invention utilizes sufficiently lower processing temperatures so that inexpensive flexible plastic substrates may be used. The so-called low-temperature plastic substrates have several advantages over conventionally used substrates such as glass, quartz, and silicon. Processing temperatures of the method of this invention are such that sustained temperatures are below a temperature of 120° C. although short duration high temperatures are used during the processing. This is accomplished using pulsed laser processing which produces the needed temperatures for short time periods while maintaining the sustained temperature of the substrate below a damage threshold (i.e. below about 120° C.). A reflective coating for radiation protection of the plastic substrates is utilized in the processing. A reflective coating layer is deposited above the plastic substrate to protect it from high intensity irradiation during processing by the laser or other high intensity radiation source. Thus, by the use of fabrication techniques of the present invention, the sustained temperature of the substrate is sufficiently low to prevent damage to the inexpensive and flexible low-temperature plastic substrates. The present invention provides a method which relies on techniques for depositing semiconductors, dielectrics, and metal at low temperatures, crystallizing and doping semiconductor layers in the TFT with a pulsed energy source.
[0009] The present invention significantly increases the type of plastic substrates that can be utilized in the fabrication of thin film transistors. In addition, plastic substrates have several advantages over conventional substrates, such as glass or silicon in that plastic can be much less expensive, lighter, more durable, rugged, and flexible. The process for fabrication of silicon thin film transistors on low-temperature plastic substrates, the thin film transistor, and the set of thin film transistor substrates for use in manufacturing thin film transistors of the present have different characteristics than existing thin film transistors. They have many and varied uses. For example, plastic displays and microelectronic circuits on flexible, rugged plastic substrates constructed in accordance with the present invention have multiple uses such as in field-deployable portable electronics, battlefield operations facilities, and the interior of ships, tanks and aircraft. Large area plastic displays are in need for high resolution large area flight simulators. Flexible detector arrays have use in radiation (X-ray, gamma-ray) detection. Silicon-on-insulator films may be used in radiation-hardened IC circuits. Many other uses exist and the development of the invention will produce additional uses.
[0010] It is an object of the present invention to enable fabrication of silicon-based thin film transistors on plastic substrates.
[0011] A further object of the invention is to provide a method for manufacturing thin film transistors wherein low cost, low-temperature substrates can be utilized.
[0012] Another object of the invention is to provide a method of fabricating thin film transistors wherein inexpensive plastic substrates may be used in place of standard glass, quartz, and silicon wafer-based substrates.
[0013] Another object of the invention is to provide a method for fabricating thin film transistors involving replacement of standard fabrication procedures with procedures utilizing sufficiently lower processing temperatures so that inexpensive plastic substrates may be used.
[0014] Another object of the invention is to enable the manufacture of thin film transistors using plastic substrates which enable use for large area low cost electronics, such as flat panel displays and portable electronics.
[0015] Another object of the invention is to protect transparent plastic substrates from damage due to exposure by radiation during processing through the use of a narrow-band reflective layer.
[0016] Other objects and advantages of the present invention will become apparent from the following description, accompanying drawings, and through practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings, which are incorporated into and form a part of the disclosure, illustrate embodiments of the invention, and, together with the description, serve to explain the principles of the invention.
[0018] [0018]FIGS. 1A, 1B, and 1 C illustrate pulsed laser melting of silicon on a plastic substrate to form poly-si.
[0019] [0019]FIGS. 2A, 2B, and 2 C provide an illustration of damage which can occur to a plastic substrate during pulsed laser melting of a patterned silicon film.
[0020] [0020]FIG. 3 shows the results of measuring reflectance of the coating.
[0021] [0021]FIGS. 4A, 4B, 4 C, 4 D, and 4 E show configurations in which a reflective layer can be used to protect an underlying substrate or layer from high intensity radiation during the processing of another layer.
[0022] [0022]FIGS. 5A, 5B and 5 C show a TFT structure that is produced using laser processing.
[0023] [0023]FIG. 6 shows shallow junction formation in a MOSFET by laser doping.
[0024] [0024]FIG. 7 shows the results of measuring reflectance of another coating used in the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention involves ( 1 ) a method or process for fabrication of silicon thin film transistors on low-temperature plastic substrates, ( 2 ) a thin film transistor, ( 3 ) a set of thin film transistor substrates for use in manufacturing thin film transistors, and ( 4 ) the preparation of a reflective coating to protect the substrate and device from process radiation. The present invention utilizes techniques for depositing semiconductors, dielectrics, reflective coatings, and metals at low temperatures and crystallizing and doping semiconductor layers in the thin film transistors with a pulsed energy source, such as an excimer laser. The present invention enables the fabrication of amorphous and polycrystalline channel silicon thin film transistors at temperatures sufficiently low to prevent damage to plastic substrates. Low-temperature substrates are defined as those materials incapable of withstanding sustained processing temperatures higher than about 150°-250° C., compared to the so-called high-temperature materials such as silicon, glass, quartz, etc., which can withstand sustained processing temperatures of 400° C. and higher. While the low-temperature substrate may be heated higher than about 150°-250° C. for short time durations, such may be damaged if that time duration is longer than about 10 −4 seconds ( 100 μs).
[0026] High intensity radiation is used to process materials in the manufacture of the thin film transistors (TFT). In many cases it is desirable to expose only specific materials or regions of the TFT to the radiation. This is often the case because other materials that are present, including the substrate, may be vulnerable to damage by the radiation. The TFT of the present invention is constructed by depositing a reflective coating in a layer above these vulnerable materials so that the radiation is reflected away and prevents such damage. High intensity radiation sources can be used on TFT that would otherwise be damaged by direct exposure to such radiation. It also enables greater flexibility in designing processes using materials that are vulnerable to damage by high intensity radiation.
[0027] Processes in which this procedure may be applied include using high intensity radiation for annealing, melting, crystallization, doping, ablation, photolithography, direct laser writing/patterning, etc. High intensity radiation sources include those with a short wavelength that will be readily absorbed by the substrate material (e.g. pulsed UV excimer lasers, frequency doubled NdYAG lasers, UV flashlamps, X-ray sources, etc.). Reflective coatings include single layer and multiple layers for narrowband or broadband reflection.
[0028] Methods or processes for fabrication of silicon TFT on low-temperature plastic substrates including techniques for depositing semiconductors, dielectrics, and metals at low temperatures and crystallizing and doping semiconductor layers in the thin film transistors with a pulsed energy source, such as an excimer laser. processes are described and claimed in U.S. Pat. No. 5,817,550 issued Oct. 6, 1998, to P. G. Carey et al., assigned to the Assignee of the instant application. The description, specification, and drawings of U.S. Pat. No. 5,817,550 are incorporated herein by reference.
[0029] A better understanding of the present invention can be obtained from the descriptions of the following specific (1) methods or processes for fabrication of silicon thin film transistors on low-temperature plastic substrates, (2) thin film transistors, and (3) sets of thin film transistor substrates for use in manufacturing thin film transistors. The descriptions provide a preferred embodiment of the invention.
[0030] The first embodiment provides pulsed laser crystallization or doping of a patterned silicon film on a transparent plastic substrate which has a multilayer narrowband reflective coating. The second embodiment provides pulsed laser doping of CMOS junctions whereby a reflective layer is deposited on top of the MOSFET gates, isolation oxides, and other regions to protect them from the laser pulse. This procedure will make possible the manufacture of: 1) Shallow junction formation for CMOS integrated circuits using silicon substrates or silicon-on-insulator; 2) Shallow junction formation for silicon (or germanium) microelectronics on plastic substrates; 3) Active matrix flat panel displays on plastic substrates; 4) High performance silicon (or germanium)-based electronic circuits on plastic substrates.
[0031] Two technical hurdles that have been overcome are (1) to manufacture and (2) to dope a poly-si film while preventing any thermal damage to the plastic substrate. Conventional processes to produce or dope poly-si require sustained temperatures at or above 600° C., a temperature range that will damage plastics. The present invention overcomes these hurdles by utilizing pulsed laser annealing to produce poly-si and using a reflective coating to prevent damage to the plastics.
[0032] Information that is helpful in an understanding of the present invention is provided with reference to FIGS. 1A, 1B, and 1 C. These figures show a process of pulsed laser melting on a plastic substrate, generally designated by the reference numeral 10 , to form poly-si. This illustrates manufacturing polycrystalline silicon (poly-si) based thin film transistors at low temperatures on plastic substrates.
[0033] The technique, illustrated in FIGS. 1A, 1B, and 1 C involves using a high intensity ultraviolet excimer laser pulse that is absorbed at the surface of the silicon film 11 . The pulse energy is sufficient to melt the silicon film 11 . However, due to the short time scales involved, and the thermal barrier layer 12 below the silicon, the plastic substrate 13 experiences a small thermal load for only a brief time (tens of microseconds) which prevents any damage to the plastic substrate 13 . In FIG. 1A the initial amorphous silicon film and thermal barrier on plastic substrate is shown. In FIG. 1B the melting of silicon layer by laser pulse 15 is shown. In FIG. 1C the resulting p-si 16 after solidification is shown.
[0034] One limitation of this process is that if the plastic substrate is directly exposed to the laser pulse it would be severely damaged. In the current implementation of this process the entire area of the substrate is covered by the silicon film, preventing any exposure to the laser.
[0035] However, it is sometimes desirable to pattern the silicon film prior to laser exposure, which would lead to the situation illustrated in FIGS. 2A, 2B, and 2 C. A high intensity ultraviolet excimer laser pulse 25 is absorbed at the surface of the silicon film 21 . The pulse energy is sufficient to melt the silicon film 21 . The thermal barrier layer 22 below the silicon 24 protects the plastic substrate 23 and prevents any damage to the plastic substrate 23 in that region.
[0036] As shown in FIGS. 2A, 2B, and 2 C, when a pattern is used, the silicon 21 / 24 does not cover the entire area of the thermal barrier 22 . The region of the thermal barrier/plastic substrate that is not covered by Si 21 / 24 is exposed to the laser pulse 25 . As shown in FIG. 2B, the laser energy 25 is transmitted through the thermal barrier 22 layer and absorbed by the plastic substrate 23 . Those regions of the plastic substrate 23 that are exposed to the laser energy 25 are readily damaged, and any films covering those regions may also be damaged or delaminated. The damaged area 24 is shown in FIG. 2C.
[0037] In the present invention, a highly reflective coating is deposited in a layer above the substrate to protect the plastic from the laser pulse. In a specific application where an optically transparent substrate is desirable, a narrow-band reflective coating which is designed to transmit in the visible, while being highly reflective at the wavelength of the laser, is deposited. Incorporating an appropriately engineered high reflectance layer allows for more flexibility in the procedures of laser processing.
[0038] A narrow band reflectance coating is deposited by sputtering on a polyester (PET) substrate. This is an actual multi-layer design. It was manufactured using the materials SiNx and SiO 2 . The results of measuring reflectance of this coating are shown in FIG. 3. As displayed, the coating had a high reflectance in the UV, greater than 70% for wavelengths between 300 nm and 335 nm, while still being visibly transparent. This coated plastic was then exposed to Excimer laser pulses with a 308 nm wavelength. The plastic survived laser pulses with energy densities up to 350 millijoules cm −2 . An uncoated PET wafer was tested and could only survive energy densities up to 50 millijoules cm −2 . This clearly illustrates that a plastic wafer coated with such a reflective layer could be used in a process sequence where the substrate would be exposed to an intense laser pulse.
[0039] The results of measuring reflectance of another coating used in the preferred embodiment of the present invention are shown in FIG. 7. It can be produced using the materials HfOx and SiO 2 . HfOx, has less absorption at the design wavelength (308 nm) than SiNx, and is also much easier to fabricate. This reflectance coating is deposited by sputtering on a polyester (PET) substrate. The graph, FIG. 7, shows the theoretical reflection and transmission curves of this layer design. The design will give greater than 99% reflection at 308 nm and >94% transmission of visible wavelengths, (400 nm-700 nm).
[0040] The present invention consists of the procedure and the physical product of depositing a reflective layer above a substrate and/or other material layers to protect them from high intensity irradiation during processing by a laser or other high intensity radiation source.
[0041] Referring again to the drawings and in particular to FIGS. 4A, 4B, 4 C, 4 D, and 4 E configurations in which a reflective layer 32 can be used to protect an underlying substrate or layer 31 from high intensity radiation 35 during the processing of another layer are shown. The reflective layer 32 is configured such that the radiation used during processing would be reflected away from the substrate and/or any material layer 31 that is vulnerable to undesired damage by the radiation. This is illustrated in FIGS. 4A, 4B, 4 C, 4 D, and 4 E for several layer configurations.
[0042] In FIG. 4A a reflective layer 32 is deposited directly on the substrate 31 and the material to be processed 33 is deposited directly on the reflective layer 32 . FIG. 4B is similar to 4 A except for the possibility of a transparent layer(s) located directly above the reflective layer 32 . FIG. 4C illustrates the scenario in which the reflective layer 32 protects not only the substrate 31 but also any layer(s) above the substrate that could absorb the radiation and be damaged.
[0043] The reflective layer 32 could also be configured to protect materials that are located above the material to be processed 33 . This is illustrated in FIG. 4D in which the layer(s) 36 that need to be protected are located above the layer to be processed 33 , and the reflective layer 32 is patterned to allow irradiation of specific areas. FIG. 4E provides an example where the radiation is used to process exposed regions of the substrate 37 , while the reflective layer 32 is patterned to protect layer(s) 36 that are above the substrate.
[0044] As illustrated, the reflective layer reflects the radiation that would otherwise cause undesired damage to the substrate or any other layer(s) on the substrate. This invention will enable processing using high intensity radiation sources on substrates that would otherwise be damaged by direct exposure to such radiation. Furthermore, the configurations in FIGS. 4D and 4E can be useful in laser processing of silicon substrate during IC fabrication.
[0045] Processes in which the present invention may be applied include using high intensity radiation for annealing, melting, crystallization, doping, ablation, photolithography and direct laser writing/patterning of either the substrate or any materials above it. High intensity radiation sources include those with a short wavelength that will be readily absorbed by the substrate material (e.g. pulsed UV excimer lasers, frequency doubled NdYAG lasers, UV flashlamps, X-ray sources, etc.). Reflective coatings include single layer and multiple layers for narrowband or broadband reflection. A narrowband reflective coating has the advantage that the coating can be transparent to visible wavelengths of light in situations where it is desirable to have a transparent substrate. The narrow band reflectance coating can be deposited by sputtering on a polyester (PET) substrate. This can be a multi-layer design using the materials SiNx and SiO 2 . The coating has a high reflectance in the UV, greater than 70% for wavelengths between 300 nm and 335 nm, while still being visibly transparent. Another coating used in the preferred embodiment of the present invention can be produced using the materials HfOx and SiO 2 . HfOx has less absorption at the design wavelength (308 nm) than SiNx and is also much easier to fabricate. This reflectance coating is deposited by sputtering on a polyester (PET) substrate. The design will give greater than 99% reflection at 308 nm and >94% transmission of visible wavelengths, (400 nm-700 nm).
[0046] The present invention is further illustrated by the example of processing a silicon thin film transistor (TFT) on a plastic substrate. Background can be obtained from a review of U.S. Pat. No. 5,817,550 issued Oct. 6, 1998, to P. G. Carey et al. and assigned to the Assignee of the instant application. The disclosure of U.S. Pat. No. 5,817,550 is incorporated herein by reference.
[0047] [0047]FIG. 5A shows one embodiment of the completed structure produced using the present invention. The device is made on plastic substrate 41 . A transparent PET (polyethyleneterephthalate) substrate was used. This PET is readily damaged when exposed to an excimer laser pulse with energy densities used in laser processing of semiconductors. A reflective coating 42 is deposited directly on the substrate 41 . For the process this layer could be a narrow-band reflective coating consisting of a multilayer that reflects ultraviolet radiation but is transparent in the visible. An optional thermal barrier may be deposited above or below the reflective layer 42 . This barrier is currently either SiO x or SiN x and protects the plastic from the high intensity radiation used during laser processing of the silicon layer.
[0048] The TFT consists of a metal gate 46 , a gate insulator 45 , and a semiconductor layer which contains a source 44 , drain 47 and channel 48 region. We currently use Aluminum as the metal and SiO 2 as the insulator. The semiconductor can be either silicon or germanium, and the source and drain regions are doped to achieve high conductivity and ohmic contact. This is a conventional top-gate TFT structure.
[0049] The present invention is best understood by considering the laser melting and laser doping steps used in producing the TFT. These two steps are illustrated in FIGS. 5B and 5C. During laser melting, excimer laser pulses (308 nm wavelength) are used to melt the semiconductor layer. As illustrated in FIG. 5B, in regions where there is no semiconductor, the laser pulse is reflected by the reflective layer. Without this reflection, the laser energy would be absorbed by the plastic substrate, resulting in damage. Without this reflective layer it has been necessary to leave the entire substrate area covered with the semiconductor film to protect the substrate. This reflective layer enables patterning the semiconductor before the laser processing, increasing the flexibility of arranging processing steps.
[0050] The plastic substrate is also protected by the reflective layer during laser doping (FIG. 5C). In this step, the laser pulse melts the source and drain regions of the semiconductor, while being reflected away from the channel region by the gate metal. While the semiconductor is molten, dopant molecules diffuse into the semiconductor. These dopant species are introduced either in the gas phase (traditional GILD processing) or in a thin film deposited on the surface just prior to the laser melt. Background information can be obtained from a review of U.S. Pat. No. 5,918,140 incorporated herein by reference. U.S. Patent No. 5,918,140 was issued Jun. 16, 1997, to P. Wickboldt, P. G Carey, P. M. Smith, A. Ellingboe and T. W. Sigmon for deposition of dopant impurities and pulsed energy drive-in. A semiconductor doping process which enhances the dopant incorporation achievable using the Gas Immersion Laser Doping (GILD) technique. The enhanced doping is achieved by first depositing a thin layer of dopant atoms on a semiconductor surface followed by exposure to one or more pulses from either a laser or an ion-beam which melt a portion of the semiconductor to a desired depth, thus causing the dopant atoms to be incorporated into the molten region. After the molten region recrystallizes the dopant atoms are electrically active. The dopant atoms are deposited by plasma enhanced chemical vapor deposition (PECVD) or other known deposition techniques.
[0051] Again, in regions where there is no semiconductor, the reflective layer reflects the laser pulse and protects the plastic substrate. The thermal barrier included in FIGS. 5 A-C need not be located above the reflective layer but could also be located below it. This could be beneficial in situations where this layer is not transparent to ultraviolet. In addition, if other materials are used that are vulnerable to damage by the laser pulse, they could be located below the reflective layer.
[0052] This current process is tailored for making TFTs for use on transparent PET for use in flat panel displays where a transparent plastic substrate is desired. This invention, however, could be used in the laser processing of devices for use in flexible circuitry and other applications where semiconductor devices are needed on substrates that can be damaged if exposed to the laser.
[0053] This invention can also be used in laser processing of CMOS devices. FIG. 6 illustrates the particular example of shallow junction doping of a MOSFET. The semiconductor junctions 51 are doped by laser melting using an excimer laser pulse 56 . While the semiconductor is molten, dopant molecules diffuse into the semiconductor. These dopant species are introduced either in the gas phase (traditional GILD processing) or in a thin film deposited on the surface just prior to the laser melt (see U.S. Pat. No. 5,918,140 issued Jun. 16, 1997, to P. Wickboldt, P. G Carey, P. M. Smith, A. Ellingboe, and T. W. Sigmon for deposition of dopant impurities and pulsed energy drive-in). Prior to the laser exposure, reflective layer 55 is deposited over the device structure and patterned. The reflective layer is patterned to cover and protect the gate region 52 and 54 , the isolation oxide region 53 , and any other regions across the substrate which may contain materials vulnerable to laser damage 57 . Correspondingly, the reflective layer is patterned to expose those regions the silicon substrate 50 that are doped to make the junctions 51 .
[0054] This application can be used to protect poly-silicon or silicide gates 54 which will absorb the laser radiation, resulting in undesired damage. In addition, the “field regions” 53 are conventionally made with thermally grown oxide on a silicon substrate and could be damaged by laser melting.
[0055] This example illustrates use of the invention in MOSFET fabrication. However, a similar approach can be adopted to make use of this invention in laser processing of a variety of IC devices.
[0056] The process for fabrication of silicon thin film transistors on low-temperature plastic substrates, the thin film transistor, and the set of thin film transistor substrates for use in manufacturing thin film transistors of the present invention have many and varied uses. The process for fabrication of silicon thin film transistors on low-temperature plastic substrates, the thin film transistor, and the set of thin film transistor substrates for use in manufacturing thin film transistors of the present have different characteristics than existing thin film transistors. There will be many and varied uses of the new thin film transistors. For example, plastic displays and microelectronic circuits on flexible, rugged plastic substrates constructed in accordance with the present invention have multiple uses such as in field-deployable portable electronics, battlefield operations facilities, and the interior of ships, tanks and aircraft. Large area plastic displays are in need for high resolution large area flight simulators. Flexible detector arrays have use in radiation (X-ray, gamma-ray) detection. Silicon-on-insulator films may be used in radiation-hardened IC circuits. Other uses, too numerous to describe here, also exist. While particular embodiments, operational sequences for fabrication, materials, parameters, etc., have been set forth to exemplify and explain the principles of the invention, such are not intended to be limiting. Modifications and changes may become apparent to those skilled in the art, and it is intended that the invention be limited only by the scope of the appended claims.
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Fabrication of silicon thin film transistors (TFT) on low-temperature plastic substrates using a reflective coating so that inexpensive plastic substrates may be used in place of standard glass, quartz, and silicon wafer-based substrates. The TFT can be used in large area low cost electronics, such as flat panel displays and portable electronics such as video cameras, personal digital assistants, and cell phones.
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CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM OF PRIORITY
[0001] The present application is related to and claims the benefit under 35 U.S.C. §119(a) of a Korean patent application filed in the Korean Intellectual Property Office on Jan. 10, 2011 and assigned Serial No. 10-2011-0002158, the entire disclosure of which is hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to a mobile communication system.
BACKGROUND OF THE INVENTION
[0003] As techniques have been developed, a variety of mobile communication terminals which gradually specialize for persons have been provided. In this mobile communication environment, in order to classify communication entities and provide services according to the classified communication entities, the most basic process is performed. That is, a mobile communication terminal is normally recognized on a network to allow a user to use all services provided from the mobile communication terminal.
[0004] In this example, a method basically used for classifying the user and services the user joins uses a registration process which is performed between the mobile communication terminal and the network during a process of booting the mobile communication terminal after the user inserts a Subscriber Identity Module (SIM) card into the mobile communication terminal.
[0005] If the registration process is normally performed, it is authenticated that the user is an authorized user and the mobile communication terminal may use services.
[0006] There is a location update process during this registration process. If the mobile communication terminal must normally perform the location update process, it may use a voice telephone service, a video telephone service, a Short Message Service (SMS), and all the other services well.
[0007] However, even though the user uses a normal SIM card and a normal mobile communication terminal, there is a problem in that a location update is not normally performed by unknown cause and the mobile communication terminal is shifted to a limited service state due to reject of the location update.
[0008] Therefore, a method and apparatus for allowing a mobile communication terminal to be not shifted to the limited service state is needed.
SUMMARY OF THE INVENTION
[0009] To address the above-discussed deficiencies of the prior art, it is a primary object to provide at least the advantages described below. Accordingly, a primary aspect of the present disclosure is to provide a method and apparatus for performing a location update in a mobile communication system.
[0010] Another aspect of the present disclosure is to provide a method and apparatus for providing a normal service to a user by preventing reject of a location update intermittently generated by a network problem even though the user uses a normal SIM card and a normal mobile communication terminal and preventing a limited service state of the mobile communication terminal due to the reject of the location update in a mobile communication system.
[0011] Another aspect of the present disclosure is to provide a method and apparatus for preventing a service disable state from being generated in a mobile communication terminal when a location update is temporarily rejected due to major cause by a network even though the mobile communication terminal uses a normal International Mobile Subscriber Identity (IMSI) and a normal International Mobile Equipment Identity (IMEI) in a mobile communication system.
[0012] In accordance with an aspect of the present disclosure, a method of performing, a location update of a mobile communication is provided. The method includes trying the location update, determining whether a reject cause is a major cause when the location update is rejected, retrying the location update using a current location indicator when the reject cause is the major cause, and retrying the location update using a different location indicator when the retried location update is rejected.
[0013] In accordance with another aspect of the present disclosure, an apparatus for performing a location update of a mobile communication terminal is provided. The apparatus includes a modem for communicating with a different node and a controller for trying the location update through the modem, determining whether a reject cause is a major cause when the location update is rejected, retrying the location update using a current location indicator when the reject cause is the major cause, and retrying the location update using a different location indicator when the retried location update is rejected.
[0014] Before undertaking the DETAILED DESCRIPTION OF THE INVENTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, such a device may be implemented in hardware, firmware or software, or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts:
[0016] FIG. 1 illustrates location update processes which are classified according to an embodiment of the present disclosure;
[0017] FIG. 2 illustrates a process of performing a location update according to an embodiment of the present disclosure;
[0018] FIG. 3 illustrates a process of performing a location update using a different location area identity (LAI) according to an embodiment of the present disclosure; and
[0019] FIG. 4 is a block diagram illustrating a structure of a mobile communication terminal according to an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0020] FIGS. 1 through 4 , discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged wireless communication system.
[0021] Hereinafter, a method and apparatus for performing a location update in a mobile communication system according to an embodiment of the present disclosure will be described in detail.
[0022] The present disclosure relates to a method and apparatus for enhancing a location update success rate in a mobile communication terminal.
[0023] FIG. 1 illustrates location update processes which are classified according to an embodiment of the present disclosure.
[0024] Referring to FIG. 1 , in accordance with the standard, a location update process performed for registering a mobile communication terminal may be classified into the following three processes.
[0025] Firstly, there is a general location update process 100 . The general location update process 100 may be a location update process performed such that the mobile communication terminal registers its own location on a network. The general location update process 100 may correspond to a process of booting the mobile communication terminal after a user inserts a SIM card into the mobile communication terminal.
[0026] Secondly, there is a periodic location update process 110 . The periodic location update process 110 may be a location update process performed such that the mobile communication terminal informs its own location to the network at intervals of timer T3212 values defined on the network.
[0027] Thirdly, there is an IMSI attachment location update process 120 . The IMSI attachment location update process 120 is a process performed for informing the network that an IMSI of the mobile communication terminal is in an active state. The IMSI attachment location update process 120 indicates that an active update state of an inserted SIM card is an updated state and a stored location indicator, that is, a stored LAI is equal to a selected LAI.
[0028] FIG. 2 illustrates a process of performing a location update according to an embodiment of the present disclosure.
[0029] Referring to FIG. 2 , in general, a mobile communication terminal tries a location update for registering its own location after being booted (step 210 ).
[0030] If the location update succeeds (step 220 ), the mobile communication terminal operates in an idle state and provides a normal service to a user (step 230 ).
[0031] If the location update does not succeed (step 220 ), the mobile communication terminal operates in a limited service state (step 240 ). The mobile communication terminal may only transmit an emergency call in the limited service state. That is, only the emergency call may be possible.
[0032] In accordance with the standard, a reject cause of a location update received from a network when a location update of the mobile communication terminal is rejected is classified into the following two general types.
[0033] Firstly, by way of example, and without limitation, there may be the following causes when the reject cause is a major cause.
[0034] 1) An IMSI is unknown in a Home Location Register (HLR). That is, the HLR determines that an IMSI value of a SIM card is not valid.
[0035] 2) The mobile communication terminal is an illegal Mobile Station (MS). That is, a problem occurs in an IMEI value of the mobile communication terminal or an IMSI value of the SIM card. In this example, the IMSI value or the IMEI value is not valid.
[0036] 3) The mobile communication terminal is illegal Mobile Equipment (ME). That is, a problem occurs in an IMEI value of the mobile communication terminal. That is, the IMEI value is not valid.
[0037] Secondly, for example, without limitation, there may the following causes when the reject cause is not a major cause, that is, when the location update is rejected by a minor cause.
[0038] 1) A Public Land Mobile Network (PLMN) where the mobile communication terminal is positioned is not permitted at the mobile communication terminal.
[0039] 2) A location area where the mobile communication terminal is positioned is not permitted at the mobile communication terminal.
[0040] 3) Roaming where the mobile communication is positioned is not permitted at the mobile communication terminal.
[0041] 4) A cell suitable for the mobile communication terminal does not exist.
[0042] If the reject cause is the minor cause (step 250 ), the mobile communication terminal may perform a network registration process according to the respective causes (step 270 ). That is, if the mobile communication terminal discovers a new PLMN or location area, it retries a location update.
[0043] However, when the reject cause is the major cause (step 250 ), the mobile communication terminal immediately operates in a limited service state. The mobile communication terminal remains in a recovery disable state until a user turns on or off the mobile communication terminal or until the user attaches a SIM card after detaching it (step 260 ).
[0044] However, even through a problem does not occur in the IMSI of the SIM card and the IMEI of the mobile communication terminal, it occurs temporarily from a network by an unspecified cause.
[0045] FIG. 3 illustrates a process of performing a location update using a different LAI according to an embodiment of the present disclosure.
[0046] Referring to FIG. 3 , a mobile communication terminal tries a location update (step 305 ).
[0047] If the location update succeeds (step 310 ), the mobile communication terminal operates in an idle state and provides a normal service to a user (step 315 ).
[0048] If the location update does not succeed (step 310 ) and a reject cause of the location update is not a major cause (that is, a minor cause) (step 320 ), the mobile communication terminal operates according to the standard (step 325 ).
[0049] If the location update does not succeed (step 310 ) and the reject cause of the location update is the major cause (step 320 ), the mobile communication terminal retries the location update using a current LAI and increases a counter by 1 (e.g., LU Retry Count_Major++;) (step 330 ). Herein, it is assumed that an initial value of the counter is 0.
[0050] If the retried location update succeeds (step 335 ), the mobile communication terminal operates in the idle state and provides the normal service to the user (step 315 ).
[0051] However, the retried location update does not succeed (step 335 ), the mobile communication terminal retries the location update using a different LAI until the counter value is 3 (step 340 ), that is, until the total number of times to retry the location update is 4 when the different LAI exists (steps 355 and 360 ).
[0052] If the location update succeeds during these repeated processes (step 335 ), the mobile communication terminal operates in the idle state and provides the normal service to the user (step 315 ).
[0053] If the location update does not succeed although these location update processes are repeated, the mobile communication terminal operates in a limited service state (step 345 ). It is possible for the mobile communication terminal to transmit only an emergency call in the limited service state.
[0054] Before this location update process, the mobile communication terminal determines validity of its own IMSI and IMEI. If the IMSI and IMEI are valid, the mobile communication terminal performs the location update process described above.
[0055] FIG. 4 illustrates a structure of a mobile communication terminal according to an embodiment of the present disclosure.
[0056] Referring to FIG. 4 , the mobile communication terminal includes a modem 410 , a controller 420 , a storage unit 430 , and a location update unit 440 .
[0057] The modem 410 is a module for communicating with a different device. The modem 410 includes a radio frequency processor, a baseband processor, etc. The radio frequency processor converts a signal received through an antenna into a baseband signal and provides the baseband signal to the baseband processor. The radio frequency processor converts a baseband signal from the baseband processor into a radio frequency signal to be transmitted on a real radio path and transmits the radio frequency signal through the antenna. Radio access technology of the modem 410 is not limited.
[0058] The controller 420 controls an overall operation of the mobile communication terminal. Particularly, the controller controls the location update unit 440 according to an embodiment of the present disclosure.
[0059] The storage unit 430 stores programs for controlling the overall operation of the mobile communication terminal and temporary data generated while the programs are executed.
[0060] The location update unit 440 performs a location update. If the location update succeeds, the location update unit 440 operates in an idle state and provides a normal service to a user.
[0061] If the location update does not succeed and a reject cause of the location update is not a major cause, the location update unit 440 operates according to the standard.
[0062] If the location update does not succeed and the reject cause of the location update is the major cause, the location update unit 440 retries the location update using a current LAI.
[0063] If the retried location update succeeds, the location update unit 440 operates in the idle state and provides the normal service to the user.
[0064] However, if the retried location update does not succeed, the location update unit 440 retries the location update using a different LAI until the total number of times to retry the location update is 4 when the different LAI exists.
[0065] If the location update succeeds during these repeated processes, the location update unit 440 operates in the idle state and provides the normal service to the user
[0066] If the location update does not succeed although these location update processes are repeated, the location update unit 440 operates in a limited service state. It is possible for the mobile communication terminal to transmit only an emergency call in the limited service state.
[0067] Before the location update process, the location update unit 440 determines validity of its own IMSI and IMEI. If the IMSI and IMEI are valid, the location update unit 440 performs the location update process described above.
[0068] In the structure described above, the controller 420 may perform the function of the location update unit 440 . The present disclosure includes the controller 420 and the location update unit 440 separately to differentially describe the respective functions thereof.
[0069] Therefore, when the present disclosure is implemented as a real product, all functions of the location update unit 440 may be performed in the controller 420 . Only some of the functions of the location update unit 440 may be performed in the controller 420 .
[0070] The present disclosure has an advantage in that the mobile communication terminal may be successfully registered on a network using a different LAI when a location update of the mobile communication terminal is temporarily rejected by a network problem.
[0071] Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as fall within the scope of the appended claims.
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A method and apparatus enhances a location update success rate in a mobile communication terminal. The method includes trying the location update, determining whether a reject cause is a major cause when the location update is rejected, retrying the location update using a current location indicator when the reject cause is the major cause, and retrying the location update using a different location indicator when the retried location update is rejected.
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BACKGROUND OF THE INVENTION
This invention is a continuation-in-part of U.S. patent application, Ser. No. 166,868, filed July 7, 1980.
The invention relates in general to generating holes in composites, and in particular, to generating holes in composites comprising at least two materials having different moduli of elasticity with a trepanning tool.
In the past, it has been difficult to quickly and accurately drill holes in composite material, such as, for example, aramid fiber/epoxy or other resin-bonded laminates. Experience has shown that the aramid fibers, which have a smaller diameter and a higher tensile strength, elasticity, and sheer resistance than the more conventional glass fibers used in similar composite compositions, tend to deflect and bend before being cut by the shearing action of the cutting edge of the drill. This action forces the fibers into the softer resilient resin matrix material, increasing radial compressive forces on the drill and the surrounding composite material. These compressive forces generate frictional heat which further softens the resin matrix, by allowing the rough aramid fiber to further escape the shearing action of conventional drills. The heat generated also limits the drill speed and feed pressure so that the material surrounding the drill hole is not damaged by excessive heat. Also, as a result of this characteristic of aramid fiber reinforced resin laminates, holes drilled by conventional means are often undersized holes with frayed, fuzzy edges, with mushrooming of the aramid fibers at the tool exit.
The above-referenced U.S. patent application Ser. No. 166,868 discloses an optimized method and tool for quickly and easily generating deep holes with clean hole edges in composites of materials with different moduli of elasticity.
The method provides for simultaneous point and surface cutting. Point and surface cutting occur at the outer circumferential surface of the hole and generally along a radius of the hole to be drilled. At the outer circumferential surface, the point cutting proceeds normal to the planar area of the hole, while the surface cutting proceeds circumferentially.
The tool, which is generally shaped as a cylindrical rod, has an axially extending flute and an end surface which is inclined to the tool axis. The intersection of the end surface with one side surface of the flute, the intersection of the end surface with the semi-cylindrical outer surface of the rod, and the intersection of the one end surface of the flute and semi-cylindrical outer surface of the rod define a cutting single end point and associated cutting edges. The end surface intersects the one side of the flute adjacent the end point at an acute angle to form a first cutting edge. The same side of the flute intersects the outer surface adjacent the end point to form the second cutting edge. The second cutting edge intersects the first cutting edge at an acute angle at the single end point. The end surface also intersects the semi-cylindrical outer surface to form a third edge which intersects the first and second cutting edges at the single end point at respective acute angles.
During a hole forming operation, the single end point first cuts the composite and thereafter penetrates successive transverse planes of the composite, i.e., transverse to the longitudinal axis of the hole to be generated, and the portions of the cutting edges immediately adjacent the single end point cleanly cuts the fibers of the composite of each successively cut transverse plane in the immediate region of penetration. Penetration is facilitated by the two cutting edges and the third edge adjacent the single end point. The first cutting edge also cuts away chips from the cylindrical composite portion to be removed to form the hole progressively inward. By penetrating the composite and severing the fibers in the immediate region of the penetration, very little deflection of these fibers occurs; thus, the radial compressive forces exerted on the tool by these fibers and the thrust requirements of the tool are reduced to a minimum, and an accurately sized, clean-cut hole is produced.
However, for generating relatively large holes in a composite, it is preferable to use a trepanning tool having multiple teeth or cutting elements, which remove only an annular portion of the composite during the hole-forming operation.
OBJECTS AND SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to provide an optimized method and trepanning tool for generating accurate holes with clean hole edges in composites of at least two materials in which one material has a higher modulus of elasticity than the other material.
It is a further object of the invention to provide an optimized method and trepanning tool for generating holes in composites according to which less heat is generated during the cutting operation than prior known methods and tools, to thus allow higher cutting speeds and the use of cutting edges formed of very hard material, such as various carbides.
It is still another object of the invention to provide an optimized method and tool for quickly and easily generating large diameter holes with clean hole edges in composites of materials with different moduli of elasticity.
Still another object of the invention is to provide an optimized trepanning tool for generating large diameter holes in composites of the type described above which is relatively easy and inexpensive to manufacture.
The method provides for simultaneous point and surface cutting. Point and surface cutting occur at the inner and outer circumferential surfaces of an annular hole being formed, and generally along an outer radial portion of the annular hole between its inner and outer circumferential surfaces. The point cutting proceeds normal to the planar area of the annular hole at its inner and outer circumferential surfaces, while the surface cutting proceeds circumferentially.
The trepanning tool includes a generally cylindrical side wall, portions of which are removed at one end to form a plurality of cutting elements, or teeth, spaced about that end of the cylindrical side wall. Each tooth includes a cutting single end point and associated cutting edges, the geometry of which is essentially the same as that of the single end point and associated cutting edges of the tool described in the above-referenced U.S. patent application Ser. No. 166,868, so as to produce a unique shearing action on the outermost fibers of the portion of the composite to be removed to thereby produce a clean-cut edge. Some of these teeth are disposed so that their single end points define the outer cutting radius of the trepanning tool; the remainder of these teeth are disposed so that their single end points define the inner cutting radius of the trepanning tool. The outwardly-directed teeth are disposed in a common plane orthogonal to the axis of the tool; similarly, the inwardly-directed teeth are disposed in a common plane which is orthogonal to the axis and which is displaced from the common plane of the outwardly-directed teeth so that, during a hole-forming operation, cutting of the composite is initiated by the single end points of the outwardly directed teeth.
In a preferred embodiment of the invention, each tooth includes an insert of metal carbide which defines the single end point and associated cutting edges. When the trepanning tool includes several outwardly-directed teeth, the carbide inserts of these teeth may be disposed so their outer surfaces extend radially outward beyond the outer surface of the cylindrical side wall to form parallel, axially-extending wear strips for guiding the tool during the hole-forming operation. Also, the metal carbide inserts of the inwardly-directed teeth may be disposed so that their inner surfaces extend radially inward towards the tool axis beyond the inner surface of the cylindrical side wall to minimize the transfer of forces from the trepanning tool to the center core or slug generated by the tool during the hole-forming operation.
The above and other objects and features of the invention will become more readily apparent from the following description of preferred embodiments of the invention.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a front elevational view of a trepanning tool, according to the invention, viewed with the axis A--A of the tool disposed parallel to the plane of the paper.
FIG. 2 is a top view of the embodiment of FIG. 1.
FIG. 3 is a front view of the cutting end portion of one tooth of the trepanning tool of FIGS. 1 and 2, taken along the line 3--3 of FIG. 2.
FIG. 4 is a side view of the cutting end of one tooth of the trepanning tool shown in FIGS. 1 and 2, taken along the line 4--4 of FIG. 2.
FIG. 5 is a front elevational view of a second, preferred, trepanning tool, according to the invention.
FIG. 6 is a top view of the embodiment of FIG. 5.
FIG. 7 is a front view of the cutting end portion of inwardly-directed tooth of the trepanning tool shown in FIGS. 5 and 6, taken along the line 7--7 of FIG. 6.
FIG. 8 is a side view of the cutting end portion of an inwardly-directed tooth of the trepanning tool shown in FIGS. 5 and 6, taken along the line 8--8 of FIG. 6.
FIG. 9 is a cross-sectional view of a composite work piece having a hole formed therein by the trepanning tool of FIG. 5, showing the composite slug cut from the work piece by the trepanning tool in its initial position.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIGS. 1 through 4, a trepanning tool 10 includes a cup-shaped cutter body 12 having a cylindrical side wall 14 which is symmetrically disposed about the tool axis A--A, and a radially extending bottom wall 16 affixed to an axially extending arbor 18. Side wall 14 has concentric cylindrical inner and outer surfaces 20 and 22, respectively. The upper end of the side wall 14 is formed with five, regularly spaced, identical cutting teeth 24 and gullets 26.
Each cutting tooth 24 includes an insert 28 of metal carbide material, such as tungsten carbide or titanium carbide. Each insert 28 has a semi-cylindrical outer surface 30 concentrically disposed radially outward from the side wall outer surface 22, a semi-cylindrical inner curface 32 concentrically disposed radially inward from the side wall inner surface 20, a planar front surface 34 disposed in a common plane with the tool axis A--A and a planar top surface 36. The front surface 34 orthogonally intersects the outer and inner surfaces 32 and 34 to form outer and inner circumference cutting edges 38 and 40, respectively. The front surface 34 also intersects the top surface 36 at an acute angle to form a top end cutting edge 42. The end cutting edge 42 intersects the outer circumference cutting edge 38 at an angle B of approximately 55 degrees to define thereat a single, topmost, cutting end point 44. The top surface 36 intersects the outer surface 30 to form an outer trailing edge 46, and intersects the inner surface 32 to form an inner trailing edge 48. The outer trailing edge 46 intersects the outer circumference cutting edge 38 at the cutting end point 44 at an acute angle C of approximately 65 degrees. Hence, the inner trailing edge 48 intersects the inner circumference cutting edge 40 at the same acute angle C of approximately 65 degrees, and the top surface 36 intersects the front surface 34 at an acute angle of approximately 45 degrees. Since the end cutting edge 42 intersects the outer circumference cutting edge 38 at an acute angle B of approximately 55 degrees, the end cutting edge 42 also intersects the inner circumference cutting edge 40 at an obtuse angle D of approximately 125 degrees.
The cutting end points 44 of the five cutting teeth 24 are disposed in a common plane orthogonal to the tool axis A--A, so that, during a hole forming operation in a composite, penetration of the composite is simultaneously initiated at the five cutting end points 44.
During a hole-forming operation in a composite, the trepanning tool 10 removes an annular portion of the composite to separate a cylindrical slug, or core, from the main body of the composite. The outer diameter of this annular portion of the composite, which is also the diameter of the hole to be formed, is determined by the cutting end points 44 and the outer circumference cutting edges 38 of the cutting teeth 24; the inner diameter of this annular portion, which is also the diameter of the core separated from the main body of the composite, is determined by the inner circumference cutting edge 40 and adjacent portions of the top end cutting edge 42.
The geometry of the cutting end point 44 and associated cutting edges 38 and 42 of each cutting tooth 24 is essentially the same as the geometry of the single cutting end point and associated cutting edges of the tool described in the above-referenced U.S. patent application Ser. No. 166,868; hence, the cutting forces generated at each cutting tooth 24 of the trepanning tool 10 during the hole-forming operation produce a shearing action on the outermost fibers of the annular portion of the composite to be removed, thereby producing a clean-cut edge, in the same manner as the tool described in U.S. patent application Ser. No. 166,868.
The trepanning tool 10 may also include a pilot member 50, which extends axially upward from the open end of the cutter body 12, for guiding the trepanning tool 10 when this tool is used to form a hole concentrically about an existing pilot hole in a composite workpiece.
During the hole forming operation in a composite in which the trepanning tool 10 removes an annular portion of the composite, the outermost fibers of the annular portion are sheared cleanly, as described above, but the cutting action at the inner diameter of the annular portion of the inner circumference cutting edge 40 and the adjacent portion of the top end cutting edge 42 is very poor. This poor cutting edge builds up thrust, causing the transfer of forces from the slug through the final laminates at the time of break-through, thereby producing delamination in the finished part at the exit side of the hole. Thus, the trepanning tool 10 is limited to forming holes through relatively thin composite work pieces, in which thrust caused by the poor cutting action at the inner diameter of the annular portion removed by the trepanning tool 10 is insufficient to cause delamination at the exit side of the hole.
This limitation in the use of the trepanning tool 10 is overcome by modifying this trepanning tool as illustrated by the trepanning tool 52, which is shown in FIGS. 5 through 8 and which is the preferred embodiment of the invention. Since most of the elements of the trepanning tool 52 are identical to corresponding elements in trepanning tool 10, the same numbers have been used in the drawings to identify identical elements of the two trepanning tools 10 and 52.
In the trepanning tool 10, all of the cutting teeth 24 are radially outwardly directed, i.e., the sharp cutting end point 44 of each cutting tooth 24 is disposed at the outer periphery of the cutter body 12. In the preferred embodiment of the invention, two non-adjacent, outwardly-directed cutting teeth 24 have been replaced with two, inwardly-directed cutting teeth 54, each having a single cutting end point 56 disposed on the inner periphery of the cutter body 12. Otherwise, the two trepanning tools 10 and 52 are identical.
Each cutting tooth 54 includes a metal carbide insert 58 having concentric, semi-cylindrical, outer and inner surfaces 60, 62 and planar front and top end surfaces 64, 66. The front surface 64 orthogonally intersects the inner surface 62 to form an inner circumference cutting edge 68, and intersects the top end surface 66 at an acute angle to form a top end cutting edge 70. The top end surface 66 intersects the inner surface 62 to form a top trailing edge 72. The inner circumference cutting edge 68 intersects the top cutting edge 70 at the cutting end point 56 at an acute angle E of approximately 55 degrees, and intersects the top trailing edge 72 at the cutting end point 56 at an acute angle F of approximately 65 degrees; hence, the top end surface 66 intersects the front surface 64 at an acute angle of approximately 45 degrees.
The geometry of the end cutting point 56 and its associated cutting edges 68, 70 of each cutting tooth 54 is essentially the same as the geometry of the single end cutting point and associated cutting edges of the tool described in the above-referenced U.S. patent application Ser. No. 166,868, except the cutting teeth 54 is radially inwardly directed to perform as a turning tool rather than a boring tool Thus, during the hole forming operation, the cutting forces generated at the inwardly-directed cutting teeth 52 produce a shearing action on the innermost fibers of the annular portion of the composite to be removed, thereby producing a clean cut edge at the outer diameter of the slug.
Thus, during a hole-forming operation, in which an annular portion of the composite work piece is removed by the trepanning tool 52, the three outwardly-directed cutting teeth 24 remove an outer part of the annular portion and produce a clean cut edge at the outer cutting diameter of the tool 52, and the two inwardly-directed cutting teeth 54 remove the remaining inner part of the annular portion and produce a clean cut edge at the inner cutting diameter of the tool 52.
In the trepanning tool 10, since each cutting tooth 24 includes both outer and inner circumference cutting edges 38 and 40, the outer surfaces 30 of all five cutting teeth 24 are disposed equidistant from the tool axis A--A to define the outer cutting diameter of the tool 10, and similarly, the inner surfaces 32 of the five cutting teeth 24 are disposed equidistant from the tool axis A--A and define the inner cutting diameter of tool 10. The equivalent inner and outer surfaces of the five cutting teeth 24, 54 of the trepanning tool 52 may be disposed in the same manner. However, since no cutting is performed by the inwardly-directed cutting teeth 54 at the outer cutting diameter of the tool 52, and similarly, no cutting is performed by the three outwardly-directed cutting teeth 24 at the inner cutting diameter of the tool 52, the metal carbide inserts 58 of the two inwardly-directed cutting teeth 54 may be disposed so that their semi-cylindrical outer surfaces 60 are flush with the cutter body outer surface 22 and their inner surfaces 62 which define the inner cutting radius of the tool 52 are disposed inwardly of the inner surfaces 32 of the three outwardly directed cutting teeth 24, which may be ground to be flush with the cutter body inner surface 20, as shown in FIG. 5. By so disposing the metal carbide inserts 58, the surface area of the trepanning tool 52 which is disposed in rubbing contact with the composite work piece is much less than that of the trepanning tool 10.
The cutting end points 44 of the three outwardly-directed cutting teeth 24 are disposed in a first radially-extending plane X--X. Similarly, the cutting end points 56 of the two inwardly-directed cutting teeth 54 are disposed in a second radially-extending plane Y--Y, which is displaced toward the arbor end of the trepanning tool 52 from the first plane X--X by a slight distance G to assure that the slug formed during the hole forming operation is separated from the main body of the composite workpiece at the outer cutting diameter of the trepanning tool 52. Typically, this distance G is in the order of 0.015 to 0.020 inch.
Referring to FIG. 9, to form a hole 74 in a composite work piece 76 using the trepanning tool 52, a pilot hole 78 is first drilled through the composite workpiece 76. The guide element 50 of the trepanning tool 52, which has a diameter only slightly smaller than that of the pilot hole 78, is then inserted in the pilot hole 78 to provide guidance for the trepanning tool 52 during initial stages of the whole cutting operation. The trepanning tool 52 is rotated in a counter-clockwise direction, as seen in FIG. 5, and moved in an axial direction to simultaneously engage the cutting end points 44 of the three outwardly directed cutting teeth 24 with the composite work piece 76 along the circumference of the hole to be formed therein. After the cutting end points 44 have penetrated the first transverse plane of the composite, i.e., transverse to the longitudinal axis of the hole to be generated, the cutting end points 56 of the two inwardly directed cutting teeth 54 are simultaneously engaged with the composite work piece 76 at the circumference of the center core or slug 80 to be formed. Thereafter, the outwardly disposed end cutting points 44 penetrate successive transverse planes of the composite, with the portions of the top and outer cutting edges 36, 38 immediately adjacent the cutting end points 44 cleaning cutting the fibers of the composite work piece 76 at each successively cut transverse plane in the immediate area of the penetration. At the same time, the inner cutting end points 56 penetrate the successive transverse planes of the composite, with the inner and top cutting edges 68, 70 immediately adjacent the inner end cutting points 56 cleaning cutting the fibers of the composite work piece 76 in the immediate region of the penetration. The end cutting edges 42 of the three outwardly directed cutting teeth 24 also cut away chips progressively inward from the annular composite portion to be removed to form the hole 74 and the center core or slug 80 therein, and the top cutting edges 70 of the two inwardly directed cutting teeth 54 cuts away chips progressively outward from the annular composite portion to be removed. After initial penetration of the composite work piece 76 by both the inner and outer cutting end points 44, the semi-cylindrical outer surfaces 30 of the three outwardly directed cutting teeth 24 and the semi-cylindrical inner surfaces 62 of the two inwardly-directed cutting teeth 54, constitute six parallel axial-extending wear strips similar to those of a gun drill, which guide the tool and allow the tool to be used for generating deep holes.
The hole-forming operation is completed when the three outer cutting end points 44 penetrate the last transverse plane of the composite to sever the slug 80 from the composite work piece 76.
Since the cutting end points 44 of the three outwardly-directed cutting teeth 24 cleanly sever the fibers at the hole periphery 82, and the cutting end points 56 of the two inwardly directed cutting teeth 54 cleanly sever the fibers along the cylindrical side 84 of the slug 90, very little deflection of these fibers occurs; thus, the radial compressive forces exerted on the trepanning tool 52 by these fibers and the thrust requirements of the tool 52 are reduced to a minimum, and an accurately sized, clean cut hole is produced.
To demonstrate the superior performance of the trepanning tool 52 over that of the trepanning tool 10, holes were drilled at 1200 rpm in a specimen of approximately 0.150 inch thick, laminated kevlar/epoxy composite by a trepanning tool 10 and by a trepanning tool 52, both tools 10, 52 having an outer cutting diameter of 1 inch, and inner cutting diameter of 13/16 inch, and the geometry and values for angles B, C, E, F given above, by way of example, for these tools 10, 52.
Because of the poor cutting characteristics of the inner circumference cutting edges 40 of the tool 10, much more thrust was required to feed the tool 10 at the same rate as the tool 52.
The tool 52 formed a hole of excellent quality, with virtually no fuzzing or delamination. Similarly, the side of the slug 80 formed by the tool 52 was of excellent quality. However, the side of the slug formed by the tool 10 was fuzzy along its entire length, with delamination occurring at both the tool entrance and exit sides of the slug. The hole generated by the drill 10 was of excellent quality at the tool entrance side of the hole, but with delamination and mushrooming of the aramid fibers occurring at the tool exit side of the hole.
The optimum range values for the end point front angles B, E and for the end point side angles C, F of the trepanning tool 52 will depend on such factors as the type of composite material being drilled, the material of the trepanning tool 52, the inner and outer diameters and the depth of the annular portion of the composite removed by the trepanning tool 52, and the drilling speed. For example, minimum values for these end point angles B, C, E, F are limited by the characteristics of the tool material, whereas maximum values for these angles are limited by the characteristics of the composite. As these angles B, C, E, F are decreased, the cutting end points 44, 56 will be more quickly worn down and more likely to break, and heat can be conducted away from these cutting end points 44, 56 through the cutter body coils; as these angles B, C, E, F are increased, delamination, fraying, and mushrooming are more apt to appear.
To assure a minimum risk of breakage, and acceptable amount of wear, and an acceptable degree of heat transfer, the minimum value of the end point front angles B, E is preferably at least 20 degrees, and the minimum value of the end point side angles C, F is preferably at least 65 degrees. To assure acceptable hole quality, the maximum value of the end point front angles B, E is preferably no more than 65 degrees, and the end point side angles C, F is preferably no more than 75 degrees.
There are many other modifications, variations, and adaptations which can be made to the trepanning tool 52 without adversely affecting its ability to generate holes of high quality in composite work pieces with minimum thrust and torque requirements. For example, the front surface 34 of each outwardly-directed cutting tooth 24 may intersect the outer surface 30 adjacent the cutting end point 44 at an acute angle to form the outer circumference cutting edge 38; similarly, the front surface 64 of each inwardly-directed cutting tooth 54 may intersect the inner surface 62 adjacent the cutting end point 56 at an acute angle to form the inner circumference cutting edge 68.
Neither the front surface 34 nor the top surface 36 of each inwardly-directed cutting tooth 24 are required to be planar surfaces, so long as the front surface 34 intersects the top surface 36 adjacent the cutting end point 44 at an acute angle to form the top end cutting edge 42, the top surface 36 intersects the outer surface 30 adjacent the cutting end point 44 at an angle not exceeding 90 degrees to form the outer circumference cutting edge 38, and the top surface 36 intersects the outer surface 30 adjacent the cutting end point 44 at an acute angle to form the outer circumference cutting edge 38. Similarly, neither the front surface 64 nor the top end surface 66 of each inwardly-directed cutting tooth 54 are required to be planar surfaces, so long as the front surface 64 intersects the top surface 66 adjacent the cutting end point 56 at an acute angle to form the top end cutting edge 70, the front surface 64 intersects the inner surface 66 adjacent the cutting end point 56 at an angle not exceeding 90 degrees to form the inner circumference cutting edge 68, and the top end surface 66 intersects the inner surface 62 adjacent the cutting end point 56 at an acute angle to form the top trailing edge 72.
The number of cutting teeth 24, 54 of the trepanning tool 52 may be varied, depending on the type of composite and size of hole to be driller therein, the tool material, and the drilling speed, so long as it includes at least one outwardly-directed cutting tooth 24, and at least one inwardly-directed cutting tooth 54. Preferably, when an even number of cutting teeth is used, half of these cutting teeth will be outwardly-directed cutting teeth 24, and the remainder will be inwardly-directed cutting teeth 54, with outwardly-directed cutting teeth 24 being disposed between two inwardly-directed cutting teeth 54, and vice versa.
Also, other known types of guiding devices can be used for the initial positioning and guidance of the trepanning tool 52 to replace the pilot member 50 and eliminate the need for drilling a pilot hole 78 for receiving the pilot member 50. For example, it is well known in the art to use an axially extending, retractable, spring-biased, pilot member having one end slidably disposed within the tool arbor 18 and an opposite sharp pointed end which is pressed into the composite to provide initial placement and guidance for the trepanning tool 52. If desired, the surface of the composite may be pricked or punched to receive the sharp end point of this spring-biased pilot member. When the trepanning tool 52 is used with a hand-held power tool, it is desirable that the tool 52 include a pilot element such as the pilot member 50 or the above-described known retractable spring biased pilot member to correctly position the tool 52 and prevent it from skipping across the composite work piece when the hole forming operation is initiated. The trepanning tool 52 does not need to include a pilot element when it is used with hole-drilling apparatus which includes guiding elements for the tool 52. For example, the tool 52 may be guided with conventional hardened guide bushing, which is well known to the art.
The foregoing relates to preferred embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
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A method and tool for trepanning holes in a composite of materials having different strength and elastic characteristics. The method provides for simultaneous point and surface cutting which occurs at the inner and outer circumferential surfaces of an annular hold being formed. The trepanning tool includes a cylindrical side wall with portions removed at one end to form a plurality of cutting elements or teeth. Each tooth includes a cutting single end point and associated cutting edges, there being inwardly and outwardly directed teeth.
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RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Application No. 60/883,656, entitled WALL AVOIDING MOUNT FOR FLAT PANEL ELECTRONIC DISPLAY, filed Jan. 5, 2007, and U.S. Provisional Application No. 60/957,941, entitled WALL-AVOIDING SELF-BALANCING MOUNT FOR TILT POSITIONING OF AN ELECTRONIC DISPLAY, filed Aug. 24, 2007, both of which are hereby fully incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
The present invention relates to flat panel display devices, and more specifically to mounting devices for flat panel electronic display devices.
BACKGROUND OF THE INVENTION
An attribute of modern flat-panel electronic displays that makes them highly desirable to consumers is the aesthetic appeal of a very flat device that has the appearance of a framed photo or painting when hung from a wall. This same attribute is also desirable in that floor and interior space taken up by the display is minimal.
With current flat panel display technology, however, best viewing quality is typically achieved when the screen is viewed at as near as possible to a ninety degree angle from the plane of the screen. Liquid crystal displays will often appear perceptibly darker at the more oblique angles. In other cases, particularly with plasma displays, glare from the screen surface may impair viewing. Consequently, it is desirable to have the ability to selectively position the display to enable best viewing quality.
Numerous wall mounting devices for flat panel displays have been developed so as to enable tilt and/or swing positioning of the display. Examples of such mounting devices are disclosed, for example, in U.S. Pat. Nos. 6,905,101, 7,028,961, and 7,152,836, all of which are owned by the owner of the present invention and are hereby fully incorporated herein by reference.
A drawback of these previous mount designs is that the edges of the display may sometimes collide with the wall surface during positioning. These collisions may leave unsightly marks or gouges in the wall surface, or may cause damage to the display itself. Hence, there is still a need for a flat panel display mount that enables selective positioning of the display while alleviating the undesirable effects of wall collisions.
SUMMARY OF THE INVENTION
The present invention addresses the need in the industry for an electronic display mount that enables selectively positioning of the electronic display, while alleviating the undesirable effects of wall collisions. Device and methods according to the present invention generally include a support structure operably connected to a display interface structure and a tilt head assembly. The display interface structure is attached to the electronic display. The support structure includes an extendable arm assembly, a pivot column, and a swingstop post. The support structure can be used to rotatably position the electronic device about a substantially vertical axis. The tilt head assembly includes an attachment member, a positionable plate, and guide structures. The tilt head assembly can be used to rotatably position the electronic display about a substantially horizontal axis.
According to an embodiment of the present invention, the extendable arm is selectively positionable to a plurality of positions. The pivot column defines the substantially vertical axis about which the support structure can be rotated. The swingstop post defines a plurality of ranges of rotation of the extendable arm assembly about the substantially vertical axis. Each position of the extendable arm assembly corresponds to a range of rotation.
According to another embodiment of the present invention, the first and second guide structures define a path of rotation of the electronic display about the substantially horizontal axis. The electronic display is substantially self-balancing at any point along the path of rotation.
According to another embodiment of the present invention, the plate is positionable in a plurality of positions. Each position defines a different location of the substantially horizontal axis.
According to another embodiment of the present invention, a system comprises an electronic display device and a support structure operably connected to a display interface structure and a tilt head assembly. The display interface structure is attached to the electronic display. The support structure includes an extendable arm assembly, a pivot column, and a swingstop post and can be used to rotatably position the electronic device about a substantially vertical axis. The tilt head assembly includes an attachment member, a positionable plate, and guide structures. The tilt head assembly can be used to rotatably position the electronic display about a substantially horizontal axis.
According to another embodiment of the present invention, a method provides for positioning an electronic display mounted to a substantially vertically oriented surface with a mounting device. The mounting device includes a support structure operably connected to a display interface structure and a tilt head assembly. The method comprises extending the support structure to a first extended position, rotating the electronic display about a substantially vertical axis within a range of rotation defined by the first extended position, positioning the tilt head assembly, and rotating the electronic display about a substantially horizontal axis to a first tilted position. The electronic display is self-balancing in the first tilted position.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the present invention may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings, in which:
FIG. 1 is a front perspective view of a flat panel electronic display and mount according to an embodiment of the invention;
FIG. 2 is a perspective view of a mount according to an embodiment of the invention coupled with a wall assembly and with a flat panel electronic display mounted thereon and shifted away from the wall assembly;
FIG. 3 is a rear perspective view of the display and mount of FIG. 1 ;
FIG. 4 is a rear perspective view of a mount according to an embodiment of the invention coupled with an electronic display;
FIG. 5 is another rear perspective view of a mount according to an embodiment of the invention coupled with an electronic display;
FIG. 6 is a fragmentary rear perspective view of a portion of the mount of FIG. 3 depicted without the extendable arm assembly and display for clarity;
FIG. 7 is a fragmentary rear perspective view of the display and mount of FIG. 3 ;
FIG. 8 is an exploded view of the tilt head and support column assemblies of a mount according to an embodiment of the invention;
FIG. 9 is a fragmentary side elevation view of the tilt head portion of a mount according to an embodiment of the invention;
FIG. 10 is a fragmentary side elevation view of the tilt head of FIG. 9 with the pitch member removed for clarity;
FIG. 11 is a fragmentary side elevation view of the inner yoke of the tilt head of FIG. 9 ;
FIG. 12 is a side elevation view of the mount and display of FIG. 3 , depicting the tilting motion of the display;
FIG. 13 is a rear perspective view of a display coupled with the tilt head and display interface structure portions of a mount according to an embodiment of the invention;
FIG. 14 is a top plan view of a display and mount according to an embodiment of the invention depicting the swing motion of the display in a first position relatively spaced apart from a wall surface;
FIG. 15 is a top plan view of a display and mount according to an embodiment of the invention depicting the swing motion of the display in a second position relatively more proximate a wall surface;
FIG. 16 is a top perspective view of a lower pivot bushing of a mount according to an embodiment of the invention;
FIG. 17 is a top plan view of the bushing of FIG. 16 ;
FIG. 18 is a side elevation view of the bushing of FIG. 16 ;
FIG. 19 is a top perspective view of an upper pivot bushing of a mount according to an embodiment of the invention;
FIG. 20 is a top plan view of the bushing of FIG. 19 ;
FIG. 21 is a side elevation view of the bushing of FIG. 19 ;
FIG. 22 is a front perspective view of the swing limit cam of a mount according to an embodiment of the invention;
FIG. 23 is a top plan view of the cam of FIG. 22 ;
FIG. 24 is a bottom plan view of the cam of FIG. 22 ;
FIG. 25 is a fragmentary bottom perspective view of a portion of a mount according to an embodiment of the invention, depicting the bottom pivot bushing interfacing with the swing limit cam;
FIG. 26 is a fragmentary perspective view of the lift adjuster mechanism of a mount according to an embodiment of the invention;
FIG. 27 is a side elevation view of a mount and display according to an embodiment of the invention with the display in an upright position;
FIG. 28 is a side elevation view of the mount and display depicted in FIG. 4 with the display in a fully tilted position;
FIG. 29 is a top plan view of a mount according to an embodiment of the invention;
FIG. 30 is a rear elevation view of a mount according to an embodiment of the invention;
FIG. 31 is a side elevation view of the mount depicted in FIG. 7 ;
FIG. 32 is a fragmentary perspective view of a mount according to an embodiment of the invention, depicted in a tilt position;
FIG. 33 is a perspective view of the yoke component of a mount according to an embodiment of the invention;
FIG. 34 is a perspective view of the threaded coupler component of a mount according to an embodiment of the invention;
FIG. 35 is a perspective view of the interface plate component of a mount according to an embodiment of the invention;
FIG. 36 is a perspective view of the outer pitch arm component of a mount according to an embodiment of the invention;
FIG. 37 is a perspective view of the inner pitch arm component of a mount according to an embodiment of the invention;
FIG. 38 is a side elevation view of the outer pitch arm component of a mount according to an embodiment of the invention;
FIG. 39 is a side elevation view of the inner pitch arm component of a mount according to an embodiment of the invention;
FIG. 40 is a fragmentary perspective view of the slide block and guide track of a mount according to an embodiment of the invention;
FIG. 41 is a perspective view of a slide block component of a mount according to an embodiment of the invention;
FIG. 42 is a perspective view of the second mounting plate component of a mount according to an embodiment of the invention;
FIG. 43 is a perspective view of the first mounting plate component of a mount according to an embodiment of the invention; and
FIG. 44 is a perspective view of a mount according to an embodiment of the invention with an in-wall mounting interface.
While the present invention is amendable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the present invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-5 , a wall-avoiding mount is generally depicted with reference numeral 100 . Mount 100 can be used to mount flat panel display 101 to wall 102 . Generally, mount 100 includes support structure 103 , tilt head 104 , and display interface structure 106 . Mount may also include in-wall box 108 .
Support structure 103 generally includes extendable arm assembly 110 , support column assembly 112 , and swing limit cam 114 . Extendable arm assembly 110 generally includes wall interface 116 and arms 118 , pivotally coupled together at pivots 120 . Lateral spacers 122 may be provided at pivots 120 to provide lateral spacing between adjacent arms 118 in order to avoid pinch points and shearing action as extendable arm assembly 110 is extended and retracted. As depicted in FIGS. 14-15 , extendable arm assembly 110 enables display 101 to be selectively positioned at any desired distance outward from wall surface 124 .
It will be readily appreciated that extendable arm assembly 110 may include virtually any desired number of arms 118 so as to enable a desired range of movement outward from wall surface 124 . Further, consistent with other aspects of embodiments of the invention disclosed herein, support structure 103 may include or consist of any other structure providing support for tilt head 104 , such as swing arm arrangements or fixed mounting brackets. Moreover, support structure 103 may be attached directly to wall surface 124 , or may be advantageously used with in-wall attachment arrangements such as disclosed for example in the U.S. Provisional Application No. 60/883,652 CENTERING IN-WALL MOUNT filed by the owners of the present invention on Jan. 5, 2007, the complete disclosure of which is hereby fully incorporated herein by reference.
Support column assembly 112 generally includes tubular vertical column 126 , upper pivot bushing 128 , lower pivot bushing 130 and lift adjuster assembly 132 . Upper pivot bushing 128 , as depicted in FIGS. 19-21 , generally includes body portion 134 defining central bore 136 . Tab 138 extends from body portion 134 and defines pivot aperture 140 . Body portion 134 is generally cylindrical with front edge 142 having a smaller radius than rear edge 144 , defining a pair of shoulders 146 , 148 .
Similarly, lower pivot bushing 130 , as depicted in FIGS. 16-18 , generally includes body portion 150 defining central bore 152 . Tab 154 extends from body portion 150 and defines pivot aperture 156 . Body portion 150 is generally cylindrical with front edge 158 having a smaller radius than rear edge 160 , defining a pair of shoulders 162 , 164 .
Upper and lower pivot bushings 128 , 130 , are vertically and rotationally slidably disposed on column 126 , with column 126 extending through central bores 136 , 152 , respectively. Separate arms 118 of extendable arm assembly 110 are pivotally attached to tabs 138 , 154 , of each of upper and lower pivot bushings 128 , 130 , with pivots 166 extending into pivot apertures 140 , 156 .
Lift adjuster assembly 132 as depicted in FIG. 26 generally includes body 168 , attaching fastener 170 , and lift screw 172 . Body 168 is attached proximate upper end 174 of column 126 with attaching fastener 170 . Lift screw 172 is threadedly received in body 168 and includes bearing plate 176 at lower end 178 . Thumb knob 180 may be provided on upper end 182 to enable lift screw 172 to be easily threaded in and out of body 168 with the fingers.
In use, bearing plate 176 slidably bears on upper surface 184 of upper pivot bushing 128 , thereby vertically locating upper pivot bushing 128 on column 126 . The relative vertical position of upper pivot bushing 128 is selectively adjustable by threading lift screw 172 in or out of body 168 , thereby lowering or raising upper pivot bushing 128 relative to column 126 . As extendable arm assembly 110 is extended and retracted, upper pivot bushing 128 remains in position while lower pivot bushing 130 slides vertically on column 126 .
Swing limit cam 114 , as depicted in FIGS. 22-25 , generally includes elongate body 186 presenting lower end 188 and upper end 190 . Lower end 188 has width dimension W that is generally wider than width dimension W 1 of upper end 190 . Intermediate portion 192 is tapered, presenting upwardly sloping opposing flanks 194 . Front side 196 is concave, conforming to the radius of front edge 158 of lower pivot bushing 130 .
Swing limit cam 114 is affixed to the inner side 198 of tilt head 104 as depicted in FIG. 13 , with front edge 158 of lower pivot bushing 130 in registry with front side 196 as depicted in FIG. 25 . Column 126 is positioned along concave front side 196 of swing limit cam 114 and is fixed in rotational and vertical position relative thereto. In use, with display 101 positioned proximate wall surface 124 as depicted in FIG. 15 , lower pivot bushing 130 is relatively closer to bottom end 200 of column 126 . In this position, shoulders 162 , 164 , of lower pivot bushing 130 engage sides 202 of lower end 188 of swing limit cam 114 , limiting side-to-side swinging motion of display 101 to a relatively greater degree as depicted in FIG. 15 , so as to prevent contact of display 101 with wall surface 124 .
As extendable arm assembly 110 is extended outward and display 101 is positioned further away from wall surface 124 , lower pivot bushing 130 slides upward on column 126 and upward relative to swing limit cam 114 , which is vertically fixed in position on tilt head 104 . Once lower pivot bushing 130 reaches intermediate portion 192 , the greater distance between each of shoulders 162 , 164 , and sloping flanks 194 enables a steadily increasing range of side-to-side swinging motion for display 101 . When lower pivot bushing 130 reaches upper end 190 of swing limit cam 114 , a full range of side-to-side swinging motion for display 101 is enabled, as depicted in FIG. 14 .
It will be appreciated that the vertical position of swing limit cam 114 may be adjusted on tilt head 104 to alter the relative distance from wall surface 124 at which lower pivot bushing 130 begins to encounter intermediate portion 192 and upper end 190 . Moreover, it will be appreciated that the geometry of swing limit cam 114 may be altered as desired to produce desired swing limiting characteristics. For example, swing limit cam 114 may be made relatively longer with more gently sloping flanks 194 to enable a more gradual limiting of swing motion relative to distance. In another example, opposing flanks 194 may a provided with differing slopes so as to enable a greater range of swing motion in one direction relative to the opposing direction.
Tilt head 104 is generally attached intermediate support structure 103 and display interface structure 106 . In a first example embodiment, tilt head 104 generally includes inner yoke 204 , pitch cams 206 , and pitch member 208 , as depicted in FIGS. 8-11 . In a second example embodiment, tilt head 104 generally includes body portion 210 , a pair of inner pitch arms 212 , a pair of outer pitch arms 214 , and a display interface assembly 216 , as depicted in FIGS. 27-32 .
Referring to the first example embodiment of tilt head 104 depicted in FIGS. 8-11 , inner yoke 204 generally includes back plane 218 defining laterally oriented opening 220 , and having parallel projecting flanges 222 , 224 . Each of flanges 222 , 224 , define upright guide structure 226 , first oblong aperture 228 , and second oblong aperture 230 , in lateral registry across tilt head 104 .
Each pitch cam 206 defines a guide structure 232 , which may be in the form of an elongate slot, and a pair of apertures 234 , 236 . Pitch cams 206 are secured on the outer surface 238 of each of flanges 222 , 224 , with aperture 234 in registry with oblong aperture 228 and aperture 236 in registry with oblong aperture 230 . Travelers (not depicted) extend through each of the registered aperture pairs 228 , 234 and 230 , 236 . The travelers are slidable in oblong apertures 228 , 230 such that pitch cams 206 are selectively positionable relative to inner yoke 204 as depicted in FIG. 10 .
Pitch member 208 generally includes back plane 239 having parallel projecting flanges 240 , 242 . Each of flanges 240 , 242 , define apertures 244 , 246 , in lateral registry across tilt head 104 . Inner yoke 204 and pitch cams 206 are disposed between flanges 240 , 242 , with apertures 244 in registry with guide structures 232 , and apertures 246 in registry with guide structures 226 . Followers 248 extend through apertures 244 and slidably engage in each guide structure 232 , and followers 250 extend through apertures 246 and slidably engage in each guide structure 226 .
Display interface structure 106 as depicted in FIG. 13 , generally includes vertical uprights 252 , 254 , horizontal braces 256 , 258 , central reinforcing plate 260 , and gusset plates 262 , 264 . Vertical uprights 252 , 254 , are secured to back side 266 of display 101 with fasteners 268 . Horizontal braces 256 , 258 , are secured to vertical uprights 252 , 254 , and are coupled with gusset plates 262 , 264 . Central reinforcing plate 260 extends between and is secured to horizontal braces 256 , 258 . Pitch member 208 engages and is secured to horizontal braces 256 , 258 .
In use, as depicted in FIG. 12 , display 101 is tiltable about a generally horizontal tilt axis by grasping the top edge 270 of the display 101 and pulling outward. As display 101 tilts, followers 248 slide in guide structures 232 , and followers 250 slide in guide structures 226 to guide and define the tilting path of travel for display 101 . Notably, as display 101 tilts forward, bottom edge 272 maintains substantially the same distance from wall surface 124 . Hence, even when extendable arm assembly 110 is retracted so that display 101 is positioned immediately proximate wall surface 124 , display 101 will not contact wall surface 124 at any point in the tilting motion.
Another desirable feature of tilt head 104 as also depicted in FIG. 12 is that guide structures 226 and guide structures 232 may be oriented so as to define a path of travel about a tilt axis located generally below and forward of display 101 , such that center of gravity 274 translates along a substantially horizontal axis 198 , and the display 101 is substantially “self-balancing.” That is, display 101 will maintain a desired tilt position without being held by a secondary friction source.
It will be appreciated that the position of pitch cams 206 may be adjusted so as to alter the position of the tilt axis for display 101 and also the path along which the center of gravity will translate upon tilting. Further, it will be appreciated that the shape of guide structures 226 , 232 , may be altered so as to give a desired effect to the tilt motion of display 101 . For example, guide structures 226 , 232 , may be substantially straight as depicted, or either or both may be curved, angular, or any other desired shape. Guide structures 226 , 232 themselves, although depicted as slots, may be any other suitable structure capable of guiding a follower, such as channels, grooves, cam surfaces, and the like.
Referring to the second example embodiment of tilt head 104 depicted in FIGS. 27-32 , body portion 210 generally includes yoke portion 276 with a pair of projecting uprights 278 , 280 . Yoke portion 276 defines central bore 282 , of which a portion proximate bottom end 284 may be threaded to receive threaded coupler 286 . Each of uprights 278 , 280 , defines guide track 288 facing laterally outward. A slide block 290 is slidably disposed in each guide track 288 as depicted in FIG. 40 . Slide block 290 defines aperture 292 . Each upright 278 , 280 , defines aperture 294 therethrough proximate top end 296 .
Inner pitch arm 212 is elongate, presents opposing ends 298 , 300 , and defines apertures 302 , 304 proximate ends 298 , 300 , respectively. Inner pitch arm 212 further defines aperture 306 intermediate ends 298 , 300 .
Outer pitch arm 214 is also elongate, presents opposing ends 308 , 310 , and defines apertures 312 , 314 proximate ends 308 , 310 , respectively. Clearance notch 316 is defined in lateral margin 318 proximate aperture 320 .
Display interface assembly 216 generally includes interface plate 322 , first mounting plate 324 , and second mounting plate 326 . Interface plate 322 includes display attachment portion 328 and projecting parallel flanges 330 , 332 . Display attachment portion 328 defines apertures 334 and elongate apertures 336 for attaching first and second mounting plates 324 , 326 and display 101 with fasteners (not depicted). Each flange 330 , 332 defines elongate guide slot 338 and pivot apertures 340 .
Each inner pitch arm 212 is pivotally coupled to one of uprights 278 , 280 , with a pivot pin 342 extending through aperture 294 . The other end of each inner pitch arm 212 is coupled with interface plate 322 with pivot 344 slidable in elongate guide slot 338 . Each outer pitch arm 214 is pivotally coupled to slide block 290 with pivot 346 extending through aperture 292 . The other end of each outer pitch arm 214 is pivotally coupled to interface plate 322 with pivot pin 348 extending through apertures 312 , 314 , 340 . Notch 316 enables outer pitch arm 214 to clear pivot 344 when mount 100 is positioned in an upright position, as depicted in FIG. 27 .
In use, display 101 may be first disposed in a generally vertical upright position, as depicted in FIG. 27 . Lower corner 350 is disposed a distance D from upright column 352 of extendable arm assembly 110 , upon which yoke portion 276 is received. Center of gravity C.G. of display 101 is disposed along generally horizontal axis A-A, which is a distance X above bottom end 284 of yoke portion 276 .
A user may selectively tilt display 101 forward as depicted in FIG. 28 by grasping and pulling top edge 270 of display 101 . As the user pulls, each inner pitch arm 212 pivots about pivots 344 , 346 , and pivot 344 slides in elongate guide slot 338 . Simultaneously, each outer pitch arm 214 pivots about pivots 346 , with each slide block 290 sliding upward in guide tracks 288 . Advantageously, center of gravity C.G. of display 101 translates substantially along axis A-A, which is maintained at distance X above the bottom end 284 of yoke portion 276 , while lower corner 350 remains substantially at the same distance D from upright column 352 . The effect is for display 101 to be essentially self-balancing, able to maintain any desired tilt position between the upright position depicted in FIG. 27 and the fully tilted position depicted in FIG. 28 without the addition of significant additional friction between any of the components of mount 100 . Further, the lower corner 350 of display 101 maintains an essentially constant distance from wall assembly 354 as display 101 is tilted, thereby eliminating the problem of display 101 striking wall assembly 354 , even when mount 100 is fully retracted as depicted in FIG. 44 .
In the embodiment depicted in FIGS. 30-31 , mount 100 additionally includes friction element 356 , which may include a bolt 358 extending through an aperture defined in inner pitch arm 212 and guide slot 360 defined in outer pitch arm 214 . Friction washer 362 abuts outer surface 364 of outer pitch arm 214 and is held in place with nut 366 . Notch 368 is defined in each of parallel flanges 330 , 332 to clear friction element 356 .
In use, friction can be selectively added if needed to maintain a desired tilt position by tightening nut 366 . Conversely, friction can be removed to enable freer positioning of mount 100 by loosening nut 366 .
The embodiments above are intended to be illustrative and not limiting. Additional embodiments are encompassed within the scope of the claims. Although the present invention has been described with reference to particular embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.
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A device for mounting an electronic display to a wall includes a support structure operably connected to a tilt head assembly and a display interface structure. The support structure includes an arm assembly that can be extended and rotated so that the electronic display avoids contacting the wall. The tilt head assembly includes an attachment member, guide structures for tilting the electronic display so that the electronic display remains self-balancing, and a plate for positioning the guide structures. The display interface structure facilitates attachment of the attachment member to the electronic display.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 08/027,395 filed Mar. 8, 1993, now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 07/981,282 filed Nov. 25, 1992, and now abandoned, the disclosures of which are incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE PRESENT INVENTION
The present invention is related to cut-resistant yarns and associated fabrics, cordage, or non-woven products, which may be produced with the yarn. It is also related to static dissipative materials, materials reinforced for strength, and abrasion-resistant materials. Most particularly, the present invention is related to the above products when containment of a core material is required due to the potential for hazard to the employee, product, or environment if the core material is exposed.
There has been significant activity in recent years with regard to the manufacture of yarns and fabrics for cut-resistant protective apparel. Many of these activities deal with the use of stainless steel wire in conjunction with various fibers to attain an optimal balance of cut resistance and flexibility, coupled with cost of production.
U.S. Pat. No. 4,384,449 to Byrnes, Sr., et al. teaches the use of a longitudinally positioned wire strand covered with aramid, and the numerous resulting advantages of such wrapped wire. One advantage is superior cut resistance performance, when compared to gloves formed of pure aramid. Byrnes, Sr. also describes improved knitability on a conventional glove knitting machine, and improved dexterity of a glove knitted from such a wire yarn.
U.S. Pat. No. 4,470,251 to Bettcher extends the teachings of the above-mentioned Byrnes, Sr. patent by illustrating two primary discoveries. First, that two or more smaller wire strands yield greater flexibility than one strand, while allowing a larger quantity of wire to be used, and the use of a longitudinally positioned fibrous strand incorporated with the wire strands further improves flexible movement. Second, Bettcher demonstrates that an outer covering formed of a polyamide, such as nylon, improves the comfort of the glove to the wearer.
Kolmes/Plemmons, in U.S. Pat. Nos. 4,838,017 and 4,777,789, teach the wrapping of annealed stainless steel wire about a core fiber; wrapping the strands of wire in opposing directions and further increasing flexibility of the fabric while maintaining cut protection. Kolmes/Plemmons also documented a broad range of fibers that can be used in the core and outer wraps of the composite yarn.
The established prior art referenced here offers teachings that have improved the state of protective apparel. While each is representative of improvement, the present invention extends far beyond these prior teachings and demonstrates a novel and unique approach which solves a serious and heretofore unaddressed issue related to the manufacture of protective apparel. One previously unrecognized problem is the fact that in the use of wire composite yarns, the wire strands frequently break, puncturing the skin of the wearer, contaminating various manufacturing and production operations, and exposing the wearer to the possibility of disease. Wire will invariably fracture after repeated flexure and will penetrate the surface of any known composite yarn.
The present inventor has discovered that the invention taught herein provides a method of containing wire and other materials such as fiberglass when these materials are used as the yarn core. To date, there has been no serious attempt by the Food and Drug Administration (FDA) or the U.S. Department of Agriculture (USDA) to eliminate the use of such materials as a yarn core, but the issue is volatile and will eventually need to be resolved. The resolution may not be one which industry finds acceptable or even practical.
Wire and fiberglass are known to provide additional cut resistance to composite yarns by microscopically altering the edge of the cutting surface. This is due to exceptional high density and abrasiveness, which dulls the edge of any cutting instrument or device that contacts the material. Wire and fiberglass also add strength to a yarn. The materials are preferred because of the many benefits they add to a composite relative to the cost. However, these same materials are controversial because they cannot be allowed to escape from the composite yarn into the work place for environmental and/or health reasons. The present invention provides a composite yarn and fabric which may selectively incorporate wire and/or fiberglass and/or other necessary but potentially harmful materials into the basic yarn core, but which offers protection to the worker from exposure to the materials, which materials may fragment or splinter and threaten the health of the worker and also damage the end product.
The present invention provides a novel method of forming a containment barrier around a single component or multi-component core of such controversial and potentially contaminating materials, and substantially decreases the risk of these contaminates being released. The foundation of the present invention is a composite yarn which uses melt-fusible thermoplastics or liquid adhesive coatings to encapsulate and thereby isolate one or more core materials which may present a threat of contamination to workers or the environment. This novel yarn is basically comprised of one or more core materials which are covered in thermoplastics or liquid adhesives and additional layers of material which form one or more outer layers. The combination is then heat-set or otherwise cured to form a flexible fiber barrier which surrounds and entraps the unsafe core.
In a first method of manufacture, the barrier which contains the selected core is created by melt fusing a thermoplastic material with other differing fiber products in such a way that these undesirable materials are trapped between a shroud of fused fibers and a fiber core. In other embodiments, materials which are longitudinally positioned to form the core are encapsulated in a continuous fibrous sheath with no adhesion between the sheath and an inner core yarn.
It is preferred to trap wire in a fused-fiber layer having a smooth outer surface which is unlikely to bond with subsequent outer cover layers. Because wire itself has a smooth surface unlikely to bond with thermoplastic, it is important that the core bond to the thermoplastic and isolate the wire therebetween. The combination becomes a highly effective containment vehicle that retains a high level of flexibility. While the end product, such as a glove, may become slightly more rigid after heat-treating to retain shape, the composite yarn is highly flexible and can therefore be easily knitted, woven, braided, or otherwise formed into a glove or other product. There are many different materials and processing methods available to form the composite yarn, depending on the end use desired. Conventional covering or wire-wrapping equipment is most suitable to manufacture this form of the composite yarn. Other equipment may be used as needed to preprocess materials that can later be wrapped or used as wraps. Examples are commingling machines, twisting equipment, and extruding machines.
It has also been discovered that a new group of adhesive coatings can be utilized and do not require the application of heat to fuse the containment fibers together. Most of these adhesive coatings are liquid at room temperature, enabling a method which allows greater freedom in yarn design by eliminating the effect that high temperature curing can have on fibers. With the exception of those compounds, which become thermoplastic when cured, these adhesives are thermostable and normally will not return to their original state. Therefore it is possible to manufacture yarns containing adhesives with cured melting temperatures higher than the associated fibers.
The group of useful adhesives includes, but is not limited to polyurethanes, silicone, natural or synthetic rubber, polysulfide systems, epoxy-polysulfides, vinylidene chloride and blended polymers derived from this group. The novel method eliminates the necessity for in-line curing ovens because curing occurs within the protective outer sheath. As will be described in more detail in the following material, coatings can be applied, covered, and the yarn taken up on the finished yarn package in a space of approximately sixty inches, with the yarn being processed at speeds of 150 feet per minute or more.
Methods of application will vary somewhat depending on the materials being processed, the volume of adhesive being required, and the characteristics desired for the finished product. These methods are more fully described below.
In either method of manufacture, the basic core of the composite yarn is selected from a group of fibers or types of other materials, which may be spun, continuous, multifilament, or monofilament. The basic core is selectively comprised of a single strand or multiple strands of single fiber type or a mixture of fiber types. The core structure is virtually unlimited and may include fiberglass, wire strands, thermoplastics, and/or other such controversial materials or combinations of such materials. The core structure may be of a plurality of such fibers combined by blend spinning, twisting, extrusion or any other method deemed appropriate to accomplish the desired core and end product.
Several previously unknown benefits of yarns manufactured in accordance with these methods have been discovered. It has been found that abrasives such as wire or fiberglass perform their function better when locked firmly in place. The function of abrasives in cut resistant yarns has been explained as dulling the cutting edge and thereby increasing the performance of the other high strength fibers. When wire is used, it tends to move away from the cutting edge exposing more fiber to the threat. When wire is fused in place as with the present invention, it engages the edge more directly and is more abrasive. It effectively shields subsequent layers until the full abrasive effect is used. This is also true with fiberglass. Fiberglass is not effective once it is fragmented and this occurs quickly upon contact with the cutting edge and during normal flexure.
By bonding the glass with the methods described, it is less easily shattered. The maximum abrasive ability is obtained by presenting the glass as a unified and unmoving abrasive surface that is not easily shattered. By making these abrasives more effective, it is now possible to attain equal cut protection with a lower abrasive content or to increase protection with equal contents.
When the cutting threat is from a chopping blow as opposed to a slashing movement, the present invention also exhibits unique abilities. The fused fibers of the invention are pulled in the direction of the cutting edge thus increasing the concentration of protective fiber and abrasives in the threat area. This increases the level of protection to this type of threat.
It has also been found that this method of manufacturing creates a yarn with improved abilities to absorb impacts and vibration of all types. This is due to the resilient properties present in the compounds used for fusing the composite together. This characteristic is useful to dampen vibration and provide a measure of protection from blunt trauma.
The core containment barrier has been found more useful in containing wire than originally believed. It was believed that longitudinally positioned strands of wire should not exceed 0.002 inch diameter due to an increased likelihood of puncturing the core containment barrier. Success was found with longitudinal wire strands of 0.006 inch diameter without increasing the overall diameter to the finished yarn. This allows the use of heavier wire strands with minimal risk of barrier puncture.
Finally, it has been observed that embodiments having cores formed largely of melt fusible thermoplastics become hollow after heat treatment. These embodiments are very unique and exhibit improved ductility. This is important in apparel applications where wearer comfort is important.
In some embodiments, rather than bond the core directly to the thermoplastic adhesive, it is desirable that the selected core is next covered with a layer of material which creates an inner core containment barrier separating the core from the surrounding melt-fusible thermoplastics. This is necessary to prevent the core structure from bonding with the thermoplastics and thereby restricting flexibility. Core materials that are particularly brittle will deteriorate quickly if not allowed to move freely within such a shroud. This inner core containment barrier may be of any material that has a higher melt point than the thermoplastics that surround it.
Using the heat-set method rather than liquid internal coating, a preferred embodiment includes a basic core, and around the circumference of the basic core, the first layer of one or more strands of wire may be wrapped to provide a second component to the core. The wire may be wrapped in one direction with one or more strands applied parallel to each other, or the wire may be twisted or combined in any other known way. The wire may also be wrapped in opposing directions relative to each other, with one strand being clockwise, and the other counterclockwise. The preferred wire is an annealed stainless steel 304 with a range of 0.008 inch diameter or smaller. The most preferred is 0.0045 inch for a single wrap, or 0.003 inch for a double wrap. Finer strands may be used when there is a combined plurality of wire strands. In such embodiments, using wire of 0.002 inch diameter or more, wrapping is preferred. The wire wrapped about the basic core may be wrapped at a pitch of 1 to 100 turns per inch, as the embodiment requires. It has been observed that the helical shape that is thus formed directs the wire's angle more to the center of the composite yarn structure. This becomes important when a wire strand fractures. Longitudinally positioned wire strands tend to project a rigid point when broken. This rigid point is then so oriented as to puncture the surface when the yarn is flexed and is difficult to contain.
Following application of the wire component to the basic core and/or the inner core containment barrier, an adhesive layer to be added to the composite yarn is selected from the group of melt-fusible thermoplastics. These may be polypropylene; low, high, or ultra-high-density polyethylene; low-melt nylon polyamid; or polyamid blends; or low-melt polyesters. A number of higher melt temperature thermoplastics exist which have not been tested, but are believed to be applicable for higher temperature applications and embodiments. This layer adhesive may be applied in several different ways, including wrapping, twisting or spinning about the core and the inner core containment barrier; may be longitudinally positioned with the core, extruded over the core, blended with the core, commingled with the core, or any combination of these methods. The thermoplastics also may be applied to the wire strands prior to wrapping the strands around the basic core. The selected method of combining the thermoplastics with the wire is dependent upon the number and size of the wire strands being utilized. The wire strands may be wrapped, twisted, paralleled, paralleled and wrapped with more thermoplastic, paralleled and wrapped with very fine denier non-thermoplastic, or the wire may be coated by means of any of the more conventional coating methods.
Selected thermoplastics for this layer may be monofilament, multifilament, spun or blended with other materials. The percentage of thermoplastic content in this layer is limited only to that which is necessary to properly contain and stabilize the underlying materials. When combining with the wire prior to wrapping the wire around the basic core member, two benefits are attained. First, prior combining allows a step to be eliminated in processing by not requiring a separate wrapping of thermoplastic. Secondly, the thermoplastic is concentrated only in the area that surrounds the wire, leaving some unfused areas to increase the flexibility of the composite. Some of the more effective methods will be detailed below.
The next layer is the primary core containment barrier and is selected from a broad group of synthetic or organic materials including but not limited to: polyester, nylon, aramid, high density polyethylene, ultra high molecular weight extended chain polyethylene, such as Allied Signal's SPECTRA, cotton, wool, polycotton, rayon, Hoechst Celanese's PBI, Dupont's TEFLON and blends thereof. The exceptions are those materials which are the same as those to be contained, and materials having melt points which are lower than the selected thermoplastic. This layer serves several functions:
1) It forms the layer of fiber that is fused with the underlying adhesive layer to form a shroud.
In certain embodiments wrapped wire is the material to be contained and this layer is utilized to fuse with the material of the basic core around which the wire is wrapped. This results in a sandwich effect that thoroughly traps the wire in a flexible capsule or fused fibrous material that is almost impenetrable.
2) In embodiments using wrapped wire, this shroud functions to prevent the wire from moving as the composite is heated. The selected fiber must therefore be of reasonably high tenacity and not generally susceptible to loss of strength at the fusion temperature of the underlying thermoplastic.
3) This layer adds cut resistance to the finished composite yarn.
4) This layer serves as a shroud that has sufficient thickness to absorb the underlying melt-fusible polymer and prevent the polymer from passing to the outer wraps. This is of particular importance when subsequent outer covers must be able to function independently of the core and core containment barrier yarns. Independent movement is sometimes necessary primarily for flexibility, but also allows the performance characteristics of the yarn not to be impeded by entrapment. It has been observed that yarns are more cut and/or abrasion resistant when the yarns are allowed to move freely with the cutting or abrading surface. This is simply illustrated by observing the relative ease with which a yarn may be cut under tension, versus one that is cut under less tension.
In addition to the above functions, when used in the wrapped wire embodiments, it is preferred that this third layer be wrapped at the number of turns per inch which provides an angle as close to 90 degrees relative to the wire as feasible. Near perpendicular angles are optimal to allow the finished composite yarn to perform. Present embodiments have attained a 70 degree angle at 8 turns per inch using 840 denier nylon. In other embodiments it is necessary to apply a lighter denier at a very high range of turns per inch. This is particularly true where multiple ends of wire are wrapped in opposing directions. The turns per inch must be a combination of optimal angles, total encapsulation, density of the layer and the fiber's ability to prevent movement of the wire during the heat cycle. It should be noted that the type 304 alloy of stainless steel has a coefficient of thermal expansion equal to 10.1×10 -6 per degree rise in temperature Fahrenheit. If the composite is processed at 295 degrees Fahrenheit then a one-inch section would normally expand to 1.00226846 inch. While this amount of movement may appear small, it does have the ability to deform the fabric if not controlled. Testing has shown that wire can push through the thermoplastic layer as the wire expands during the heat cycle, and this movement prevents a proper bond from forming because the thermoplastics tend to cool more quickly than wire. This layer ideally should be wrapped with a comparable range of turns per inch as the underlying core using a yarn of sufficient weight or diameter to provide complete coverage and density. However, yarns from 20 to 4800 denier may be used and may be applied from 3 to 200 turns per inch as the embodiment requires. This shroud layer may be one or more wraps in similar or opposing directions relative to one another. As with the basic core, this layer can be made up of a multiplicity of yarns, depending on the desired end effect or product.
In the preferred embodiments described below, it will be obvious that the simpler methods and yarn combinations achieve the best results.
A final, or outer, layer may also be added. This outer layer is of particular importance when the underlying layer is not capable of absorbing the molten thermoplastic and preventing it from rising to the surface of the finish product (known as "wet out"). The fiber content of this outer layer may be selected from the same group as the wire-containment barrier. There may be one or more of these outer layers and each may be similar or dissimilar. The selected material wrap may be of a single strand, multiple strands of a single yarn or a multiplicity of differing yarn fibers or types. This outer layer may also be spun over the underlying layers as with friction spinning equipment.
With use of such overlying multiple layers it is preferred, but not required, that each of the layers be wrapped in opposing directions. This method of wrapping in opposing directions is known as counterbalancing and has the effect of making the yarn balanced, straight, and with separate covering layers that tend to lock together and do not easily fray.
The combined selection of yarn fibers and types is based primarily on the end use of the yarn, the fabric or the product. Some of the more common materials are nylon, polyester, aramid, extended chain polyethylene, rayon, cotton or wool. However, the fibers/types may be selected from any of the synthetic or natural materials group. Any one of the layers or wraps may serve any of the functions of enhanced cut resistance, abrasion resistance, improved comfort to the wearer, increased thermal performance, enhanced texture for handling special materials, improved knitability, or other such characteristics.
When utilizing the liquid adhesive method of manufacture, the liquid coatings are applied to one or more of the aforedescribed core materials, prior to application of the other layer(s). This is done by drawing the selected core member through a trough mounted near the entry point of the covering mechanism. The volume of adhesive applied is controlled by dilution of the fluid, by varying the number of core yarns coated, and by altering the core's dwell time in the trough with repeated loops over a submerged feed wheel.
Following this liquid application the core member enters directly into the covering spindle(s) or spinning head and is covered with one or more fibers which absorb the excess adhesive and form the aforedescribed containment barrier. Sufficient fibers should be applied to prevent any possible fluid migration to the outer surface of the yarn. By absorbing the excess adhesive and eliminating possible migration to the outer surface of the yarn, the finished yarn can be immediately wound onto a package, before the liquid adhesive is cured. It has been proven that the volume of liquid adhesive which is applied to the core can be controlled and that a finished yarn can be accomplished with sufficient adhesive to migrate close to the yarn surface, thereby affecting texture and appearance, but without bonding the yarn to the package.
Such an application has been found beneficial in modifying yarns which have an unacceptable hand or color, but which otherwise demonstrate desirable characteristics. One example of such a yarn, manufactured by Allied Signal and sold under the trademark SPECTRA, demonstrates superior strength but is too slippery or slick for use in articles such as gloves.
It has also been discovered that with this liquid internal coating process, beneficial additives may be put into the core of the yarn. One such additive is grit which can be mixed with the liquid adhesive in sufficient volume to act as an abrasive which has the affect of dulling a cutting edge, therefore aiding in the cut resistance of the finished product. Grit of a sufficient size is also effective in inhibiting or preventing puncture by surgical needles by dulling the point of the needle, and by blocking the hollow channel of the needle. By blocking this channel, the surface area of the needle is increased and further penetration is substantially inhibited.
The finished novel composite yarn is applicable to knitting, weaving, braiding, twisting, or otherwise forming into a desired fabric or product. Once the end product is provided, the final step of thermoplastic fusion generally takes place. Treatment temperatures and exposure times will vary according to the characteristics of the thermoplastic, density of the composite and thickness of the article manufactured. With gloves, for example, a typical heat treating method would make use of a glove dotting machine which is designed for precise temperature and exposure time control. Yarns may also be heat treated on the package in a dry or wet yarn-conditioning oven.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A, 1B, 2A, 2B and 2C, 3, 4, 5, 7 and 8 are schematic representations of various embodiments of the composite yarn;
FIG. 6 is a perspective view of a glove made from the composite yarn;
FIG. 9 is a schematic representation of the manufacturing process of liquid adhesive application; and
FIGS. 10, 11 and 12 are schematic representations of embodiments wherein the yarn is manufactured according to the liquid adhesive application method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
These definitions will be helpful in identifying the various designations and functions of the described layers.
(1) Basic Core: May be one or more longitudinal materials including all thermoplastic fibers, and carbon fibers or other possible contaminate groups. Basic core may have these selected materials spun, wrapped, twisted or coated by application of liquid adhesive over one or more longitudinal members.
(2) Inner Core Containment Barrier: This is an optional layer for use in those embodiments that require separation of the core and adhesive layers. It may be spun or wrapped over the core. Selected materials only exclude those contaminates of the basic core or materials with melt temperatures equal to or lower than the thermoplastics of the heat processed embodiments.
(3) Adhesive layer: This layer may be used as the only source of adhesives, in conjunction with adhesives in the basic core, or not used at all when sufficient adhesion is available from materials in the basic core. The layer may be wrapped, spun, coated by application of liquid adhesive, twisted or positioned longitudinally to the basic core or inner core containment barrier layers.
(4) Primary Core Containment Barrier: From the same group of materials selected for the inner core containment barrier; may be wrapped or spun over the inner layers and be singular or a plurality of yarns combined in any way.
(5) Outer Layer(s): From the same group of containment barrier fibers; this layer or layers are optional to enhance performance as needed.
Looking first at FIG. 1A, a first embodiment is detailed as having a basic core 20 formed of 840 denier industrial grade nylon. A single wrap 25 of 0.0045 inch diameter annealed stainless wire is applied over core 20 at approximately 8 turns per inch of core length. Wrapped about this single wire wrap 25 is a low-melt-temperature thermoplastic adhesive layer 30 of a type such as 0.006 inch Shakespeare monofilament NX 1012 terpolyamide, thereby forming a wire/thermoplastic layer 32. The thermoplastic adhesive layer 30 is applied over wire 25 at approximately 10 turns per inch of wire core length. A primary core containment barrier 35 is applied in the opposite direction (relative to the wire/thermoplastic layer 32) and is preferably formed of 840 denier industrial grade nylon; again wrapped at approximately 8 turns per inch of core or yarn length. A final outer layer 40 is comprised of one strand, wrapped in a direction opposite to the underlying layer 35 at approximately 8 turns per inch of core or yarn, formed of 840 denier industrial grade nylon.
While this embodiment in FIG. 1A is one of the basic approaches, it combines the thermoplastic fiber with the wire wrap prior to wrapping the wire about the basic core. Thus, the adhesive action of the thermoplastic is concentrated in the critical areas. By wrapping the wire core with 840 denier nylon, the wire and nylon intersect at an optimal angle to contain the thermal expansion of the wire while still maintaining total coverage of the wire. Test results of this embodiment indicate that the composite yarn is equally cut-resistant to any other known wire/yarn products, and exhibits no detrimental rigidity resulting from the unique encapsulation of the wire.
Using the same basic structure of layers shown in FIG. 1A, another embodiment shown in FIG. 1B features a basic core material 20' of 1200 denier extended chain polyethylene wrapped with a wire strand 25' of 0.0045 inch diameter annealed stainless steel at approximately 5 turns per inch. The 0.0045 inch diameter steel wire 25' is itself wrapped with conventional multifilament or monofilament polyethylene 30' of approximately 200 denier before the wire is wrapped around the basic core 20'. A subsequent wrap 35' is, in this embodiment, formed of 650 denier extended chain polyethylene at a range of 5 to 6 wraps or turns per inch to completely cover the wire/thermoplastic layer 32'. The final outer wrapping 40' is formed of 840 denier industrial grade nylon wrapped at approximately 8 turns per inch of core or yarn.
It should be noted that this second basic embodiment described with reference to the layered structure of FIG. 1B utilizes an extended chain polyethylene having a melt point of approximately 297 degrees Fahrenheit to form layer 35' to wrap or cover the wire strand 25' which has been previously wrapped with a conventional polyethylene 30' having a melt point of approximately 200 degrees Fahrenheit, thereby ensuring formation of an adhesive bond between the encapsulating primary core containment barrier 35' and the core. Such a structure is preferred because the conventional polyethylene helps compensate for the poor adhesive performance of extended chain polyethylene. This structure also offers an exceptionally high level of cut resistance and an equally good ability to encapsulate the wire because of extended chain polyethylene's unsurpassed strength and cut resistance. Nylon is used as the outer wrap 40' because of its dissimilarity from the core. If the heat application is not precisely controlled the extended chain polyethylene material can reach the softening point and bond with the outer covers, thus increasing the likelihood of rigidity in the end product.
Looking next at FIG. 2A, and cross-sectional views 2B and 2C, a third embodiment has a core 50 formed of a single strand of 900 denier fiberglass. Positioned longitudinally of this core 50 is an adhesive layer 52 of three spaced apart strands of 0.006 inch Shakespeare NX 1012, strands 52a, 52b, and 52c having a melt point of 275 degrees Fahrenheit. A single encapsulation shroud or core containment barrier 54 is formed of 840 denier high tenacity nylon wrapped over the underlying materials at approximately 8 turns per inch of core or yarn length. A subsequent outer cover 56 is formed of the same 840 denier nylon wrapped in the opposite direction (relative to 54) at approximately 8 turns per inch. In this example the terpolyamide (melt fusible nylon) does not completely contain the core prior to application of heat. However, during the heat cycle the composite has a sufficient quantity of this melt fusible material to flow around the entire circumference of the core (FIG. 2C). Because the 840 denier nylon core containment barrier 54 is a polyamide, an excellent bond is formed with the melt fusible terpolyamide 52a, 52b and 52c. Residual polymer will adhere to the fiberglass core. The outer wrap 56 is not fused to the core containment barrier 54 because there are sufficient layers of the inner wrap to absorb the melt fusible material.
FIG. 3 illustrates a fourth embodiment which utilizes 14 strands of 35 micron type 304 stainless steel to form a longitudinally oriented core 70. The core 70 is wrapped with 650 denier extended chain polyethylene at 5 turns per inch to form an inner core containment barrier 72. Then multiple strands of 0.005 inch low density polyethylene monofilament are added to longitudinally surround the wrapped core parallel to the 14 strands of stainless steel which form core 70, thus forming adhesive layer 74. A final outer layer of 200 denier TFE fluorocarbon (such as that made by Dupont Corporation and sold under the trademark TEFLON) is wrapped in the opposite direction (relative to wrap 72) at approximately 12 turns per inch to form the outer cover or primary core containment barrier 76. In this example, unusually fine strands of wire are used to create a highly flexible core 70 which has a resulting denier equivalent to 1000; yet each of the individual strands is unable to puncture the relatively fine inner core containment barrier layer 72. The extended chain polyethylene that forms the inner core containment barrier 72 is preferably made by Allied Signal and sold under the trademark SPECTRA.
This FIG. 3 embodiment is somewhat unique when compared to the other embodiments taught herein in that the outer cover or primary core containment barrier 76 is in direct contact with the adhesive layer 74 and is therefore fused to the other materials. It has been found that due to the lubricity of TEFLON, the layer 76 must be fused in order to prevent the TEFLON layer from moving and exposing the materials beneath. Furthermore, TEFLON does not need to function independently in order to adequately perform in this embodiment. The unusually heavy layer prevents the thermoplastic adhesive layer 74 from flowing to the surface. This embodiment is particularly suited to the production of a cut-resistant surgeon's glove that is worn so as to underlie the conventional sterile latex glove used in most surgical facilities.
FIG. 4 illustrates a fifth embodiment wherein a basic core 90 is formed of 1000 denier KEVLAR 29 (aramid) made by Dupont Corporation. This basic core 90 is contained by a primary core containment barrier 94 formed of approximately 1000 denier polyester incorporated with two parallel strands 95a and 95b of 160 denier polyethylene. This layer 94 is wrapped at approximately 5 turns per inch in the opposite direction to the wrap of the outer core wire strand 92b. A final outer layer 96 is formed of the same polyester and is wrapped at approximately 5 turns per inch in a direction opposite that of the primary core containment barrier 94. This composite yarn is suitable for production of gloves that are knitted and then heat treated for approximately 5 minutes at 340 degrees Fahrenheit in a conventional glove-dotting machine.
In this embodiment of FIG. 4, the adhesive layers 91a, 91b and 91c are positioned beneath the core wire strands 92a and 92b longitudinally to the basic core 90. Additional thermoplastic is commingled with the primary core containment barrier 94 for ease of processing. Because two core wire strands 92a and 92b are used in opposing directions, the primary core containment barrier 94 is applied radially outwardly of the outer wire strand 92b. Since the first, or inner, wire strand 92a is wrapped with the same number of turns and in the same direction as the primary core containment barrier 94, it would normally push through the commonly oriented filaments of polyester during the heat cycle. By wrapping opposite the outer wire strand 92b, and thereby controlling its expansion, expansion of the inner wire strand 92a is thus also controlled. Polyester is useful as an encapsulating shroud and as an outer layer due to its shrinkage of approximately 14 percent of the heat-set temperature of 340 degrees Fahrenheit. Shrinkage causes the polyester to contract against the expanding wire and form more closely with the core material, establishing a strong adhesive bond.
The embodiment of FIG. 5 demonstrates there are a variety of yarn constructions that fall within the teachings of this disclosure and claims and can be used to create the same or similar products. This embodiment is comprised of a core 110 formed of approximately 14 strands of 35 micron type 304 stainless steel wire such as that manufactured by Beckert Company. Wrapped about this core 110 is an inner core containment barrier/adhesive layer 115 formed by combining a wrapping 115a of 200 denier industrial grade multifilament nylon, wrapped at approximately 30 turns per inch of core length, with a parallel strand 115b of 0.006 inch melt fusible terpolyamide monofilament. The preferred terpolyamide monofilament is Shakespeare NX 1012, which has a melt point of 275 degrees Fahrenheit. Positioned parallel to the core 110 and overlying layer 115 is a single strand 114 of 1200 denier TFE fluorocarbon, such as TEFLON. The TEFLON is carefully fed through a device that first flares the width of the multifilament, then tapers around the core 110 so as to surround the inner surface of the core 110 and layer 115 with TEFLON filaments. A final outer layer 116 of 200 denier nylon is wrapped at a range of 5 to 8 turns per inch in the opposite direction relative to the layer 115. This outer layer 116 holds the TEFLON in place until the composite yarn is heat-treated.
FIG. 7 illustrates a yarn construction wherein the core 200 is formed of an industrial grade polyester (500 denier) 202 combined with a single longitudinal strand of 0.003 inch type 304 stainless steel wire 205 and wrapped with a single strand of 0.003 inch type 304 stainless steel wire 205. The adhesive layer 210 is helically wrapped about the core 200 at approximately 7 turns per inch, preferably formed of 350 denier, 70 filament, low density polyethylene. Over this adhesive layer is a primary core containment barrier 215 formed of 500 denier industrial grade polyester which is helically wrapped opposite to the adhesive layer at approximately 9 turns per inch. A final outer layer 220 of 1000 denier industrial grade polyester is wrapped opposite to the primary core containment barrier 215 at a pitch of approximately 8 turns per inch. The finished yarn is then heat set for approximately two and one-half to two and three-quarter hours, at 280 degrees Fahrenheit in a steam conditioning unit. The yarn of this embodiment is highly suited for the construction of industrial gloves and other cut-resistant fabrics.
FIG. 8 illustrates a core 300 of 150 denier textile grade polyester 302 combined with 100 denier, 70 filament low-density polyethylene 305. Wrapped about this basic core is a single strand 310 of 0.002 inch type 304 stainless steel wire that is wrapped at a pitch of 24 turns per inch. The primary core containment barrier 315 (the final layer) is 300 denier textile grade polyester wrapped in a direction opposite to that of the wire at a pitch of approximately 10 turns per inch. The finished yarn is then heat set for one and three-quarter hours at 280 degrees Fahrenheit in a steam conditioning unit. This embodiment is best suited for finer cut-resistant fabrics, and most particularly, for cut-resistant surgical gloves.
FIG. 9 illustrates the progressive movement of a core member 400, formed of selected desired components, as it is drawn by known coating apparatus through a trough 410 which has a selected liquid-form adhesive therein. As previously described, the liquid adhesive 415 may be any of the polyurethanes, silicone, natural or synthetic rubber, polysulfide systems, epoxy-polysulfide, vinylidene chloride, or blended polymers derived from these. Others may also be suitable. As the coated core member 400 leaves the trough 410, it moves directly into a covering spindle or spindle head 420 where it is covered with a selected fiber, or fibers, which when combined with the liquid adhesive coating form the aforedescribed core containment barrier. The fiber covered core 400' is then wound onto a yarn package or moved forward to additional covering stations.
FIG. 10 illustrates a preferred embodiment of the finished yarn 450 wherein a basic core 454 of 650 denier SPECTRA is combined with a longitudinally positioned 0.0045 inch stainless steel wire strand 452. A single strand 456 of 0.003 inch stainless steel wire is wrapped over the basic core 454 at approximately 8 turns per inch. In a separate step, the core is coated and covered with a selected liquid adhesive 460; preferably polyester-based polyurethane containing 2 percent isocyanate crosslinker. One such crosslinker is designated UE-41-347 and supplied by Permuthane Coatings Company.
After the coating 460 is applied, the coated core receives a primary core containment barrier 462 and an outer layer 464 of 650 denier SPECTRA. The primary core containment barrier 462 is wrapped opposite to the wire strand 456 of the core, and both SPECTRA layers 462 and 464 are wrapped at approximately 9 turns per inch opposite to each other. The resulting yarn contains approximately 11 percent cured polyurethane and is suitable for cut-resistant gloves, sleeves and aprons.
FIG. 11 illustrates an embodiment wherein yarn 500 is formed by first coating a core 510 of 650 denier SPECTRA with a solution of polyester-based polyurethane and 2 percent isocyanate crosslinker which contains 30 percent by volume of a silicon grit to form a liquid adhesive coating 512. The preferred grit is a blend containing 40 percent of particle size 80 grit and 60 percent size 120 grit. The coated core then passes into the covering spindle (reference numeral 420 of FIG. 9) where a primary core containment barrier 511 and an outer layer 522 of 650 denier SPECTRA are applied, opposite to each other, at approximately 10 turns per inch. This finished yarn 500 contains 16 percent set polyurethane and 9 percent silicon carbide grit by weight. The grit is trapped in the adhesive bond that exists between the core and the outer fiber layers. This embodiment demonstrates enhanced cut resistance and additional puncture resistance. It is suited for industrial applications where such threats are a concern.
FIG. 12 illustrates another preferred embodiment wherein a yarn 600 is formed having a basic core of three strands 610 of 8.75 inch low density polyethylene monofilament combined with a parallel strand 612 of 0.0045 inch type 304 stainless steel wire. These core members are then wrapped with a strand of 0.003 inch type 304 stainless wire 611 at a pitch of approximately 10 turns per inch to complete the core. As in the embodiment of FIG. 10, the completed core is then coated with a solution of polyester-based polyurethane containing 2 percent isocyanate crosslinker to form a liquid adhesive coating 613. The next layer, primary core containment barrier 614, is 840 denier nylon wrapped opposite to wire strand 611 at 8 turns per inch. A first outer layer 616 of low-density polyethylene is wrapped opposite to the underlying primary core containment barrier 614 at a pitch of approximately 10 turns per inch. A final outer layer 618 of 840 denier nylon is then wrapped opposite to outer layer 616 at 8 turns per inch. The packaged yarn is heat treated with steam at 275 degrees Fahrenheit for approximately three hours. The resulting yarn possesses a core that is hollow except for the wire strands 612 and 611. The yarn 600 is highly cut resistant, exceptionally ductile and suited for knitting or weaving.
Finally, FIG. 6 illustrates a cut-resistant glove made from any one of the embodiments of the composite yarn described herein. The glove demonstrates improved cut resistance, flexibility and comfort. Other end products are anticipated to be made from the novel yarn described herein, other embodiments of the yarn are anticipated, and all are believed to be within the scope of the claims below.
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A composite yarn formed of melt-fusible thermoplastic fibers combined with selected other fibers and/or materials includes a containment barrier that encapsulates one or more core materials which may present a threat of contamination to workers and/or the environment. The composite yarn includes a core covered by an adhesive layer of thermoplastic material which forms a containment barrier, combined with one or more subsequent overlying layers of fibers wrapped or otherwise applied thereto using conventional yarn construction methods. In a preferred embodiment the core material is coated with a liquid adhesive, and preferably a polyester-based polyurethane which contains silicon grit, just prior to being wrapped with one or more layers of fibers which form the containment barrier. The cured and finished composite yarn is designed for knitting and weaving fabrics, or for otherwise forming cordage and non-woven products. The composite yarn also is utilized to produce end products such as cut-resistant apparel for environments where workers are exposed to possibly contaminated products or where core materials in the yarn can damage the end product of manufacture.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of German patent application 10 2011 108 112.0, filed Jul. 20, 2011, herein incorporated by reference.
BACKGROUND OF THE INVENTION
The invention relates generally to a yarn treatment chamber for the thermal treatment of a running yarn. The invention relates more particularly to a yarn treatment chamber for the thermal treatment of a running yarn, with a centre zone, in which a hot, gaseous or vaporous medium under pressure acts on the yarn, and end zones arranged on both sides of the centre zone, in which a cooling, gaseous medium is active, the end zones each having a yarn inlet opening or a yarn outlet opening with a yarn sluice, which, in the operating state in conjunction with the running yarn, seals the associated end zone and therefore the yarn treatment chamber
It is known in the textile industry to subject yarns, in particular after twisting or cabling, to a thermal treatment in a yarn treatment device and to therefore achieve a significant improvement in the yarn quality. A thermal treatment of this type does not only stabilise the state of the yarns after twisting or cabling, but also frees the yarns, in the process, from inner torsional forces. A thermal treatment of this type also often brings about an increase in volume of the yarns by shrink bulking.
Numerous patent applications, in which different yarn treatment devices are described, are known in the patent literature in connection with the thermal treatment of yarns. For example, it is proposed in various patent applications that a so-called yarn treatment chamber, with which a thermal setting can be carried out on the running yarn, is to be arranged in each case in the region of the workstations of twisters.
Yarn treatment chambers of this type, which are described in relative detail, for example, in European Patent Document EP 1 348 785 A1 or German Patent Document DE 103 48 278 A1, generally have a vertically arranged thermal treatment section with yarn inlet or yarn outlet openings opposing one another and arranged at the end.
In other words, the known yarn treatment chambers in each case have a centre zone, into which a hot, gaseous or vaporous treatment medium under pressure is blown, as well as end zones which are arranged on both sides of this centre zone and are acted on, in each case, with a cooling, gaseous medium, for example compressed air. The yarn inlet or yarn outlet opening arranged in the region of the end zones is in each case equipped with a sealing device, which seals the yarn treatment chamber from the environment. Sealing devices of this type are important components of yarn treatment chambers of this type as, on the one hand, efficient sealing has to be ensured by the yarn running through during operation and, on the other hand, the friction of the yarn running through should be as low as possible.
Even if there has been success with the known yarn treatment chambers in making the setting process of yarns relatively economical and efficient, there is still certainly potential for improvement in these yarn treatment chambers, in particular with regard to the arrangement of their yarn inlet opening and the configuration of their sealing devices. In other words, in the known yarn treatment chambers, the treatment section required for proper thermal treatment is relatively long, which, in conjunction with the vertical arrangement of the treatment section, leads to the upper yarn sluice arranged in the region of the yarn inlet opening generally being at a height of 2.5 m to 3.5 m and therefore being difficult for the operating staff to reach. In practice this means that the operating staff, if any work is necessary in the region of the upper yarn sluice, have to use an additional aid, for example a ladder or a comparable stepping assistance.
Consequently, with these yarn treatment chambers, both during maintenance work and also during the threading of a yarn, for example after a thread break or a feed material change, the operating staff always have to work with climbing assistance, which is laborious, time-consuming and not without danger when the textile machine is running.
Even if the known yarn treatment chambers are certainly configured in a comparable manner with regard to their thermal treatment section, these yarn treatment chambers differ, sometimes considerably, in particular with regard to their sealing devices, the so-called yarn sluices, arranged at the yarn inlet or yarn outlet openings.
The yarn treatment chamber described in European Patent Document EP 1 348 785 A1, for example, has sealing devices at the end of its thermal treatment section arranged in a linear orientation, which in each case consist of drivable outer sluice rollers and inner sealing rollers, the sealing rollers in turn being equipped with a resilient plastics material ring. The running yarn, when passing the sealing devices, slightly deforms the resilient plastics material rings, which leads to a proper sealing function. The plastics material rings of the sealing rollers are, however, very wear-sensitive so the relatively short service life of plastics material rings of this type requires short maintenance intervals of the yarn treatment chambers. Short maintenance intervals, however, as a rule often have a very negative effect on the overall efficiency of the textile machines equipped with yarn treatment chambers of this type. A comparable yarn treatment chamber is described in German Patent Document DE 103 48 278 A1, in other words, a yarn treatment chamber, in which the thermal treatment section formed from a centre zone and two end zones also has a linear orientation and in which a respective sealing device acting as a yarn sluice is arranged at the end in the region of the yarn inlet or its yarn outlet opening. The yarn sluice is, in this case, equipped with wear-resistant yarn guide elements. In other words, the yarn sluice either has two identical yarn guide elements, which are, in each case, configured in a semi-circular manner and which are pressed against one another by a spring element and, in the region of a common centre longitudinal axis, have recesses forming a yarn guide channel, or the yarn guide elements of the yarn sluice are configured such that one of the yarn guide elements is rotatably mounted in the manner of a revolver magazine and has a plurality of yarn guide channel recesses of different sizes.
The yarn sluices of the yarn treatment chambers known from German Patent Document DE 103 48 278 A1 are very wear-resistant, but yarn sluices of this type are problematical because of the often somewhat difficult adaptation of the cross section of their yarn guide channel to the respective thickness of the yarn.
A yarn treatment chamber for the thermal treatment of a running yarn is also described in the subsequently published German Patent Document DE 10 2010 022 211, in which the thermal treatment section has a linear orientation and, accordingly, the yarn inlet opening or the associated yarn sluice is arranged really high and is difficult to access for the operating staff. A respective yarn sluice, the yarn guide elements of which form a yarn guide channel, which is sealed by the running yarn in the operating state, is also arranged in this yarn treatment chamber in the region of the yarn inlet opening and the yarn outlet opening. For adaptation to the average thickness of the running yarn, at least one of the yarn guide elements of the yarn sluice can be positioned steplessly in various positions.
The yarn sluices also in each case have a sealing element, which rests on the yarn guide elements, extends along the yarn guide channel and reacts resiliently to defects in the running yarn. In other words, the sealing element of the yarn sluice, in conjunction with the associated yarn guide elements, ensures a proper seal of the yarn guide chamber relative to the atmosphere and therefore allows good thermal treatment of a running yarn in the yarn treatment chamber.
SUMMARY OF THE INVENTION
Proceeding from yarn treatment chambers of the type described above, the invention is based on the object of developing a yarn treatment chamber, which is designed as optimally as possible ergonomically, in other words, to provide a yarn treatment chamber, in which both the yarn inlet opening and the yarn outlet opening are accessible at all times, safely and without problems, for the operating staff.
This object is achieved according to the invention by a yarn treatment chamber for the thermal treatment of a running yarn, with a centre zone, in which a hot, gaseous or vaporous medium under pressure acts on the yarn, and end zones arranged on both sides of the centre zone, in which a cooling, gaseous medium is active, the end zones each having a yarn inlet opening or a yarn outlet opening with a yarn sluice, which, in the operating state in conjunction with the running yarn, seals the associated end zone and therefore the yarn treatment chamber. According to the present invention, the yarn inlet opening and the yarn outlet opening are arranged in such a way that the running yarn has to change its running direction, in that the yarn treatment chamber, for this purpose, has yarn deflection means to guide the yarn fed through the yarn inlet opening to the yarn outlet opening and in that both the first yarn sluice arranged in the region of the yarn inlet opening and the second yarn sluice arranged in the region of the yarn outlet opening are arranged in a manner accessible without problems to the operating staff at an ergonomically favourable height below the yarn deflection means of the yarn treatment chamber.
Advantageous features, configurations and advantages of the invention are described more fully hereinafter.
The configuration according to the invention, in which the yarn inlet opening and the yarn outlet opening are arranged in such a way that the running yarn has to change its running direction and the yarn treatment chamber is, for this purpose, equipped with yarn deflection means to guide the yarn fed through the yarn inlet opening, wherein both the first yarn sluice arranged in the region of the yarn inlet opening and the second yarn sluice arranged in the region of the yarn outlet opening are arranged to be accessible without problems for the operating staff, at an ergonomically favourable height below the yarn deflection means of the yarn treatment chamber, has the advantage, in particular, that the two yarn sluices of a yarn treatment chamber of this type can be arranged at a substantially lower installation height, so the yarn sluices of the yarn treatment chamber are accessible for the operating staff substantially with less danger and effort than the yarn sluices of the hitherto known yarn treatment chambers, which, because of their linearly running yarn treatment section, have a very high yarn inlet opening. The good accessibility both of the yarn sluices arranged in the yarn inlet opening and in the yarn outlet opening means that not only can faulty operations be minimised, but also machine stoppage times can be reduced which occur during the manual threading of a new yarn after a yarn break or during maintenance, for example during the periodic cleaning of lubrication deposits, which has a very positive noticeable effect, for example, with regard to the efficiency of the textile machine.
According to another aspect of the invention, it is provided in an advantageous embodiment that the yarn is deflected by more than 90° by the yarn deflection means. An adequately long yarn treatment chamber can be installed on a narrow space owing to a configuration of this type, both the yarn inlet opening and the yarn outlet opening being able to be positioned in an ergonomically favourable manner for the operating staff at the same time.
It is preferably provided according to another aspect of the invention that the first yarn sluice installed in the yarn inlet opening of the yarn treatment chamber and the second yarn sluice installed in the yarn outlet opening of the yarn treatment chamber are arranged in the region of the lower side of the yarn treatment chamber. An installation position of this type does not only ensure good accessibility of the two yarn sluices but also considerably facilitates the attending to the yarn treatment chamber required after an interruption of the twisting or cabling process.
According to another feature of the invention, the two yarn sluices are preferably arranged adjacently in the region of the lower side of the yarn treatment chamber and at an ergonomically favourable height. With a configuration of this type of the yarn treatment chamber, the parts of the yarn treatment chamber to be attended to by the operating staff, especially the yarn sluices, are arranged in a region, in which they are easily accessible at all times for the operating staff, even without additional aids. A configuration of this type consequently does not only ensure that the manual threading of a yarn into the yarn sluices is relatively easy and without effort, but also significantly increases the working safety at the workstations.
According to another aspect of the invention, it is furthermore provided that the centre longitudinal axis of the first yarn sluice arranged in the region of the yarn inlet opening runs parallel to the centre longitudinal axis of the second yarn sluice arranged in the region of the yarn outlet opening of the yarn treatment chamber, which also substantially facilitates the elimination of yarn breaks, for example.
The operating friendliness of the yarn treatment chamber is optimised as a whole by the above-described positioning of the yarn sluices, so a rapid and proper elimination of yarn breaks and/or disruptions becomes possible without problems. Moreover, in an arrangement of this type of the yarn sluices, the periodic cleaning of the yarn sluices from lubrication deposits also becomes substantially easier.
In a further feature of the invention, at least one thread guide tube is used as the yarn sluice, the inside width of which is in each case adapted to the diameter of the yarn to be processed. A reliable seal of the yarn treatment chamber from the environment can be realised relatively easily using thread guide tubes of this type in conjunction with the running yarn.
Thread guide tubes of this type, which preferably have a round cross section, are also safe with regard to faulty operations and relatively insensitive to soiling because of their good self-cleaning by the yarn running through. The friction losses occurring when the yarn runs through the thread guide tubes are also negligible. In other words, using yarn sluices in the form of thread guide tubes, a reliable seal of the yarn treatment chamber under excess pressure relative to the environment is always ensured during operation.
According to another aspect of the invention, it is provided in an advantageous embodiment that the respective thread guide tube can be fixed in a receiver of the yarn inlet opening or the yarn outlet opening in such a way that the thread guide tube, if necessary, for example for manual threading of a yarn after a thread break or in the course of a batch change, can easily be removed from the receiver and can be inserted into the receiver again without problems after a new yarn has been threaded in.
By a corresponding configuration of the thread guide tubes and/or the receiver, it is also to be easily ensured that the thread guide tubes are reliably held in the receivers during the working process.
Thread guide tubes are, as a whole, sealing devices, which ensure that the yarn treatment chamber is always reliably sealed relative to the environment during the thermal treatment of the yarn, regardless of the average thickness of the respective yarn.
In accordance with another feature of the invention, it is provided in an advantageous embodiment that a plurality of thread guide tubes are stored in a receiving element, in each case. The receiving element, in this case, preferably keeps ready various thread guide tubes, in other words, thread guide tubes, which differ with regard to their inside width. During a batch change, the operating staff can immediately react without problems to the new yarn and ensure a reliable seal of the yarn treatment chamber.
According to another aspect of the invention, the receiving element is preferably configured and arranged such that a first thread guide tube can be positioned in the region of the yarn inlet opening and a second thread guide tube can be positioned in the region of the yarn outlet opening of the yarn treatment chamber and can be fixed in a corresponding receiver of the yarn inlet opening or a corresponding receiver of the yarn outlet opening of the yarn treatment chamber. With a configuration of this type, the change times, in particular during a batch change, can be considerably reduced. Moreover, when a plurality of thread guide tubes with different inside widths are stored in a receiving element, as already described above, the required thread guide tubes are always available immediately for each batch.
Another embodiment is overall an economical configuration of the positioning of thread guide tubes in the region of the yarn inlet opening and the yarn outlet opening of a yarn treatment chamber.
Instead of a common receiving element for all the thread guide tubes of the yarn inlet and yarn outlet opening of the yarn treatment chamber, it is provided in an alternative embodiment that a first receiving element for thread guide tubes of the yarn inlet opening is arranged in the region of the yarn inlet opening and a second receiving element for the thread guide tubes of the yarn outlet opening is arranged in the region of the yarn outlet opening. By arranging two separate receiving elements, the number of thread guide tubes that can be kept ready in the receiving elements can be significantly increased and the variability of the yarn treatment chamber in relation to the processing of yarns with a different thickness can therefore be relatively easily increased.
The receiving elements may, in this case, have various embodiments. The receiving elements may, for example, be configured in the manner of a revolver magazine or may be configured as a linearly displaceable mounted series magazine. Which of these magazines is more advantageous during operation can only be assessed with difficulty. In other words, the type of magazine used should primarily emerge from the space conditions prevailing in the region of the workstations.
According to additional aspects of the invention, it is furthermore provided that the receiving element can be adjusted either manually or mechanically by means of a positioning drive.
The manual adjustment of the receiving element is a very economical solution here, but, with a manual adjustment of this type, the danger cannot be fully ruled out of a faulty adjustment occurring, in other words, the operator inadvertently positioning a thread guide tube in a receiver of the yarn inlet opening or the yarn outlet opening, said thread guide tube not precisely fitting the yarn to be processed.
The adjustment of the receiving element by means of a corresponding positioning drive is somewhat more complex, but has the advantage that with a corresponding configuration of the activation of the positioning drive, it can be ensured that the correct thread guide tube is always positioned in the relevant yarn inlet or yarn outlet opening.
In another feature of the invention, the positioning drive for the receiving element is preferably configured as a stepping motor. Steeping motors of this type, as is known, with regard to the exact adjustment of their angle of rotation and therefore the exact adjustment of the position of the receiving element, require only a relatively small control outlay. In other words, good reproducibility of the adjustment of the receiving element can be ensured relatively easily by means of a stepping motor.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details of the invention will be described below with the aid of an embodiment shown in the figures. In the drawings:
FIG. 1 shows a schematic diagram of a workstation of a twisting or cabling machine with a steam setting device, the yarn treatment chamber of which is configured according to the invention in such a way that the yarn inlet opening and the yarn outlet opening are arranged ergonomically favourably on one side of the yarn treatment chamber,
FIG. 1A shows one of the receivers arranged in the region of the yarn inlet opening and the yarn outlet opening to fix yarn sluices configured as thread guide tubes,
FIG. 2 shows, to a larger scale and in a perspective view, a first embodiment of a receiving element, with some of the yarn sluices configured as thread guide tubes,
FIG. 2A shows, in a perspective view, a second embodiment of a receiving element, with some of the yarn sluices configured as thread guide tubes,
FIG. 3 shows a first embodiment of the arrangement of a receiving element for positioning thread guide tubes,
FIG. 4 shows a further embodiment of the arrangement of receiving elements for positioning thread guide tubes,
FIG. 5A-5F show, as an example, a possible work sequence of various working steps, which are necessary to thread a yarn into yarn sluices configured as thread guide tubes and arranged in the region of the yarn inlet opening and the yarn outlet opening of a yarn treatment chamber.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 sketches a schematic view of a workstation 29 of a twisting or cabling machine. Textile machines of this type generally have a large number of structurally similar workstations 29 of this type, arranged next to one another.
As shown in the present embodiment, each of the workstations 29 has a twisting or cabling device 15 , a steam setting device 1 and a winding mechanism 24 . In the embodiment, a thread 17 drawn off from a feed bobbin 33 , which is arranged on a spindle of the twisting or cabling device 15 , is firstly twisted by means of the twisting or cabling device 15 with a creel thread 18 to form a yarn 14 . The yarn 14 then arrives via a draw-off mechanism 16 and via deflection means at the steam setting device 1 , in which, as already indicated above, the yarn 14 is thermally treated. The steam setting mechanism 1 , as known per se, has a yarn treatment chamber 21 , the thread treatment section of which is divided into a centre zone 5 and a front end zone 6 and a rear end zone 7 . The centre zone 5 is supplied here via a connection 8 with a hot, gaseous medium, preferably saturated steam or hot steam, while a cool gaseous medium, for example compressed air, is blown into the end zones 6 and 7 , in each case, via connections 9 A or 9 B. The centre zone 5 and the end zones 6 and 7 also have, in each case, a discharge connection 10 , by means of which steam or condensate can be discharged.
The yarn treatment chamber 21 furthermore has, in the region of the end zone 6 at the front in the yarn running direction F, a yarn inlet opening 2 and, in the region of the rear end zone 7 , a yarn outlet opening 3 . Moreover, the yarn treatment chamber 21 has yarn deflection means 12 , which ensure that the yarn 14 introduced into the yarn treatment chamber 21 via the yarn inlet opening 2 is reliably deflected toward the yarn outlet opening 3 .
Arranged in the region of the yarn inlet opening 2 or the yarn outlet opening 3 is, in each case, a yarn sluice 23 A or 23 B, which seals the yarn treatment chamber 21 , which is under excess pressure, in conjunction with the running yarn 14 relative to the environment.
The yarn 14 thermally set in the steam treatment chamber 21 is guided via a draw-off device 11 to a winding mechanism 24 of the workstation 29 and wound there, for example, to form a cross-wound bobbin 20 . The cross-wound bobbin 20 is preferably rotatably held in a pivotable creel (not shown) and rests with its surface on a winding roller 19 , which rotates the cross-wound bobbin 20 with frictional engagement.
The hot, gaseous medium is fed to the yarn treatment chamber 21 of the steam setting device 1 via a steam line (not shown) of the twisting or cabling machine.
The steam feed can be metered here by a shut-off device 4 configured as a steam valve and may, if necessary, be interrupted.
In order to make the yarn treatment chamber 1 as operator-friendly as possible, for example the front end zone of the yarn treatment chamber 21 in the yarn running direction F, as can easily be seen from FIG. 1 , is configured in such a way that its yarn sluice 23 A arranged in the region of the yarn inlet opening 2 is located adjacent to the yarn sluice 23 B, which is arranged in the region of the yarn outlet opening 3 and seals the rear end zone 7 of the yarn treatment chamber 21 . The yarn sluices 23 A and 23 B preferably arranged in parallel next to one another are positioned here at an operating height that is advantageous for the operating staff and, as described below, configured as thread guide tubes 25 in an advantageous embodiment. In other words, a receiver 32 , in the central through-opening of which a thread guide tube 25 can, in each case, be fixed, is installed, in each case, in the region of the yarn inlet opening 2 or the yarn outlet opening 3 of the yarn treatment chamber 21 , as shown in FIG. 1 A. The inserted thread guide tube 25 is matched here with its inside width A, in each case, to the titre of the yarn to be processed, so that the yarn 14 that is running through forms a reliable yarn sluice 23 A, 23 B with the yarn guide tube 25 .
As also shown in FIG. 1 , the steam treatment chamber is equipped with a delivery mechanism 37 or a delivery mechanism 38 and deflection means 12 . The delivery mechanisms 37 or 38 are used to supply the yarn 14 to be treated or to remove the treated yarn 14 from the centre zone and are correspondingly arranged in front of or behind the centre zone 5 in the end zones 6 or 7 .
The two delivery mechanisms 37 , 38 are used for the controlled transportation of the yarn 14 through the steam treatment chamber 21 . In other words, the yarn 14 is held substantially constantly without tension while running through the steam treatment chamber 21 between the delivery mechanisms 37 , 38 .
The steam setting device mechanism 1 furthermore, as conventional and indicated only schematically in FIG. 1 , has a sensor device, the sensors of which arranged in the steam treatment chamber 21 are connected by corresponding signal lines to an open- and closed-loop control device 13 .
Moreover, the yarn treatment chamber 21 , in the region of its yarn outlet opening 3 , has an injector device (not shown), which can be acted on via a connection with compressed air and allows a pneumatic threading of the yarn 14 through the entire steam setting device 1 , wherein, when thread guide tubes 25 are used as yarn sluices 23 A and 23 B, the latter firstly have to be removed before the threading of the yarn.
FIG. 2 shows a perspective view of a first possible embodiment of a receiving element 26 , which is used to keep six of the respective yarn sluices 23 ready, which are configured as thread guide tubes 25 . The receiving element 26 manufactured, for example, from a plastics material, configured in the manner of a revolver magazine and shown in the present embodiment, preferably has a central bearing opening 27 as well as six radially arranged bearing webs 28 , the bearing webs 28 each being equipped at the end with an outwardly open sliding guide body 30 , in which the thread guide tubes 25 are mounted, axially displaceably and secured by attachment pieces 31 .
The thread guide tubes 25 may have different inside widths A, two opposing thread guide tubes 25 in each case having the same inside width A in an advantageous embodiment. This means that two of the respective thread guide tubes 25 are matched to a specific yarn diameter D with regard to their inside width A and can simultaneously be positioned in the yarn inlet opening 2 or in the yarn outlet opening 3 of the yarn treatment chamber 21 .
The attachment piece 31 is matched with regard to its dimension to a receiver 32 shown schematically in FIG. 5 and shown in section in FIG. 1A and arranged in the region of the yarn inlet opening 2 or the yarn outlet opening 3 of the yarn treatment chamber 21 in such a way that the thread guide tubes 25 can be installed in the receiver 32 without problems and removed again.
As already indicated above, the receiving element 26 shown in FIG. 2 is mounted in the installed state by a central opening 27 in the manner of a revolver magazine in an advantageous embodiment. In other words, the receiving element 26 is rotatably mounted on a bearing point 34 and, if necessary, can be manually or mechanically positioned in such a way that at least one of the thread guide tubes 25 mounted in the sliding guide bodies 30 can be inserted into the receiver 32 of the yarn inlet opening 2 and/or into the receiver 32 of the yarn outlet opening 3 of the yarn treatment chamber 21 .
The receiving element arranged in the region of the yarn inlet opening and/or the yarn outlet opening may, however, also be configured as a linearly displaceably mounted series magazine 26 C in a second embodiment.
A series magazine 26 C of this type shown schematically in FIG. 2A has a base body displaceably mounted on linear guides 40 , 41 with sliding guide bodies 30 , in which the thread guide tubes 25 are mounted. The sliding guide bodies 30 can, in this case, be positioned below the receivers 32 of the yarn inlet and/or yarn outlet openings 2 , 3 in such a way that the thread guide tubes 25 can be transferred without problems into the receivers 32 .
As shown in FIGS. 3 and 4 , the receiving element 26 can either be arranged on the yarn treatment chamber 21 in such a way that, if necessary, both the receiver 32 of the yarn inlet opening 2 and the receiver 32 of the yarn outlet opening 3 of the yarn treatment chamber 21 can be supplied by means of the receiving element 26 with a thread guide tube 25 ( FIG. 3 ) or there can be provision to arrange two separate receiving elements 26 A and 26 B ( FIG. 4 ). In this case, a first receiving element 26 A is positioned in the region of the receiver 32 of the yarn inlet opening 2 and a second receiving element 26 B is arranged in the region of the receiver 32 of the yarn outlet opening 3 . In this case, as well, the receiving elements 26 A, 26 B are equipped with a plurality of thread guide tubes 25 , which, as described above, have different inside widths A.
As the two embodiments or arrangements of the receiving elements 26 , 26 A, 26 B, 26 C have advantages, it depends on the respectively existing operating conditions which of the two embodiments or arrangements is regarded as more advantageous.
The arrangement shown in FIG. 3 is, for example, more economical and the thread guide tubes 25 are very well accessible, in particular to thread the yarn, while the arrangement according to FIG. 4 has the advantage that more thread guide tubes 25 with different inside widths A can simultaneously be kept ready, which makes the device overall more flexible with regard to yarn batch changes.
FIGS. 5A to 5F schematically show the various method steps, which are necessary to again start up a yarn treatment chamber 21 according to the invention, the yarn sluices 23 A and 23 B of which in the embodiment are, in each case, formed by thread guide tubes 25 , for example after a thread break.
As can be seen from FIG. 5A , after a yarn break, the two thread guide tubes 25 being used as yarn sluices firstly have to be removed from the receivers 32 of the yarn inlet opening 2 and the yarn outlet opening 3 of the yarn treatment chamber 21 . In other words, the two thread guide tubes 25 are loaded in the direction of the arrow R and in the process slide, in each case, from the receiver 32 of the yarn inlet opening 2 or from the receiver 32 of the yarn outlet opening 3 of the yarn treatment chamber 21 .
In the next step, which is shown in FIG. 5B , the yarn 14 is drawn through one of the thread guide tubes 25 by means of a wire threader 35 and the yarn 14 is then “jetted” by means of an injector flow through the yarn treatment chamber 21 , as shown in FIG. 5C .
The yarn 14 leaving the yarn treatment chamber 21 is then, as shown in FIG. 5D , drawn by means of the wire threader 35 through the other thread guide tube 25 , which, like the first thread guide tube 25 , has an inside width A matched to the diameter D of the present yarn 14 .
The two thread guide tubes 25 with the threaded-in yarn 14 , as shown in FIG. 5E , are then inserted back into the receiver 32 of the yarn inlet opening 2 or into the receiver 32 of the yarn outlet opening 3 of the yarn treatment chamber 21 .
If the two thread guide tubes 25 , as shown in FIG. 5F , are properly fixed in their receivers 32 , the yarn 14 can be guided via the draw-off device 11 to the winding mechanism and connected to the cross-wound bobbin 20 . The workstation 29 is then ready for operation again.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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A yarn treatment chamber for thermal treatment of a running yarn, with a center zone, in which a pressurized hot, gaseous or vaporous medium acts on the yarn, and end zones on both sides of the center zone, in which a cooling, gaseous medium is active. The end zones have a yarn inlet or outlet openings with a yarn sluice, which seals the associated end zone and the yarn treatment chamber. The yarn inlet and outlet openings ( 2, 3 ) are arranged such that the yarn ( 14 ) must change direction, and the yarn treatment chamber ( 21 has yarn deflection means ( 12 ) to guide the yarn ( 14 ) between the yarn inlet and outlet openings ( 2, 3 ). Both the yarn sluice ( 23 A) and the yarn sluice ( 23 B) are accessible without problems to operating staff at an ergonomically favorable height below the yarn deflection means ( 12 ) of the yarn treatment chamber ( 21 ).
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TECHNICAL FIELD
The present invention is a method for depolymerizing or "cracking" polymeric materials The method of the present invention may be used in the disposal and/or recycling of such materials. Products of the degradation of polymeric materials using the present method may be recycled or more easily treated for disposal.
BACKGROUND
In recent years there has been increased interest in both environmental protection and the conservation of both natural resources and synthetic materials through recycling.
One of the general classes of materials known to pose some of the greatest challenges to recyclers is synthetic polymers, such as plastics. This is largely due to the fact that their chemical nature materials makes them difficult to effectively and efficiently degrade to their constituent monomers, lower molecular weight oligomers, or other breakdown products, for reuse or safe disposal. The chemical nature of polymeric materials also make them difficult to handle, dispose of and/or recycle as their degradation products are often toxic or otherwise insulting to the environment.
Another factor making synthetic polymers difficult to recycle is their variety. Many degradation techniques may target depolymerization of only a limited number or type of polymeric materials, leaving others intact. Also, polymeric materials in the waste stream are often comingled with a wide variety of solid and liquid wastes which can foul recycling/disposal treatment processes. This factor can complicate attempts at large scale recycling of polymeric materials by requiring multiple process and/or separation steps.
In addition, synthetic polymeric materials, including polyethylene, polyvinylchloride, polystyrene, polypropylene and the like, make up a substantial portion of the waste generated by industry and municipalities. Accordingly, another aspect of the challenge to recycling or disposal of polymeric materials is the need to design recycling/disposal systems capable of functioning effectively on a scale sufficient to accommodate the volume and variety of polymeric materials in an industrial or municipal waste stream.
Beyond being able to render polymeric waste to disposable form, it is of course most desirable to be able to convert polymeric waste to reusable materials. In addition to being valuable as fuel, breakdown compounds of this type provide a ready feedstock for the preparation of detergents, lubricants and other, more valuable commodities Likewise, depolymerization products can also be used in the preparation of new polymers, such as plastics.
Accordingly, it is desirable to be able to chemically degrade a wide variety of polymeric materials, particularly those classes of materials that constitute the greatest portion of waste polymeric materials generated in industrial or domestic settings.
It is also desirable to be able to render waste polymeric materials to a form amenable to reuse. This may mean producing degradation products which are both capable of being used as starting materials in the production of new materials and which are also in suitable form for such reuse, considering ease and safety of handling, demands of relative purity, etc.
Another beneficial characteristic in recycling/disposal processes is the ability to carry out the process in the presence of solid and liquid waste contaminants. Also, it is advantageous to be able to carry out recycling/disposal processes without the use of higher temperatures in the vapor phase (less than thos needed for combustion), and without having to provide specialized atmospheres (e.g. absent oxygen), pressurized atmospheres, atmospheres using constant gas streams or specific pure gases or gas mixtures.
The many embodiments of the present invention make progress toward the accomplishment of the above objectives. In light of the present disclosure and/or the practice of the present invention, other advantages and/or the solution to additional problems, may become apparent to one skilled in the relative arts.
SUMMARY OF THE INVENTION
The present invention is a method useful in the recycling or disposal of many types of polymeric materials such as those plastics found in municipal and industrial waste streams and landfills. These materials include polyethylene, polystyrene, polypropylene and the like.
As to the treatment or recycling of polyethylene, it is known that the chemical degradation of polyethylene under reactive conditions known as "alkali fusion" yields a chemically active liquid hydrocarbon product mixture having a boiling range and chemical properties resembling kerosene or diesel fuel.
Alkali fusion has been historically discussed as a method in the classical analysis of organic compounds. It is well known because it has been applied to most natural products for the purpose of structure elucidation. However, it remains mysterious because the mechanism by which it operates has been, and remains, poorly understood. It has been applied to molecules containing all known functional groups, and extensive literature exists on the subject. One example of a use for alkali fusion is the preparation of oxalic acid from sawdust.
In general terms, alkali fusion can be described as the degradation of a polymeric material through the use of a molten basic material at high temperatures which can be generally characterized as those associated with pyrolytic conditions, i.e. 750° to 900° Fahrenheit. Many such processes involve the use of pressurized atmospheres, specific gas atmospheres (e.g. absent oxygen) or continuous gas flow through the reaction vessel.
The present invention represents an improvement over known "alkali fusion" methods. It has been found that the presence of a catalytic amount of copper allows the depolymerization of polymeric substances to be carried out at relatively low temperatures and permits such depolymerization to be carried out under air at atmospheric pressure.
In broadest terms, the present invention is a process for degrading, depolymerizing or "cracking" a polymeric material, otherwise amenable to cracking by alkali fusion, comprising the steps of:
(a) preparing a molten reaction mixture comprising:
(i) a basic material;
(ii) a source of copper; and
(iii) said polymeric material; and
(b) maintaining said molten mixture at a temperature sufficient to reflux said molten mixture for sufficient time to depolymerize said polymeric material.
As used herein, the terms "depolymerization," "degradation" and "cracking" are all to understood as applied in the context of polymeric materials, and are intended to mean the breaking down of a polymeric material by the breaking of polymer-forming chemical bonds whereby the polymeric material is rendered to smaller polymeric subunits, oligomers, etc. and/or monomeric units, whether in gaseous, liquid and/or solid forms.
The term "basic material" is intended to mean any basic material capable of acting as a Lewis base. Although not limited by theory, basic materials appropriate for use in the method of the present invention include those materials which, when molten, generate hydroxide ions ( - OH) and/or hydroxy radical (.OH). Basic materials which may be used in the present invention include NaOH, KOH, Na 2 B 4 O 7 .10H 2 O, Na 3 BO 3 , Na 2 SiO 3 , K 2 SiO 3 , and mixtures thereof. Other basic materials which may be used in the present invention include basic materials used in so-called alkali fusion reactions. When used to depolymerize polyethylene, a mixture of NaOH and KOH present in weight ratio of about 1:1 is preferred.
As used herein the term "source of copper may be any source of copper, regardless of its oxidation state For example, sources of copper which may be used in the present invention include metallic copper or copper (II) such as in the form of copper oxide (CuO). When used to depolymerize polyethylene, copper metal (e.g supplied in the form of powder or even in the form of a copper reaction vessel) or copper (I) oxide is preferred. The copper used in the method of the present invention, when initially in one oxidation state (e.g. zero, one, or two), may be converted to a different oxidation state in the environment of the depolymerization reaction of the present invention. Accordingly, the present invention is not limited to the original or ultimate oxidation state of the copper used therein.
It is also preferred that the copper source be in a physical form adapted to best react in the reaction of the present invention, such as a granulated or powdered form.
The source of copper need only be present in an amount sufficient to supply a catalytic amount of copper. Typical amounts of copper are on the order of about 5% by weight of the molten reaction mixture, although a given reaction may be found to be operative with lesser amounts of copper. Accordingly, the present invention in its broadest form is not limited to a specific amount or range of amounts of copper. Rather an effective catalytic amount of copper may be ascertained without undue experimentation in light of the present disclosure.
As used herein "polymeric material(s)" may include any thermoplastic or thermosetting polymeric material including polyethylene, polystyrene, polyvinylchloride, and polypropylene. It has been found that the method of the present invention does not operate on vulcanized rubber.
The time/temperature conditions under which the molten reaction mixture is allowed to react can generally be described as those sufficient to bring about depolymerization. The extent and degree of depolymerization may vary with the time/temperature parameters as well as with the type(s) of polymeric materials to which the method is applied However the temperatures sufficient to bring about depolymerization under normal circumstances are those sufficient to bring about reflux of the reaction mixture. Such temperatures, as measured in the vapor phase over the reaction mixture, are generally in the range of from about 100° C .to about 500° C.; preferably in the range of from about 100° C. to about 350° C.; and normally between about 150° C. and about 250° C. The reaction time of the present invention may of course be varied depending upon the type(s) of polymeric materials to which the method is applied and the degree of depolymerization desired. These parameters can be readily derived in light of the present disclosure. Accordingly, the present invention in broadest terms is not limited to any particular reaction temperature, reaction time or reaction time/temperature combination, except as conforms to the parameters outlined herein and exemplified by the working examples. In many cases, breakdown products in the form of a distillate can be drawn from the reaction mixture, so the reaction can be run as long as product is being produced.
The reaction time also has been found to vary with the age and condition of the catalyst. It has been found in some instances that the catalyst loses efficiency in subsequent reaction runs. Accordingly, it is preferred that the efficiency of the reaction be monitored and fresh catalyst used as required. The need for fresh catalyst will be apparent from the reaction efficiency and can be determined by one of ordinary skill without undue experimentation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following presents a detailed description of the preferred embodiments of the present invention, which are presently considered the best mode of practicing the invention.
Plastics used in the procedures of the examples given below were obtained from household waste. They include high density polyethylene (HDPE) obtained as milk jugs (transparent, colorless), detergent or cleaning products (opaque), and oil bottles (green); polypropylene (PP) obtained from food containers; polystyrene (PS) obtained as plastic peanuts; and polyvinyl chloride (PVC) obtained as plastic tubing.
The plastic articles were cut into chips about 8 mm square by using either a mechanical cutter (scissors) or an electrical cutter composed of an array of hot nichrome wires. The bottles were drained, but no attempt was made to clean them or to remove the labels. The basic material used was commercial sodium hydroxide and commercial potassium hydroxide pellets, except where indicated.
These NaOH and KOH pellets were mixed with traces of cuprous oxide (Cu 2 O) in the ratio of 10:10:1 (NaOH:KOH:Cu2O, although the ratio was not critical to the success of the cracking process.
In general, the pellets of base (with copper) and the plastic substrate could be mixed and heated together, but a superior result was obtained when plastic chips were added to an agitated NaOH/KOH melt, commonly referred to as alkali fusion reaction conditions. It was important to note that in either case, the mixture of plastic and base was heated at or near the melting point of the base (i.e. about 210° C.) for sufficient time ( e.g. period of between 5 and 20 minutes) for the reaction to commence, as evidenced by liquid refluxing at or below 200° C.
At this point, condensate was collected at a convenient rate (1-2 drops per second) and stronger heating was applied as necessary. In these examples, product was not normally collected above 250° C., so the heat was moderated to maintain the temperature of the escaping vapor at or below this point. Rapid or excessive heating was avoided as this resulted in incomplete cracking of the plastic as evidenced by the presence of high melting wax in the condensate, and/or by polymer build-up in the cool portions of the distillation apparatus.
EXAMPLE 1
Green HDPE plastic chips (300 g) from oil plastic motor bottles were cracked in batches of 50 g each in a 400 mL copper vessel to yield about 150 mL of distilled hydrocarbons.
A 400 mL copper vessel was charged with NaOH pellets (11.8 g), KOH pellets (11.8 g) and Cu 2 O (0.8 g) and heated in a low flame with agitation until the mixture had melted. The vessel was then filled with plastic chips (about 45-50 g), attached to a PYREX® distillation apparatus consisting of a distillation adapter equipped with a 350° C. thermometer, a water-cooled condenser, a take-off adapter equipped with a side-arm, and an appropriate receiver (50 mL), and placed in an active hood. The reaction vessel was then heated gently over a low flame until refluxing vapor was evident in the glass portion of the apparatus (about 20 minutes) and then the flame was increased as needed to maintain a distillation rate of 1-2 drops per second.
Uncondensed hydrocarbon vapors emitted from the side-arm of the take-off adapter present a potential fire hazard. These should be vented far from the flame.
Distillation commenced at 160° C. as a mixture of hydrocarbons and water, and then the temperature rose to 230° C. where the bulk of the product (about 25 mL) was collected. The temperature rose rapidly to 250° C. after most of the hydrocarbon had distilled, and if it remained unchecked, a wax would distill above 250° C. and collect in the condenser. This wax, if present, was removed from the condenser and combined with the plastic chips used in subsequent batches. The apparatus was cooled to ambient temperature and a fresh supply of plastic chips was added and the procedure repeated until the catalyst was no longer active (six batches of 50 g each). At that point, the reaction vessel was emptied by pouring the residual molten alkali fusion mixture into 2 liters of water. Splattering and steam present a safety hazard, so precautions should be taken in this regard. The black wax (50 g) was then collected by filtration. Yield of liquid hydrocarbons was 50% (150 g) as a pale green liquid, the yield of wax was 16% (50 g) and the yield of gases was not measured in this experiment.
EXAMPLE 2
Colorless HDPE chips (10 g) from plastic milk jugs was liquified in a 50 mL copper vessel to yield 6.7 g of hydrocarbons consisting of a mixture of alkanes, terminal alkenes (α-olefins) and internal alkenes.
In a 50 mL copper vessel were placed NaOH (1 g) and KOH (1 g) and colorless HDPE chips (5 g). This assembly was attached to a standard PYREX® distillation apparatus by means of a 4" fractionating tube securely held to the copper reaction vessel by spring clips. Gentle heating with either a free flame, or a sand bath causes vapor to reflux in the fractionating tube after 10-12 minutes at or below 150° C. After the induction period, the heat was increased as necessary to distill the hydrocarbons at a rate of 1-2 drops per second. Fractions were taken at 1 mL intervals and analyzed. Once the temperature of the vapor reached 250° C., heating was suspended and additional plastic chips were added through the 24/40 joint located between the fractionation tube and the rest of the distillation apparatus. Heat was applied and the procedure was repeated as necessary to consume 10 g of plastic. The accumulated fractions revealed no significant difference in composition which indicated that a cracking process occurred continuously during the distillation, and the product yield (6.7 g, 67%) was relatively constant for sample sizes ranging from 1 g to 25 g without additional catalyst being added. The residue present in the reaction vessel at the end of the reaction consisted of alkali comingled with traces of copper salts and very little wax or other organic (burnable) residue. No attempt was made to measure the volume of non-condensable gases, but ignition established that they were formed. It is important to be certain that the opening to the distillation apparatus is properly vented and kept away from the open flame at all times to avoid the possibility of fire.
This procedure has been repeated using white, yellow, and green HDPE. In all cases, the product mixture was identical.
EXAMPLE 3
Colorless HDPE (1 g) was cracked by using commercial 50% NaOH at reflux in a copper reaction vessel in <30% yield.
In a clean 50 mL copper vessel, containing no trace of organic residue, were placed 50% aqueous NaOH (5 mL) and 2 g of clean dry chopped HDPE from milk jugs. The apparatus was assembled as described in Example 2 and heating was commenced. After a period of reflux (15 minutes), yellow wax-like residue was detected in the liquid and at that point, a rudimentary form of steam distillation was initiated (i.e. water was added drop wise at a rate equal to the rate at which the distillation occurred). The organic and aqueous mixture of products was collected (50 ml) and the aqueous phase was removed by decantation. The wax that remained (about 0.5 g) was taken up in dichloromethane and analyzed. This analysis showed that the product in this case was a mixture of alkanes only, and those being of higher molecular weight than the product observed in either of the previous Examples described above.
EXAMPLE 4
Colorless HDPE (1 g) was cracked by using alkali fusion in a glass vessel.
A disposable glass vessel was charged with NaOH (0.5 g) and KOH (0.5 g) and Cu 2 O (trace; about 0.1 g) and heated over a free flame until the alkali melt formed and all of the copper oxide had dissolved to give a blue solution. Caution should be taken as extensive heating of molten alkali in PYREX® glass vessels will cause leakage due to irreversible damage to the glass. Plastic chips were then added and heating was resumed. After an induction period, the blue color was dispelled and a red precipitate, presumed to be finely divided copper metal, precipitated with simultaneous "foaming" around the edges of the plastic chips. Vapor collected after this point had the composition reported in Example 2, above.
EXAMPLE 5
Polypropylene was cracked under alkali fusion conditions.
Polypropylene food containers were cut into chips and substituted for HDPE as described in Example 3. The temperature range over which the product distilled was higher in that the product was collected between 300° C. and 350° C. No low boiling fraction was observed. The yield ranged between 40-50% on a 5 g scale.
EXAMPLE 6
Polystyrene was cracked under alkali fusion conditions.
Polystyrene from so-called "plastic peanuts" was subjected to the conditions described in Example 3. The temperature over which the product distilled ranged between 110° C. and 200° C. and the yield exceeded 60% (unoptimized) on a 5 g scale. A relatively large amount of water was observed in the condensate.
EXAMPLE 7
Commingled plastic was cracked under alkali fusion conditions.
A mixture of plastics composed of polyethylene chips from milk jugs and polyvinylchloride chips from plastic water pipe were subjected to the reaction conditions described in Experiment 3. No inhibition of the cracking process was observed, but the yield was generally lower, ranging between 40-50% depending on the quantity of PVC used.
Results
The first conclusion evident from the experiments above was that the colorant additives present in polyethylene that render it opaque do not interfere with the process of the present invention described herein. Additives present in oil residue do have a damaging effect and were not cracked under the conditions used in the experiments done to date. Similarly, the presence of other plastics does not alter the chemistry of polyethylene in any significant way, and polyvinyl chloride was no exception. The breakdown products from different plastics boil at different temperatures and this effectively alters the yield of product isolated in a given distillation temperature range.
The basic material needed to bring about the reaction of the present invention was insensitive to inorganic impurities such as silicates and borates present in glass. In fact, intentional addition of borax and sodium silicate to the reaction mixture had no significant effect on the production of liquid distillate, and pure borax catalyzes the plastic cracking under the conditions described above. Although not limited by theory, this suggests that borax could be a source for the hydroxide ion or radical implicated as being central to the mechanism of the reaction.
The presence of water leads to higher molecular weight alkane fragments. This suggests that water was necessary for the reaction leading to hydrocarbons in general, and this is consistent with the data once it is remembered that commercial grade NaOH and KOH retain water in their solid structure. Experiments designed to reduce the concentration of water in the melt led to the formation of more short-chain alkenes, thus establishing that changing water concentration is a means for controlling the composition of the product mixture.
The need for copper ion or other reducible species to be present in the reaction mixture was established via the use of a negative control. Reaction vessels composed of high nickel stainless steel and Sterling silver were employed to crack polyethylene under conditions similar to those described above but which did not involve copper ion in any form. The result was low yield (<20%) in both cases. Addition of Cu 2 O to the melt in a silver vessel caused an immediate reaction and efficient cracking was obtained as described in Example 3. Without the addition of copper the reaction rate was unmeasurably slow even at extreme temperature. This observation was one of the first to implicate copper in the reaction mechanism since traditional wisdom indicates that the nature of the reaction vessel has no significant effect on the products of alkali fusion, and that silver vessels are preferred since they are only slowly attacked by molten alkali.
Another of the initial clues to the importance of copper ion in the alkali melt came through the observation that certain glass vessels were superior to others in catalyzing in the process. Since iron and copper are common impurities in glasses, these were investigated, but only copper showed any measurable effect. This was consistent with the observation that a high nickel stainless steel vessel containing traces of iron proved to be inferior to a copper reaction vessel. Flakes of CuO scraped off the copper reaction vessel proved to be sufficient to catalyze the plastic cracking reaction in a silver reaction vessel.
The need for molten alkali was established by conducting experiments in clean glass apparatus. Polyethylene was melted and heated in air and cracking ensued at temperatures in excess of 400° C. and coated the interior of the vessel with a film of wax. The addition of NaOH pellets to the molten plastic caused an immediate frothing and foaming and cracking initiated. The yield obtained by this method was inferior to any of the examples specified above, but it did establish the utility of molten alkali. In instances where the cracking reaction had stopped during the procedure described in Example 3 the addition of NaOH and KOH pellets has been used successfully to restart and extend the plastic cracking reaction.
The importance of air in this procedure should not be overlooked. In contrast to many published procedures in which oxygen was excluded from the reaction chamber during the cracking process, no attempt was made to remove or exclude oxygen in this case.
Although not limited to a mechanistic theory, it is believed that the mechanism involves cycling the oxidation state of copper from +1 to zero (0) or +2 to zero (0) and in this way copper ion provides a sink for an electron from hydroxide ion. Oxidation of copper with atmospheric oxygen provides a convenient rationalization for the presence of oxidized forms of copper and it seems to explain the catalytic nature of the alkali mixture containing them.
Characteristics of the Product
The primary analytical tool used in studying the nature of the products obtained from the method of the present invention has been GCMS. These data disclose the number of components and their relative concentrations.
NMR has been used to detect the presence of terminal and internal olefins, and to search for branching in the alkyl chain. No branching was detected in the alkyl chains of products from polyethylene, but the products from other plastics, such as polypropylene were more complicated. The product formed from the depolymerization of PVC was not characterized.
In view of the foregoing disclosure and representative Examples, it will be within the ability of one skilled in the chemical or chemical engineering art to make modifications and variations to the disclosed embodiments, including the use of equivalent materials and process steps without departing from the spirit of the invention.
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The present invention is a method for depolymerizing or "cracking" polymeric materials. The method of the present invention may be used in the disposal and/or recycling of such materials. Products of the degradation of polymeric materials using the present method may be recycled or more easily treated for disposal.
The present invention is a process for degrading, depolymerizing or "cracking" a polymeric material, otherwise amenable to cracking by alkali fusion, comprising the steps of:
(a) preparing a molten reaction mixture comprising:
(i) a basic material;
(ii) a source of copper; and
(iii) said polymeric material; and
(b) maintaining said molten mixture at a temperature sufficient to reflux said molten mixture for sufficient time to depolymerize said polymeric material.
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This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/249,740, filed Nov. 17, 2000, and is a continuation-in-part of U.S. patent application Ser. No. 09/988,360 now abandoned filed Nov. 19, 2001.
BACKGROUND OF THE INVENTION
The present invention relates to a golf swing training apparatus and method. The disclosed apparatus and method allow golfers of all levels to perfect their golf swing. When used by a golfer the disclosed device encourages the golfer to replicate the ideal double pendulum model golf swing while also feeling the correct rotation of the clubface necessary to hit golf balls long and straight. Additionally, the apparatus provides a golfer with the necessary feedback regarding the feel of a correct golf swing and trains the golfer to consistently execute an ideal swing.
The United States Golf Association (“USGA”), golfs governing body, utilizes a machine named “Iron Byron” to test golf clubs and balls to ensure that both conform to USGA's regulations. Iron Byron hits a perfect golf shot—long and straight—every time. The ideal golf swing that Iron Byron mimics is a two lever or double pendulum model swing.
In a double pendulum model swing there are two levers connected by a hinge that is fixed to rotate about a fixed axis. The first lever (closest to the axis) corresponds to the golfer's shoulders and arms, while the second lever (below the hinge) corresponds to the golf club. The hinge corresponds to the golfer's wrists and hands. The present invention has been developed to accurately replicate Iron Byron's double pendulum motion on a human. The first lever is simulated by an adjustable strap that extends between a golfer's chest and his club, attaching to the grip end of the club. The second lever continues to be the golf club and the hinge continues to be the golfer's hands and wrists which are assisted by a “club clamp” that connects the adjustable strap to the golf club; this “club clamp” is designed to “dial-in” a pre-determined torque on the clubface.
The ideal model requires that the golfer's swing in each direction be made in a single inclined plane and that the hands of the golfer rotate around a fixed point somewhere on a golfer's chest. Moreover, angular momentum is conserved throughout the swing and during impact with the golf ball.
Many devices have been created for training golfers to produce a proper golf swing. Many of the known devices attempt to prevent the golfer from doing something detrimental to his swing, rather than encouraging the golfer to train proactively with his own clubs to create a proper swing. Additionally, known training devices fail to promote a double pendulum model swing motion or to give the golfer necessary feedback regarding the feel of a proper swing. Known devices are generally unable to train the golfer in the proper fundamentals necessary to make a lasting improvement on his golf swing.
For example, it is known to provide a “jacket” to create a link between the golfer's arms and the golfer's torso to guide him through the full range of motion of a golf swing. Another known device is in the form of an elastic loop that is worn over the golfer's head, rests on his shoulders and hangs in front of his chest and stomach with the lowermost portion of the loop held by the left hand as the left hand grips the golf club.
Still other training devices include an elastic cord with a grip that is worn over a golfer's head and rests around his neck, with the golfer grasping the grip and the club, and extending his arm applying tension to the cord during the swing. While tension is maintained in the cord throughout the swing, this device does not define the center of the golf swing and does not encourage a double pendulum motion.
Still yet another known golf swing training apparatus employs a harness and utilizes a weighted shortened shaft for practicing the swing, but may not be used with the golfer's actual golf clubs and to practice actually hitting golf balls.
This, the aforementioned devices inhibit the free motion of a golfer's arms and wrists, are limited in their ability to work with actual clubs, and hitting balls, fail to define the center of the golfer's swing, fail to address clubface rotation (which is a key element to striking a golf ball with a “square” clubface directing straight shots at the intended target, and/or fail to promote a double pendulum swing motion. Also, some prior art provides poor upper levers designed as bungee cords or fixed wands or rods that can be dangerous when used and actually promote poor golf fundamentals.
The present invention allows the golfer to reproduce the double pendulum model and reinforces through muscle memory the fundamentals of this ideal swing. One embodiment of the present invention overcomes the limitations of the prior art by utilizing a harness with a chest plate offering multiple mounting rings options and a uniquely contoured design to fit chests of most sizes of men, women and children, to define the ideal point on a golfer's chest about which a golf swing should rotate. A flexible yet inelastic and adjustable strap extends from the chest plate to a golf club requiring the golfer to maintain a proper radius throughout the swing. The present invention does not inhibit the hinged motion of a golfer's wrists which enables the transfer of angular momentum from the club face to the ball at impact. Moreover, a golfer may utilize their actual golf clubs and balls while training with this device.
Accordingly, it is an object of the present invention to obviate many of the above problems in the prior art and to provide a novel device and method for golf swing training.
It is another object of the present invention to promote a double pendulum model swing motion.
It is yet another object of the present invention to provide a novel device for golf swing training that allows for the free movement of a golfer's hands, wrists and arms.
It is still another object of the present invention to provide a novel device for golf swing training that is adjustable to fit golfers of various sizes and body types (men, women and children of many ages).
It is a further object of the present invention to provide a harness that defines an ideal point on a golfer's chest through the use of multiple rings about which a golfer should swing to initiate power when executing the perfect golf swing.
It is a further object of the present invention to provide an adjustable flexible yet inelastic strap between a golfer's chest and a golfer's club that encourages full extension of a golfer's arm throughout the golf swing and maintenance of a proper swing radius, both creating greater centrifugal force and clubhead speed while eliminating the inherent dangers and other limitations of the prior art.
It is still a further object of the present invention to provide a clamp hinging means which can be attached to a golf club in various positions to control the orientation of the club face, and produce the torques required to vary hand, wrist and arm rotation, which ultimately affects the curvature of ball flight.
These and many other objects and advantages of the present invention will be readily apparent to one skilled in the art to which the invention pertains from a perusal of the claims, the appended drawings, and the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial illustration of one embodiment of the present invention from the front thereof with a golf club.
FIG. 2 is a pictorial illustration of the embodiment shown in FIG. 1 from the left side.
FIG. 3 is a schematic illustration of a double pendulum model golf swing at address.
FIG. 4 is a schematic illustration of a double pendulum model golf swing at the top of the back swing.
FIG. 5 is a schematic illustration of a double pendulum model golf swing immediately before the clubface impacts the golf ball.
FIG. 6 is an illustration of a golfer wearing the embodiment of FIGS. 1 and 2 addressing the golf ball.
FIG. 7 is an illustration of a golfer wearing the embodiment of FIGS. 1 and 2 at the top of the back swing.
FIG. 8 is an illustration of a golfer wearing the embodiment of FIGS. 1 and 2 immediately before the clubface impacts the golf ball.
FIG. 9 is a perspective view showing the club clamp of the training device of the present invention adjustably mounted on a golf club grip.
FIG. 10 is a perspective view of the club clamp of the training service of the present invention.
FIG. 11 is an end view of the club clamp of the training device of the present invention showing the latch release thereof.
FIG. 12 is an exploded view of the club clamp of the training device of the present invention.
FIG. 13 is a perspective view of the training device of the present invention on a user and attached to a golf club grip.
FIG. 14 is a detailed perspective view of the club clamp of the training device of the present invention on a golf club grip.
FIG. 15 is a top view of the attachment to a golf club grip of the club clamp and of the strap of the training device of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to the drawings, like numerals represent like components throughout the several drawings.
With reference to FIGS. 1 , 2 and 13 , respectively, a front and side elevational view of one embodiment of the training device is illustrated. The adjustable harness 10 includes two shoulder straps 12 and a chest strap 14 that encircles a golfer's chest. The shoulder straps 12 and the chest strap 14 include adjustment means, 16 and 18 , respectively, that may be a fastening tape consisting of a strip of nylon with a surface of minute hooks that fasten to a corresponding strip with a surface of uncut pile, buckles, hooks or other suitable conventional means to adjust the size of the harness 10 . The harness 10 is adjustable so that it may fit golfers of various size (men, women and children of most ages) and must be properly fitted to achieve maximum training benefits.
With continued reference to FIGS. 1 , 2 and 13 , a chest plate 20 is attached to the chest strap 14 of the harness 10 . The chest plate 20 may be sewn, riveted, glued or otherwise secured to the chest strap 14 . The chest plate 20 should be attached to the chest strap 14 and when properly fitted should be positioned generally midway between the golfer's shoulders and level with his armpits to define a point about which the golfer should swing. In the ideal golf swing, there is a point generally midway between a golfer's shoulders and level with his armpits about which the ideal golf swing rotates.
Attached to the chest plate 20 is a inelastic flexible strap 22 that includes an adjustment means 24 for altering the length of the inelastic flexible strap 22 . By making the inelastic flexible strap 22 slightly shorter than the actual length of his arms, a golfer will be encouraged to maintain the proper amount of extension and radius away from the chest plate 20 throughout the swing and thus the golfer will learn the “feel” of an ideal golf swing. The inelastic flexible strap 22 may be constructed from any flexible fabric or material that can support the tensile forces associated with a golf swing without inhibiting the swing motion. Inelastic flexible strap 22 is comprised of a flexible yet inelastic material, preferable a synthetic organic polymer, that is upper lever 34 of FIGS. 3 , 4 and 5 , below. There are inherent dangers of utilizing a rigid tube or wand like structure to guide a golf club while actually striking golf balls. Also there is a need for a perfect balance of flexibility and rigidity to capture the feel needed to duplicate the double pendulum swing model that rigid structures lack. In testing, such rigid devices have caused trauma to the chest arms and wrists of the end user. While these inherent dangers have been overcome in the present invention, a likewise disastrous effect can be seen if the material is made elastic. It has been shown mathematically by using a bungee like elastic material to represent the upper lever 34 of the 2-lever model of FIGS. 3 , 4 and 5 would produce an infinite number of lever lengths, none of which could be consistently replicated for training resulting in a useless training device. One end of the inelastic flexible strap 22 may be attached to the chest plate 20 by a ring or attachment point 26 , or other suitable fastener that will allow for free movement of the strap throughout the swing. Preferably, as shown in FIGS. 1 and 13 , more than one ring or attachment point 26 are present. Most preferably, two or three rings or attachment points 26 are present, disposed vertically with respect to one another on chest plate 20 such that the training device of the present invention can be employed by golfers having different fulcrum locations of their golf swings with respect to their torsos. The purpose of multiple rings is to offer the golfer an option to properly locate the ideal fulcrum (fixed axis) location of the double pendulum professional swing.
Connected to the unattached end of the inelastic flexible strap 22 is a swivel buckle 28 which secures a club clamp 30 to the inelastic flexible strap 22 . The swivel buckle or rotatable fastener 28 is free to rotate with the natural motion of the golfer's arms and wrists throughout a golf swing. When training with this device, an actual golf club is secured to the club clamp 30 . Alignment of the club clamp 30 is variable, allowing the golfer to intentionally curve the ball or hit it straight while experiencing the desired amount of club face rotation.
With reference to FIGS. 3 , 4 and 5 , the double pendulum model golf swing is illustrated at address, at the top of the back swing and immediately before impact, respectively. The essential elements necessary for performing this swing motion include the lower lever 32 and upper lever 34 . Connecting the lower lever 32 with the upper lever 34 is the hinge 36 . The upper lever 34 rotates about a fixed point 38 .
With reference to FIGS. 6 , 7 , and 8 , a golfer wearing an embodiment of the present invention is illustrated addressing the golf ball, at the top of the back swing and immediately before impact, respectively. The present training device has been developed to accurately replicate the double pendulum model golf swing. A golfer G when wearing the device executes a double pendulum model golf swing as is evident from comparing FIGS. 3 , 4 and 5 with FIGS. 6 , 7 and 8 . The golf club A parallels the lower lever 32 and the inelastic flexible strap 22 simulates the upper lever 34 . The hinge 36 corresponds to the golfer's hands and wrists B. The fixed point 38 about which the golf swing rotates is the chest plate 20 .
Next referring to FIGS. 9 through 15 , the individual components an embodiment of the training device of the subject invention are shown.
As shown in the FIGS. 9 through 12 , club clamp 30 has a hollow body or annulus 40 preferably comprised of a flexible yet resilient material such as, for example a synthetic organic polymer, that allows annulus 40 to be removably yet tightly secured to golf club grip H whereby annulus 40 can be positioned at a plurality of locations along the longitudinal axis of golf club grip H, which often tapers along this longitudinal axis, as well as positioned in numerous locations radially around grip H upon axial rotation of annulus 40 , as best shown in FIG. 9 .
Club clamp 30 , as shown in FIGS. 10 through 12 , also includes thumb lever 42 , which is pivotally secured to thumb lever attachment 44 on annulus 40 by attachment pin 46 that passes through eye 47 of thumb lever attachment 44 and through eyes 49 of thumb lever 42 which axially overlap with eye 48 of thumb lever attachment 44 . Attachment pin 48 passes through eyes 50 of band 52 and through eye 54 of thumb lever 42 , eye 54 axially overlapping with eyes 50 of band 52 . Band 52 has lip 56 on its edge remote from eyes 50 . In operation, annulus 40 of club clamp 30 is placed around golf club grip H with band 52 pivotally separated from annulus 40 . Lip 56 is then secured in one of the plurality of grooves 58 radially disposed on annulus 40 as band 52 is pivoted toward annulus 40 . Thumb lever 42 is then depressed toward annulus 40 , closing club clamp 30 at the desired longitudinal and radial location on golf club grip H depending on the diameter of often tapering golf club grip H and the amount of “torqueing effect” (discussed further below) that is desired in order to alter the angular orientation of the club head and club face of the golf club in consistent, reproducible swings in order to elicit a hook or slice effect.
Next referring to FIGS. 14 and 15 , removable attachment of inelastic flexible strap 22 (which is calibrated by numbers along its length to allow the golfer to quickly identify their ideal swing radius) to club clamp 30 by swivel buckle or rotatable fastener 28 is described. Swivel buckle or rotatable fastener 28 is attached by ring 60 to the end of inelastic flexible strap 22 remote from the end thereof that is attachable to ring or attachment point 26 of chest plate 20 by snap fastener 62 (which can rotate with respect to inelastic flexible strap 22 ). Body 66 of swivel buckle or rotatable fastener 28 is attached to axle 64 and ring 60 rotates around axle 64 with respect to body 66 . Body 66 has a substantially C-shaped portion in which shaft 68 of club clamp 30 is sized and shaped to fit. Attachment clasp 70 is also substantially C-shaped and is pivotally secured to body 66 of swivel buckle or rotatable fastener 28 by pivot point 72 in inverse or “mirror” orientation to the substantially C-shaped portion of body 30 such that, when pivoted in an “open” orientation attachment clasp 70 allows entry of shaft 68 of club clamp 30 into the substantially C-shaped portion of body 66 , and when in a “closed” position attachment clasp 70 secures shaft 68 of club clamp 30 between itself, and the substantially C-shaped potion of body 60 . Shaft 68 of club clamp 30 has head 74 on the end thereof remote from the end of attachment of shaft 68 to annulus 40 of club clamp 30 . Head 74 is sized of a greater diameter than the orifice formed from the substantially C-shaped portion of body 60 and attachment clasp 70 when in their “closed” position such that shaft 68 , and hence club camp 30 , is secured thereto.
When club clamp 30 is secured to swivel buckle or rotatable fastener 28 as described in the previous paragraph, and annulus 40 of club clamp 30 is attached to the golf club grip H, the rotation of ring 60 of swivel buckle or rotatable fastener 28 with respect to body 66 (and around axle 64 ) is in a plane substantially parallel to the longitudinal axis of shaft 68 of club clamp 30 , and axle 64 (the axis of rotation of ring 60 of swivel buckle or rotatable fastener 28 with respect to body 66 ) is substantially perpendicular to the longitudinal axis of shaft 68 of club clamp 30 .
Club clamp 30 and rotatable fastener or swivel buckle 28 thus connect the lowermost portion of upper lever 34 of FIGS. 3 , 4 and 5 to the uppermost portion of the grip of the golf club in such a way as to:
a. Accurately duplicate the anatomical hinge point of a golfer. b. Provide an orientation of attachment perpendicular to the axis of the golf club shaft, which can be axially adjusted around the grip H of the golf club to produce a desired torqueing effect on the hands and clubface when in use, and linearly adjusted to different locations on the grip H of the club. By not limiting the end user to a predetermined mounting location as seen in the prior art, the golfer can now pre-determine the desired “torqueing effect” by rotating the club clamp 30 into a desired position.
While preferred embodiments of the present invention have been described, it is to be understood that the embodiments described are illustrative only and that the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalence, many variations and modifications naturally occurring to those of skill in the art from a perusal hereof.
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A method and device for golf swing training is disclosed wherein a double pendulum model swing is replicated by defining a point on a golfer's chest about which a golfer's swing rotates and extending therefrom a inelastic flexible strap for attachment to the grip of a golf club. The inelastic flexible strap encourages the golfer to fully extend his arms throughout the golf swing to maintain a proper swing radius without inhibiting the movement of the golfer's wrists; therefore, allowing the golfer to experience the ideal golf swing.
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DESCRIPTION
Background of the Invention
This invention relates to sewing machines and, more particularly, to electronically controlled sewing machines.
Sewing machines employing sophisticated electronic technology for the storage and subsequent retrieval of stitch pattern information for a multiplicity of patterns have enjoyed great commercial success in recent years. One great advantage of the use of an electronically controlled sewing machine is in its simplicity of operation and control, as perceived by the user. On the other hand, if such a machine malfunctions, it is often difficult for a service technician to diagnose the reason for such malfunction. Accordingly, it would be desirable to provide an aid to help a service technician in diagnosing faults in an electronically controlled sewing machine.
It is therefore an object of the present invention to provide an arrangement for operating an electronically controlled sewing machine in a diagnostic mode.
It would also be desirable to provide such an arrangement without adding any hardware, so that the cost of the sewing machine is kept low.
It is therefore a further object of the present invention to provide an arrangement for operating an electronically controlled sewing machine in a diagnostic mode which utilizes the already existing hardware of the sewing machine.
SUMMARY OF THE INVENTION
The foregoing and additional objects are attained in accordance with the principles of this invention by providing an electronically controlled sewing machine including diagnostic means for operating the sewing machine in a diagnostic mode. The sewing machine includes input means for allowing an operator to select functions to be performed by the sewing machine and indicating means for providing an indication of the function selected by an operator via the input means. The diagnostic means includes means for utilizing the indicating means to provide an indication to the operator of the operation of the sewing machine while in the diagnostic mode.
In accordance with an aspect of this invention, the arrangement includes means for monitoring the speed of operation of the sewing machine and utilizing the indicating means to indicate the speed of operation.
In accordance with another aspect of this invention, the sewing machine includes motor control means for controlling the speed of operation of the sewing machine which normally operates in response to an operator setting of a speed control device, such as a foot controller. The arrangement includes means for operating the sewing machine at a fixed predetermined speed independent of operator control.
In accordance with a further aspect of this invention, the arrangement includes means for utilizing the indicating means to indicate the relative position of the sewing machine needle.
In accordance with yet a further aspect of this invention, the diagnostic means includes means for controlling the indicating means to indicate the sewing machine functions in a predetermined ordered sequence and at a regular rate. This allows the service technician to check on the functioning of the indicating means.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be more readily apparent upon reading the following description in conjunction with the drawings wherein:
FIG. 1 is a front elevational view of an illustrative sewing machine in which this invention may be incorporated;
FIG. 2 illustrates a general block diagram of a microcomputer based control system for the sewing machine of FIG. 1; and
FIGS. 3A, 3B, 4A, 4B and 5 are flow charts of programs and subroutines for operating the microcomputer of FIG. 2 in accordance with the principles of this invention.
DETAILED DESCRIPTION
Referring now to the drawings, wherein like elements in different figures thereof have the same reference character applied thereto, FIG. 1 shows a sewing machine designated generally by the reference numeral 10. The sewing machine 10 includes a work supporting bed 12, a standard 14, a bracket arm 16 and a sewing head 18. The sewing machine stitch forming instrumentalities include a needle 20 capable of being endwise reciprocated and laterally jogged to form zig zag stitches and a work feed dog (not shown) operating upwardly through slots formed in a throat plate on the bed 12 to transport the work across the bed 12 between needle penetrations. The pattern of stitches produced by operation of the sewing machine, i.e., the positional coordinates of each stitch penetration may be influenced, for example, by data stored in a memory unit and extracted in timed relation with the operation of the sewing machine, as is well known in the art.
On the front panel of the sewing machine 10 there is provided an input means whereby the operator can effect control of the functions of the sewing machine. This input means includes switches and dials whereby the operator may select a pattern to be sewn by the sewing machine as well as effecting modifications to the pattern. Pattern selection is effected illustratively through an array 22 of pushbutton switches 24, each of which corresponds to a pattern of stitches, the information for forming which is stored within the memory of the sewing machine 10. Associated with each of the pushbutton switches 24 is a pictorial representation of the pattern as it would be sewn by the sewing machine upon actuation of that switch. The input means also includes a stitch width control (bight override) 26 and a stitch length control (feed override) 28. The controls 26 and 28 each includes a pushbutton switch which is operator actuated to effect the respective width or length modification and includes a rotary portion for setting the magnitude of the modification. There are also provided pushbutton switches 30, 32 and 34 for selecting large buttonhole, small buttonhole and round end buttonhole patterns, respectively. A pushbutton switch 36 is provided for reverse sewing. Single pattern selection is effected via a switch 38. The mirror image of a pattern in the bight direction is selected via the switch 40 and the mirror image of the pattern in the feeding direction is selected via the switch 42. The switch 44 is utilized for doubling the length of a sewn pattern. Indicating means for indicating to an operator the status of each of the various functions which may be selected is also provided on the front panel of the sewing machine 10. Illustratively, this takes the form of a plurality of light emitting diodes (LED's) 46 each in close proximity to its respective input switch.
FIG. 2 shows a general block diagram of a microcomputer based controller for an electronic stitch pattern sewing machine, which controller may be utilized to control the operation of the sewing machine 10 (FIG. 1) and which operates in accordance with the principles of this invention. Accordingly, the microcomputer 50 receives input signals from the input switches 52 indicative of the functions the sewing machine operator desires to be performed by the sewing machine. The input switches 52 may include the pattern selection switches 24 and 30-34 as well as the function switches 26, 28 and 36-44. The microcomputer 50 includes an internal central processor unit (CPU) 54 and a program and pattern ROM 56. The CPU 54 obtains from the ROM 56, in timed relation with the operation of the sewing machine, pattern data for controlling the bight actuator system 58 and the feed actuator system 60. The bight actuator system 58 and the feed actuator system 60 are similar in construction and are adapted to convert a digital code word from the microcomputer 50 into a mechanical position which locates the sewing machine needle in a conventional stitch forming instrumentality and provides a specific work feed for each needle penetration, respectively, as is well known in the art. The microcomputer 50 also provides signals to the LED drivers 62 to control the illumination of the LEDs 46 (FIG. 1) to indicate the function selected by the sewing machine operator. Also shown in FIG. 2 is a motor control system 64 which communicates with the microcomputer and which may be controlled by the microcomputer such as, for example, to prevent the sewing machine from operating or to limit the speed at which the sewing machine can be operated or even to operate the sewing machine without operator intervention. During normal sewing, the motor control system 64 operates the sewing machine 10 in accordance with operator commands received from, for example, a foot controller 65. Illustratively, the microcomputer 50 is a type TMS 7040 microcomputer manufactured by Texas Instruments wherein the CPU 54 provides addresses to the ROM 56 over the leads 66 and receives in return bytes of data and program over the leads 68.
In accordance with the principles of this invention, under operator control, the sewing machine 10 may be placed in a diagnostic mode. This may be accomplished by supplying to people authorized to operate the machine in a diagnostic mode, such as for example, service technicians, a plug-in module which fits into an appropriate receptacle (not shown) and which functionally replaces the program and pattern ROM 56 (FIG. 2) with a diagnostic ROM for operating the sewing machine 10 in a diagnostic mode. Alternatively, the program and pattern ROM 56 may be provided with a diagnostic program and data for operating the sewing machine in a diagnostic mode, which program and data would be accessed by the operator (technician) actuating an anomalous combination of the pattern selection switches 24, such as, for example, by simultaneously depressing a defined pair of the switches.
When the machine is placed in the diagnostic mode, a test of the LEDs 46 is automatically initiated. Each of the LEDs 46 from left to right, beginning with the LED associated with the reverse switch 36, and proceeding across and down the panel of the sewing machine 10, ending with the LED associated with the feed override switch 28, is lit for about 1/2 second. When the sewing machine is in the diagnostic mode, the actuation of only five of the switches is recognized, all other switch actuations being ignored. Thus, if the operator actuates the straight stitch switch, the sewing machine 10 will be controlled to sew a straight stitch. If the operator actuates the zig zag switch, the sewing machine is caused to sew a ric rac pattern. If the operator actuates the blindstitch switch, a motor test is performed, as will be described hereinafter. If the bight override switch 26 or the feed override switch 28 is actuated, the corresponding override is turned on or off.
During the LED test, the needle bar remains in the center (straight stitch) position, but signals from the armshaft sensor (not shown) are ignored and the bight and feed actuators remain stationary. When the LED test is completed, the LED associated with the reverse switch 36 is caused to respond to the armshaft sensor such that it is dark when the needle is up and illuminated when the needle is down. Actuating the straight stitch switch selects that pattern and if the LED test is still running, it is terminated immediately. The LED associated with the straight stitch switch is illuminated. Actuating the zig zag switch selects the ric rac pattern but illuminates the LED associated with the zig zag switch. This operation also terminates the LED test if it is running. Actuating the blindstitch switch causes the sewing machine to run at a fixed speed without operator control of the foot controller. This test is a partial check to isolate a defect in the foot controller. The LED test is terminated when this test is selected.
After the LED test is concluded, the speed of the sewing machine is monitored and displayed by means of the bottommost row of the LEDs 46. Thus, if the sewing machine speed is between 650 and 750 stitches per minute, the leftmost of the LEDs in the bottom row is illuminated. As the speed increases, in 100 stitches per minute range increments, succeeding LEDs in that row are illuminated until the last LED in the row is illuminated when the speed is between 1150 and 1250 stitches per minute.
The APPENDIX to this specification illustrates a program for operating the microcomputer 50 in a diagnostic mode, as discussed above. This program is written in assembly language for the TMS 7040 microcomputer, and is for a machine having a specific switch configuration slightly different from that illustrated in FIG. 1. However, the operation of the sewing machine in accordance with the program in the APPENDIX is as described above. FIGS. 3A and 3B together form a flowchart for the program set forth in tfhe APPENDIX FIGS. 4A and 4B are flowcharts of subroutines of that program for the feed and bight overrides, respectively. FIG. 5 is a flowchart of a subroutine of that program for illuminating the LEDs.
Accordingly, there has been disclosed an arrangement for operating a sewing machine in a diagnostic mode. Since this arrangement utilizes switches and indicators which are already available in the sewing machine, no additional hardware is required. It is understood that the above-described embodiment is merely illustrative of the application of the principles of this invention. Numerous other embodiments may be devised by those skilled in the art without departing from the spirit and scope of this invention, as defined by the appended claims. For example, although a programmed microcomputer has been disclosed, this invention may also be practiced with a hard wired processor.
APPENDIX ##SPC1## ##SPC2## ##SPC3## ##SPC4## ##SPC5## ##SPC6## ##SPC7## ##SPC8## ##SPC9## ##SPC10## ##SPC11## ##SPC12## ##SPC13## ##SPC14## ##SPC15## ##SPC16## ##SPC17## ##SPC18## ##SPC19## ##SPC20## ##SPC21## ##SPC22## ##SPC23##
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An electronically controlled sewing machine includes an arrangement for operating the machine in a diagnostic mode, wherein several tests for checking the functioning of the sewing machine can be performed. In a first test, all of the light emitting diodes on the panel of the sewing machine are sequentially energized. This verifies proper operation of the display panel. In a second test, a particular light emitting diode responds to the armshaft sensor such that it is dark when the needle is up and is illuminated when the needle is down. The motor speed function is monitored by a test which lights particular light emitting diodes in 100 stitches per minute increments of motor speed. Proper overall operation of the sewing machine, including the actuators, is monitored by running several test patterns. To isolate a possible fault in the sewing machine foot controller, the sewing machine may be run at a preset speed without depressing the foot controller.
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This is a division of patent application Ser. No. 09/696,134, filing date Oct. 26, 2000, now U.S. Pat. No. 6,885,527, Integrated Spin Valve, assigned to the same assignee as the present invention, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
The invention relates to the general field of magnetic recording with particular reference to improving linear resolution.
BACKGROUND OF THE INVENTION
The present invention is concerned with the manufacture of the read element in a magnetic disk system. This is a thin slice of material located between two magnetic shields which we will refer to a primary shields. The principle governing operation of the read sensor is the change of resistivity of certain materials in the presence of a magnetic field (magneto-resistance). In particular, most magnetic materials exhibit anisotropic behavior in that they have a preferred direction along which they are most easily magnetized (known as the easy axis). The magneto-resistance effect manifests itself as a decrease in resistivity when the material is magnetized in a direction perpendicular to the easy axis, said decrease being reduced to zero when magnetization is along the easy axis. Thus, any magnetic field that changes the direction of magnetization in a magneto-resistive material can be detected as a change in resistance.
It is now known that the magneto-resistance effect can be significantly increased by means of a structure known as a spin valve (SV). The resulting increase (known as Giant magneto-resistance or GMR) derives from the fact that electrons in a magnetized solid are subject to significantly less scattering by the lattice when their own magnetization vectors (due to spin) are parallel (as opposed to anti-parallel) to the direction of magnetization of the solid as a whole.
The key elements of a spin valve structure are two magnetic layers separated by a non-magnetic layer. The thickness of the non-magnetic layer is chosen so that the magnetic layers are sufficiently far apart for exchange effects to be negligible (the layers do not influence each other's magnetic behavior at the atomic level) but are close enough to be within the mean free path of conduction electrons in the material. If, now, these two magnetic layers are magnetized in opposite directions and a current is passed through them along the direction of magnetization, half the electrons in each layer will be subject to increased scattering while half will be unaffected (to a first approximation). Furthermore, only the unaffected electrons will have mean free paths long enough for them to have a high probability of crossing the non magnetic layer. However, once these electron ‘switch sides’, they are immediately subject to increased scattering, thereby becoming unlikely to return to their original side, the overall result being a significant increase in the resistance of the entire structure.
In order to make use of the GMR effect, the direction of magnetization of one the layers must be permanently fixed, or pinned. Pinning is achieved by first magnetizing the layer (by depositing and/or annealing it in the presence of a magnetic field) and then permanently maintaining the magnetization by over coating with a layer of antiferromagnetic material. The other layer, by contrast, is a “free layer” whose direction of magnetization can be readily changed by an external field (such as that associated with a bit at the surface of a magnetic disk).
Structures in which the pinned layer is at the top are referred to as top spin valves. Similarly, It is also possible to form a ‘bottom spin valve’ structure where the pinned layer is deposited first. Although not directly connected to the GMR effect, an important feature of spin valve structures is a pair of longitudinal bias stripes that are permanently magnetized in a direction parallel to the long dimension of the device. Their purpose is to prevent the formation of multiple magnetic domains in the free layer portion of the GMR sensor, particularly near its ends.
FIG. 1 shows a typical structure that embodies the features described above. As noted above, the device is sandwiched between two primary shields 11 and 12 . Currently, the shield-to-shield separation of a spin valve head cannot be below about 800 Å, mainly due to the sensor-to-shield shorting problem. This is pointed to in the figure by arrow 13 . Since improvements in the density of recorded data require that this distance be reduced below 800 Å, there is a need for a structure (and a process for manufacturing it) that is not susceptible to said shorting problem.
An application that describes a structure that is related to that disclosed by the present invention was filed on Sep. 30, 1999 as application Ser. No. 09/408,492. Additionally, a routine search of the prior art was performed and the following references of interest were found:
In U.S. Pat. No. 5,978,182, Kanai et al. show a SV with a first soft magnetic layer. In U.S. Pat. No. 5,608,593, Kim et al. shows a SV with a non-magnetic (e.g., Cr) under-layer. Takada et al show a stabilizing layer with an under-layer of Cr and a hard magnetic layer in U.S. Pat. No. 5,828,527, while Ohsawa et al. (U.S. Pat. No. 5,777,542), Dykes et al. (U.S. Pat. No. 5,668,688), and Hsiao et al. (U.S. Pat. No. 5,999,379) all show related SV devices with shield layers.
SUMMARY OF THE INVENTION
It has been an object of the present invention to provide a spin valve structure that is free of internal electrical shorting by maintaining a relatively large shield-to-shield spacing while continuing to obtain very narrow feedback pulse widths.
Another object of the invention has been to provide a process for manufacturing said spin valve structure.
A further object has been that said structure be given its longitudinal bias through either permanent magnet or exchange magnet means.
A still further object has been that said structure be either a top or a bottom spin valve.
These objects have been achieved by inserting a high permeability, high resistivity, thin film shield on the top or bottom (or both) sides of the spin valve sensor. A permeability greater than about 500 is required together with a resistivity about 5 times greater than that of the free layer and an M r T value for the thin film shield that is 4 times greater than that of the free layer. Five embodiments of the invention are described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows how a structure made according to earlier teachings is subject to shorting (through the dielectric layer that insulated the shield from the sensor) if made too thin.
FIGS. 2 and 3 show bottom spin valve structures with permanent magnet biasing, having a single thin film shield, as taught by the present invention.
FIG. 4 shows a bottom spin valve structure with exchange magnet biasing, having a single thin film shield, as taught by the present invention.
FIG. 5 shows a top spin valve structure with exchange magnet biasing, having a single thin film shield, as taught by the present invention.
FIG. 6 shows a bottom spin valve structure with permanent magnet biasing, having two thin film shields, as taught by the present invention.
FIG. 7 compares read back signal pulse shape for structures with and without the thin film shield.
FIG. 8 plots voltage against total magnetic moment for structures with and without the thin film shield.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As already noted above, present SV designs cannot have their shield-to-shield spacing thicknesses reduced below about 800 Å because of shorting through the dielectric insulating coverage over the conductor lead. In dual stripe MR structures, it has been observed that if one of the MR stripes is not performing correctly, the signal contribution is dominated by the other MR, so that the read back pulse width, PW 50 , is reduced. PW 50 is the pulse width measured at the 50% of amplitude point (in nanoseconds or nanometers). It is measured at low frequency to avoid interference between adjacent pulses.
The present invention solves this problem by the insertion of a high permeability, high resistivity thin film shield on the top or bottom (or both) sides of the spin valve sensor. Examples of materials suitable for the thin film shields include (but are not limited to) nickel-iron-chromium, cobalt-niobium-zirconium, and cobalt-niobium-hafnium. We now describe five embodiments of the present invention. Although each embodiment is described in terms of the process for its manufacture, the structure of each embodiment will become apparent as each manufacturing process is disclosed. The following compositions and thickness ranges are common to all embodiments:
TABLE I
LAYER
COMPOSITION
THICKNESS (Å)
free
Co 90 Fe 10 , Ni 8 Fe 19
5–50
non-magnetic spacer
Cu
12–22
pinned
Co 90 Fe 10
10–30
pinning
Ni 45 Mn 55 , Mn 50 Pt 50
80–200
dielectric
Al 2 O 3 , AlN
100–200
Thin film shield
NiFeCr, CoZrNb,
50–400
CoHfNb, CoZrHf,
CoFeX (X = Cr, N, Ta, Ti)
decoupling
TaO, NiCr, NiFeCr
20–50
First Embodiment
This process is for manufacturing a top spin valve structure. It begins with the provision the first (lower) of the two primary magnetic shields. This can be seen as layer 15 in FIG. 2 on which dielectric layer 17 is deposited, followed by the deposition of free layer 21 . This is followed by the deposition of non-magnetic Layer 22 onto which is deposited pinned layer 23 . Next, onto pinned layer 23 there is deposited anti-ferromagnetic layer 24 for use as a pinning layer. This completes formation of the spin valve itself.
Now follows a key feature of the invention. On anti-ferromagnetic layer 24 , decoupling layer 25 is deposited, followed by the deposition of thin film shield 26 . The purpose of the decoupling layer is to avoid any exchange coupling of the thin film shield by layer 24 . The thin film shield is a layer of ferromagnetic material having a permeability greater than about 500. It needs to have as high an electrical resistivity as possible within other constraints of the structure. It is required to be at least 5 times more resistive than the free layer. Since the latter is about 25 micro-ohm-cm, a value greater than about 125 micro-ohm-cm is to be preferred. The thickness of the thin film shield should be such that the moment-thickness product (of the thin film shield) is 2–5 times that of the free layer. The presence of this thin film shield allows relatively thicker dielectric layers to be used, thereby reducing or eliminating the chances of shorting, while still being able to obtain very narrow feedback pulse widths (namely PW 50 ).
To initiate completion of the structure, trench 29 is formed using conventional patterning and etching. This trench extends through thin film shield 26 down as far as the top surface of dielectric layer 17 . The trench has a sidewall 30 that slopes at an angle of about 20 degrees. Onto this sidewall, as well as the exposed surface of dielectric layer 17 , is selectively deposited layer 27 of a ferromagnetic material (such as CoCrPt) that is suitable for use as a permanent magnet, the direction of permanent magnetization being set by a field that is present during or after deposition of the layer. Layer 27 will serve to provide longitudinal bias to the structure, as discussed earlier.
With layer 27 in place, a layer of conductive material 28 , suitable for use as a connecting lead to the structure, is selectively deposited thereon. This is followed by the deposition of second dielectric layer 18 onto which is deposited upper primary magnetic shield 16 .
Second Embodiment
This process is also for manufacturing a top spin valve structure. Referring now to FIG. 3 , this embodiment begins with the provision of the first (lower) of the two primary magnetic shields 15 on which dielectric layer 17 is deposited. Now follows a key feature of the invention, namely the deposition of thin film shield 36 . The thin film shield is a layer of high permeability (greater than about 500) ferromagnetic material. It needs to have as high an electrical resistivity as possible within other constraints of the structure. It is required to be at least 5 times more resistive than the free layer. Since the latter is about 25 micro-ohm-cm, a value greater than about 125 micro-ohm-cm is to be preferred. The thickness of the thin film shield should be such that the moment-thickness product (of the thin film shield) is 2–5 times that of the free layer. The presence of this thin film shield allows relatively thicker dielectric layers to be used, thereby reducing or eliminating the chances of shorting, while still being able to obtain very narrow feedback pulse widths.
With the thin film shield in place, decoupling layer 25 is laid down followed by the deposition of free layer 21 . This is followed by the deposition of non-magnetic layer 22 onto which is deposited pinned layer 23 . Next, onto pinned layer 23 there is deposited anti-ferromagnetic layer 24 for use as a pinning layer. This completes formation of the spin valve itself.
Completion of the structure then continues with the formation of trench 29 , using conventional patterning and etching. This trench extends through layer 24 down as far as the top surface of dielectric layer 17 . The trench has a sidewall 30 that slopes at an angle of about 20 degrees. Onto this sidewall, as well as the exposed surface of dielectric layer 17 , is selectively deposited layer 27 of a ferromagnetic material (such as CoCrPt) that is suitable for use as a permanent magnet, the direction of permanent magnetization being set by a field that is present during deposition of the layer or by later annealing in such a field. Layer 27 will serve to provide longitudinal bias to the structure, as discussed earlier.
With layer 27 in place, a layer of conductive material 28 , suitable for use as a connecting lead to the structure, is selectively deposited thereon. This is followed by the deposition of second dielectric layer 18 onto which is deposited upper primary magnetic shield 16 .
Third Embodiment
This process is also for manufacturing a top spin valve structure. We refer now to FIG. 4 which begins with the provision of the first (lower) of the two primary magnetic shields 15 onto which is deposited dielectric layer 17 . Then, on a selected area at the surface of layer 17 , a layer of conductive material 47 , suitable for use as a connecting lead to the structure, is deposited. Then, on layer 47 only, layer 48 of a ferromagnetic material suitable for use as an exchange magnet is deposited. This will serve to provide the needed longitudinal bias for the structure, as discussed above.
Then, free layer 21 is deposited over the full surface followed by the deposition of non-magnetic layer 22 onto which is deposited pinned layer 23 . Next, onto pinned layer 23 there is deposited anti-ferromagnetic layer 24 for use as a pinning layer.
Now follows a key feature of the invention. On anti-ferromagnetic layer 24 , decoupling layer 25 is deposited, followed by the deposition of thin film shield 46 . The purpose of the decoupling layer is to avoid any pinning of the thin film shield by layer 24 . The thin film shield is a layer of high permeability (greater than about 500) ferromagnetic material. It needs to have as high an electrical resistivity as possible within other constraints of the structure. It is required to be at least 5 times more resistive than the free layer. Since the latter is about 25 micro-ohm-cm, a value greater than about 125 micro-ohm-cm is to be preferred. The presence of this thin film shield allows a relatively large shield-to-shield spacing to be maintained (thereby reducing or eliminating the chances of shorting) while still being able to obtain very narrow feedback pulse widths.
Since the lead and biasing structure is already in place, all that remains to complete this embodiment is the deposition of second dielectric layer 18 onto which is deposited upper primary magnetic shield 16 .
Fourth Embodiment
Unlike the previous three embodiments, this process is for manufacturing a bottom spin valve structure. Referring to FIG. 5 , it begins, as before, with the provision of the first (lower) of the two primary magnetic shields 15 onto which dielectric layer 17 is deposited. A key feature of the invention now follows, namely the deposition of thin film shield 56 . The thin film shield is a layer of high permeability (greater than 500) ferromagnetic material. It needs to have as high an electrical resistivity as possible within other constraints of the structure. It is required to be at least 5 times more resistive than the free layer. Since the latter is about 25 micro-ohm-cm, a value greater than about 125 micro-ohm-cm is to be preferred. The thickness of the thin film shield should be such that the moment-thickness product (of the thin film shield) is 2–5 times that of the free layer. The presence of this thin film shield allows relatively thicker dielectric layers to be used, thereby reducing or eliminating the chances of shorting, while still being able to obtain very narrow feedback pulse widths (namely PW 50 ).
With the thin film shield in place, decoupling layer 25 is laid down followed by the deposition of anti-ferromagnetic layer 24 . This is followed by the deposition of pinned layer 23 onto which is deposited non-magnetic layer 22 . Next, onto non-magnetic layer 22 there is deposited free layer 21 which completes formation of the spin valve itself.
To initiate completion of the structure, shallow trench 59 is formed using conventional patterning and etching. This trench extends part way through the free layer 21 . On the part of the free layer that lies outside the trench, capping layer 51 of tantalum, tantalum oxide, and alumina, among others, is deposited. Its purpose is to provide protection against oxidation or other forms of contamination. On the part of the free layer that forms the base of the trench, refill layer 52 of the same material as used for the free layer (typically permalloy).
Layer 48 , comprising a ferromagnetic material suitable for use as an exchange magnet is then selectively deposited onto the trench base portion of layer 21 where it will provide longitudinal bias to the structure. Then, layer 47 of conductive material suitable for use in connecting leads to the structure is selectively deposited onto exchange magnet layer 48 . To complete this embodiment, second dielectric layer 18 is deposited onto layers 47 and 51 followed by the overall deposition of upper primary magnetic shield 16 .
Fifth Embodiment
The process of this embodiment is also for manufacturing a top spin valve structure but, unlike the previous four embodiments, it makes use of two thin film shields. While adding slightly to the overall thickness, the two shield structure has the advantage that, since PW 50 is defined by the distance between these two shields, even narrower pulse widths can be obtained. Note also that this scheme is not limited to conventional spin-valve structures. It is also readily applicable to synthetic anti-ferromagnet SVs and Dual-SV applications.
Referring now to FIG. 6 , this embodiment begins with the provision of the first (lower) of the two primary magnetic shields 15 on which dielectric layer 17 is deposited. Now follows a key feature of the invention, namely the deposition of thin film shield 66 . The thin film shield is a layer of high permeability (greater than 500) ferromagnetic material. It needs to have as high an electrical resistivity as possible within other constraints of the structure. It is required to be at least 5 times more resistive than the free layer. Since the latter is about 25 micro-ohm-cm, a value greater than about 125 micro-ohm-cm is to be preferred. The thickness of the thin film shield should be such that the moment-thickness product (of the thin film shield) is 2–5 times that of the free layer. The presence of this thin film shield allows relatively thicker dielectric layers to be used, thereby reducing or eliminating the chances of shorting, while still being able to obtain very narrow feedback pulse widths (namely PW 50 ).
With the thin film shield in place, decoupling layer 25 is laid down followed by the deposition of free layer 21 . This is followed by the deposition of non-magnetic layer 22 onto which is deposited pinned layer 23 . Next, onto pinned layer 23 there is deposited anti-ferromagnetic layer 24 for use as a pinning layer.
Now follows another key feature of the invention. On anti-ferromagnetic layer 24 , decoupling layer 25 is deposited, followed by the deposition of a second thin film shield 67 . The second thin film shield has the same properties as the first thin film shield. The presence of the thin film shields allows a relatively large shield-to-shield spacing to be maintained (thereby reducing or eliminating the chances of shorting) while still being able to obtain very narrow feedback pulse widths.
To initiate completion of the structure, trench 29 is formed using conventional patterning and etching. This trench extends through thin film shield 67 down as far as the top surface of dielectric layer 17 . The trench has a sidewall 30 that slopes at an angle of about 20 degrees. Onto this sidewall, as well as the exposed surface of dielectric layer 17 , is selectively deposited layer 27 of a ferromagnetic material (such as CoCrPt) that is suitable for use as a permanent magnet, the direction of permanent magnetization being set by a field that is present during deposition of the layer or by later annealing in such a field. Layer 27 will serve to provide longitudinal bias to the structure, as discussed earlier.
With layer 27 in place, a layer of conductive material 28 , suitable for use as a connecting lead to the structure, is selectively deposited thereon. This is followed by the deposition of second dielectric layer 18 onto which is deposited upper primary magnetic shield 16 .
In FIGS. 7 and 8 we present data that confirms the effectiveness of the present invention. FIG. 7 illustrates the reduction in PW 50 that the present invention brings about. Shown there are micro-magnetic simulated playback wave-forms. The cases involved are curve 71 , conventional SV head with 800 Å shield-to-shield spacing (dashed), and curve 72 which is for double-sided thin film shields(solid), the free layer being located at the center of the two thin film shields. The spacing between the thin film shields is 300 Å. The total distance between the primary shields is about 1000 Å. The M r T (remnant magnetization×layer thickness=total magnetic moment) of both thin film shields is four times that of the free layer. The resistivity of the thin film shield is assumed to be nine times greater than that of the free layer. Simulation shows that the PW 50 for the conventional SV is about 700 Å while the PW 50 for the thin film shield head is about 550 Å, which is approximately equivalent to a 450 Å shield-to-shield space in the case without the thin film shields.
Since the thin film shields are magnetic materials, the fringe field from the shield layers will affect the performance of the free layer and cause instability if they are not properly biased. No additional bias scheme is needed for the continuous thin film shield. For the permanent magnet (PM) abutted scheme ( FIGS. 2 , 3 , and 6 ), a permanent magnet is placed adjacent to both sides of the thin film shield to provide a horizontal bias along the track width direction, just as the free layer is given its bias. The highly localized PM field removes the magnetic charge at the ends of the thin film shield, while still keep the high permeability property of the shield layers.
From the curves shown in FIG. 7 , the data displayed in TABLE II can be derived:
TABLE II
equivalent shield-to-
structure
PW 50 (Å)
shield spacing
no TF shield
700
800
with TF shield
550
450
This shows that when the thin film shield disclosed in the present invention is used, the 550 Angstrom PW 50 that is obtained is equivalent to a shield-to-shield spacing of only 450 Angstroms.
FIG. 8 shows calculated transfer curves for the double-sided thin film shield for two different PM bias strength presented as voltage vs. total magnetic moment in milli-electromagnetic units. A “kink” 83 appears in the transfer curve where hard bias curve 81 for a field that is not strong enough crosses curve 82 which is for a field of adequate strength. Calculations show that a stability coefficient (M r T) PM /(M r T) TFS of 1 is sufficient to provide the proper horizontal bias for the thin film shields.
Note that since the thin film shield is at least two times thicker than the free layer, the degree of the magnetization rotation in the thin film shield is usually much less than in the free layer. The magnetization in the thin film shield is essentially oriented along the track width direction. The change of the free layer bias level due to the flux from the shield layer is not significant. The effect of current field from the thin film shield layers on the bias is also negligible due to the high resistivity of the shield material.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.
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Currently, the shield-to-shield separation of a spin valve head cannot be below about 800 Å, mainly due to sensor-to-lead shorting problems. This problem has now been overcome by a manufacturing method that includes inserting a high permeability, high resistivity, thin film shield on the top or bottom (or both) sides of the spin valve sensor. A permeability greater than about 500 is required together with a resistivity about 5 times greater than that of the free layer and an M r T value for the thin film shield that is 4 times greater than that of the free layer.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to a process of treating a nonwoven web with an elastomeric binder. More particularly the invention relates to treating a spunbonded polyester web to impart improved tufting properties.
[0003] 2. Description of Related Art
[0004] A tufted carpet is generally manufactured by inserting reciprocating needles threaded with a face yarn through a primary backing material to form loops or tufts of yarn in the backing. The quality, appearance and dimensional stability of tufted carpets depends in large part on the properties of the primary backing.
[0005] Primary backings are usually produced from woven or nonwoven materials. Tufting into nonwoven materials is more difficult than tufting into woven materials. A woven fabric will open within the weave to accept the tufting needle and yarn and will then close around the tufted yarn after the needle has retracted. The closing property of woven fabrics provides a firm grip on the yarn in the opening. The yarn must remain in the opening until adhesive is applied to secure the yarn in place.
[0006] On the other hand, nonwovens have no weave to open and close nor do the individual filaments have a memory to return to the original state. Tufting into a nonwoven backing usually results in creating an opening large enough to accept the tufting needle and yarn. However, when the needle retracts, the opening does not close tightly around the yarn and remains larger than necessary to grip the yarn. The result is a condition in which the tufting yarn may slip out of the opening creating defects and necessitating repair and reworking.
[0007] Nonwoven backing materials typically are spunbonded or spunlaid webs formed from thermoplastic polymers such as polyolefins, polyesters and blends of these materials. Spunbonding is a process which generally involves feeding a thermoplastic polymer into an extruder, feeding the extruded molten polymer through a spinneret to form continuous filaments, and laying down the extruded filaments on a moving conveyor belt to form a nonwoven web of randomly arranged continuous filaments. In the lay-down process, desired orientation may be imparted to the filaments by various means such as rotation of the spinneret, electrical charges, introduction of controlled airstreams, varying the speed of the conveyor belt, etc. The individual entangled filaments in the nonwoven web are then bonded primarily at filament cross-over points by thermal or chemical or mechanical treatments. The spunbonded web is then wound up in a roll form.
[0008] During the carpet tufting process, hundreds of tufting needles threaded with yarn are inserted into the primary backing material with each stroke of the needle bar. Each needle penetrates the backing material creating an opening and then retracts leaving a loop of yarn in each opening. Each needle then moves to the next insertion point.
[0009] During the tufting process, the primary backing material must provide two very important characteristics: insertion resistance to the tufting needles and the ability to grip and hold the yarn loop (tuft) in place after the needles retract. Optimally, it would be most desirable to have a backing material which has minimal insertion resistance and maximum tuft grip at any point. However, mechanical and chemical properties of the web material necessitate a designed trade-off of both characteristics. That is to say, a high gripping force would likely require a high penetration force. Conversely, a low penetration force usually results in a poor or weak tuft gripping force. A primary backing which combines a low insertion resistance with a high gripping force would be highly desirable.
[0010] It is an object of the invention to produce a nonwoven web suitable for use as a carpet backing material which has improved tuft gripping characteristics.
[0011] Another object of the invention is a process for improving the tuft gripping properties of a spunbonded or spunlaid polyester fabric.
[0012] Still another object of the invention is an improved process of producing a tufted carpet.
[0013] These and other objectives of the present invention will become readily apparent upon a review of the present disclosure.
SUMMARY OF THE INVENTION
[0014] In order to attain the above objectives, a method has now been devised which includes the steps of applying a curable, elastomeric binder formulation to a nonwoven web, treating the web to provide a series of voids or depressions in the web that are in register with the tufting needle pattern to be subsequently applied, and heating to cure the elastomeric binder. The treated nonwoven web may then be wound up into rolls for future processing.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWING
[0015] FIG. 1 is a diagrammatic representation of a process of the invention.
[0016] FIG. 2 is a view of depressions or holes in a web treated in accordance with the present invention.
[0017] FIG. 3 is a view of a tufting procedure on a web prepared by the process of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] Suitable nonwoven webs to be processed in accordance with the present invention include those prepared from thermoplastic polymers such as polyolefins, polyesters, polyamides and blends of these polymers. Nonwovens derived from polyesters are preferred and spunbonded or spunlaid polyester webs are particularly preferred. The nonwoven webs can be prepared using conventional methods and include dry-laid, wet-laid, spunlaid, melt-blown, spunbonded and spunlaced products.
[0019] Preferably, the nonwoven web is needled, heat-set and calendered before treatment with an elastomeric binder. Needling or needle-punching through the thickness of the nonwoven web creates fiber entanglement in the “Z” direction (i.e., through the thickness of the fabric) in addition to the normal thermal bonding in the “X” and “Y” direction (i.e., in the machine direction and cross-machine direction). The needling provides fiber bonding and entanglement in all directions, thereby increasing the opportunities for entanglement with the tufted yarn. Needling also provides additional loft to the fabric which results in a slightly thicker material for the same fabric weight and provides an additional grip on the tuft. The nonwoven web may be needled in one or both directions. Also, custom needling may be performed in a conventional manner to create patterns or grains in the web.
[0020] Needling (or needle-punching) can be performed using any commercially available needling apparatus. As is well known, the degree of needling affects the tensile strength of the web or fabric. The number of needle penetrations per square inch should be selected for optimum intermingling and entanglement of the individual filaments of the web.
[0021] Alternatively, fiber entanglement could be accomplished by other well-known techniques. These would include hydro-entangling using high pressure water jets instead of barbed needles.
[0022] The nonwoven web preferably is heat-set. This step improves dimensional stability and locks in the loft provided by a needle-punching step. The improved loft aids in reducing compression upon any subsequent calendering, and also preshrinks the web before locking in memory, thereby minimizing stretching or shrinking of the web which may occur during subsequent processing.
[0023] Operable heat-setting temperatures will depend in large part upon the nature of the polymer used to prepare the nonwoven web. Temperatures must be selected which are high enough to effect heat-setting but below the melting or decomposition temperatures of the polymeric materials. For spunbonded or spunlaid polyester nonwovens, a temperature range of about 190° C. to about 250° C. is preferred. A temperature of about 205°-210° C. is most preferred.
[0024] Any suitable heating apparatus can be employed. Drum ovens are particularly suitable. Heat-setting can be accomplished by exposing the web to pressurized saturated steam or by employing apparatus which provides dry heat.
[0025] The nonwoven web preferably is calendered after heat-setting by treating at temperatures and pressures sufficient to bond surface filaments and compact the web to a suitable thickness for further processing. Calendering may also be used to provide a smooth surface to the web, if desired. The temperature and pressure can be adjusted to provide a suitable thickness and surface texture to the web. Because the web was previously heat-set, the loft is unaffected and internal fiber entanglement is undisturbed.
[0026] The temperature and pressure conditions generally suitable for calendering range from about 100° C. to about 250° C. and from atmospheric up to about 500 lbs/in 2 . Conventional calender rolls or cylinders can be employed in the calendering process.
[0027] Preferably, the fabric is cooled after calendering, most preferably to room temperature. Cooling is believed to help set dimensional memory in the fabric. Cooling can be accomplished by air cooling or cooling jets or any conventional cooling means.
[0028] It is an important feature of the process of the invention to provide elastomeric properties to the web or fabric. This is accomplished by contacting the web with a liquid, curable, elastomeric binder formulation.
[0029] The elastomeric binder provides the fabric with an elastomeric property which enables the opening made with the tufting needle to shrink in size after the needle retracts. Shrinking of the opening after needle retraction increases the gripping action on the yarn tuft. The elastic nature of the binder also allows for multiple repairs of the fabric if the tuft yarn is removed from the opening for various reasons. In many backing fabrics, the piece of material between needle openings will tear when repairs are necessary. The elastic properties of nonwoven fabrics processed according to the invention allow the piece of material between needle openings to expand and stretch without tearing, thereby facilitating repairs.
[0030] Suitable elastomeric binder formulations include water-based and organic solvent-based elastomers containing conventional curatives and additions. Latexes are preferred for environmental reasons. Examples include curable polyurethanes, homopolymers and copolymers of dienes such as butadiene/styrene rubbers, acrylics, etc.
[0031] Conventional additives may be present in the elastomeric formulations. These additives include curing agents and curing adjuvants, fillers, lubricants, colorants, anti-microbials, water resists, etc. The amount of elastomeric binder and the solids content of the formulation can be adjusted for optimum performance. Generally, the solids content will range from about 10% to about 30% by weight, preferably about 15% to about 25%.
[0032] Conventional means may be employed to apply the binder to the web. Bath immersion, spraying or roller coating may be employed. Preferably, the nonwoven web is fully saturated by the elastomeric formulation. This can be accomplished by immersing the web in a dip tank containing the elastomeric binder.
[0033] After impregnating with the elastomeric binder, the web preferably is processed to remove excess binder. Simultaneous or subsequent to excess binder removal, the web is provided with holes, voids or depressions. The holes, voids or depressions are in a pattern consistent with, and in register with, the tufting needle pattern to be used when the finished web is subsequently tufted in a future carpet manufacturing operation. Preferably, the removal of excess binder and the application of holes or voids in the web occur simultaneously, for example, by feeding the web through a set of rollers, one having a smooth face and the other having a surface with raised protrusions of a predetermined height, size and pattern.
[0034] Any commercially available embossing apparatus may be employed to apply the voids (dimples), holes or depressions. Engraved heated rollers are particularly suitable.
[0035] The effect of this step is to provide a nonwoven web having little or no binder in the holes or depressions and having a hole which is smaller than the tufting needle containing the face yarn. Energy created when the hole is stretched during the tufting operation is, in effect, stored in the elastic binder which has been squeezed from the depression and surrounds the hole. When the needle retracts, the stored energy is released causing the stretched fabric around the hole to relax and hold the tuft firmly in place.
[0036] Following the treatment to apply voids or holes in the binder-treated fabric, the binder is allowed to cure. Preferably, the treated fabric is routed over drum heaters at a temperature high enough to dry the fabric and cure the binder without softening the fibers or changing the heat-set of the fibers. The drying and curing operation provides additional bonding at filament junctions and endows the fabric with elastomeric properties. A range of suitable temperatures for nonwoven polyesters for drying/curing is 100° C. to about 250° C.
[0037] The finished product is then wound up in rolls. Preferably, winding apparatus is used which is designed to drive the take-up roll at the core. Friction wheel winders may slip on a lubricated surface of the fabric and create poor packing on the roll. Core driven winders will pull the wraps tighter resulting in a much more stable package.
EXAMPLE
[0038] With reference to FIG. 1 , a base material A, which is a spunlaid nonwoven polyester, is threaded through a binder dip tank B containing a curable, liquid, elastomeric formulation. The base material, fully saturated with binder, is then threaded through a pair of squeeze rollers where pressure is set to remove a specific and predetermined amount of binder. One roller C has a surface with raised protrusions of a predetermined height, size and pattern consistent with and in register with the desired hole pattern on the finished web D. The web D is then heated to dry the material and cure the binder.
[0039] As shown in FIG. 2 , the protrusions on the surface of roller C effectively squeeze most or all of the binder from the voids or depressions beneath them and push excess binder into a ring pattern surrounding the hole or void. The result is a dimple essentially free of binder having a binder-rich ring around the void. This ring has the capacity to store the energy created during tufting by expanding in a manner similar to a rubber band when the needle is inserted into the hole or void. When the needle retracts, leaving the tuft in the hole, the stored energy is released, the ring relaxes and tightly grips the tuft. This is shown in FIG. 3 . The result is a superior grip on the yarn tuft that reduces defects, reworking and waste while providing a consistent yarn pattern on the show surface of the carpet.
[0040] Having described preferred embodiments of the invention, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit.
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A process is described for treating a nonwoven fabric to improve the gripping ability of the fabric during the preparation of tufted carpets. The process includes the steps of applying an elastomeric binder to the fabric, treating the fabric to provide a series of depressions or holes in a pattern consistent with the tufting needle pattern to be subsequently applied, and then curing the binder. The resultant fabric has a pattern of holes or depressions which are essentially free of binder with excess binder squeezed from the depressions forming rings around the depressions. When the tufting needle is inserted into the depression or hole, the elastomeric ring surrounding the hole expands. Upon retraction of the needle, the elastomeric ring contracts and exerts a firm grip on the tuft in the hole.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is based on and claims priority to U.S. Provisional Patent Application Ser. No. 61/041,333, filed on Apr. 1, 2008.
BACKGROUND OF THE INVENTION
The present disclosure generally relates to a system and method for communicating information from a plurality of devices in a home to a remote location. More specifically, the present disclosure relates to a method and system that can communicate utility-related information from a home to a remote site, such as a utility, through either a home gateway located within a home or a utility gateway positioned remotely from the home.
Presently, various different systems exist for a utility to receive consumption information from a plurality of meters distributed throughout a remote area. Many of these systems incorporate a gateway positioned within a neighborhood or a defined area that communicates using an RF local area network (LAN) to a plurality of meters distributed within an area surrounding the gateway. Typically, the gateway includes some type of communication device that allows the gateway to communicate over a wide area network (WAN) with a utility provider. This wide area network can be various systems, such as a public telephone system, the internet, or one of various other types of communication platforms.
In currently available advanced meter infrastructure (AMI) systems, the utility gateway is positioned on a tower or pole such that the gateway has a clear communication path for RF signals to reach the various meters distributed in the area. Although these types of AMI systems currently work effectively to receive utility consumption information from meters located within customer homes, the utility gateways must be mounted on towers or poles, which requires capital infrastructure expenditures by the utility. Further, the utility poles and towers must be distributed in desired locations to provide communication to a large number of meters. In rural areas, AMI systems are often not cost effective due to the low density of the meters in such locations.
Current developments in radio frequency communications have led to the inclusion of radio frequency communication devices in various home appliances, such as refrigerators, thermostats and other large appliances. These radio frequency communication devices allow the devices to communicate either with each other or with a monitoring device located within the home. The monitoring device allows a user to monitor energy consumption, operating characteristics, or other important information regarding the operation of the RF equipped devices. However, since the RF equipped devices may be provided by different manufacturers, the RF equipped devices located within a home often communicate utilizing various different types of RF protocols. These RF protocols may include GSM, Zigbee, Bluetooth, as well as other proprietary RF protocols or protocols yet to be developed. Thus, it is often difficult for devices to communicate with each other, or with a central location, utilizing the various different RF protocols available.
SUMMARY OF THE INVENTION
The present disclosure relates to Universal Software Defined Home Gateway (USDHG), which is a device that enables wireless RF peripheral devices in a home to seamlessly communicate to a backhaul public WAN network, such as the internet.
The home gateway contains a RF multi-band software defined radio. The radio is fully programmable and configurable so that it is capable of emulating, transmitting, and receiving any of a plurality of RF protocols. The radio is capable of multi-band operation so that it can simultaneously communicate with peripheral devices that operate on significantly different frequencies. The multi-band radio is capable of operating over multiple channels such that the radio can communicate over portions of different radio spectrums. The home gateway radio is capable of full-duplex operation, which enables it to simultaneously transmit and receive RF messages. The home gateway radio is also capable of half-duplex operation so that it either only transmits or receives RF messages at the same time.
The home gateway supports commonly used interfaces for communicating to the public WAN network, such as but not limited to DSL, Cable Modem, Phone Modem, USB, Ethernet, GSM, RF Modem, etc . . . These interfaces are used to pass data back and forth between the peripherals and the backend over public WAN networks. The backend may be located at various monitoring locations, such as at a utility provider, a security company or any other location that could monitor the status of a home.
The home gateway may be a printed circuit board (PCB) that plugs into commonly used third party devices such as cable set top boxes. The home gateway may be a fully stand alone packaged box product that has backend interface connections as described above. Alternatively, the home gateway can be incorporated into other device within the home, such as within one of the home appliances or within the metering endpoint, such as the electricity meter. Alternatively, the home gateway could be incorporated within a local collector such that the local collector could receive information from devices located within more than one home.
The home gateway is capable of downloading all required digital signal protocols (DSP) and protocol firmware files via the backend (i.e. Ethernet) so that it is fully migratable and upgradeable to new protocols while in the home or plant. It is contemplated that the home gateway would be pre-loaded with a common set of RF protocols and could be upgraded with other RF protocols as desired using the backend communication.
The home gateway is capable of communicating to peripherals over the following standards and RF protocols, but not limited to them:
IEEE 802.15.4 Zigbee GSM Sensus FlexNet Wi-Fi (IEEE 802.11.x) Bluetooth Any third party AMI protocol Sensus RadioRead
The home gateway may communicate to the following types of peripheral devices but is not limited to them.
Sensus FlexNet RF Water, Gas, and Electric Meters Sensus RadioRead RF Water, Gas, and Electric Meters GSM RF modems Programmable Controllable Thermostats (PCTs) RF enabled Electric Utility Load Controllers Any home smart appliances that are RF enabled RF enabled water, gas and electric meters
The home gateway is capable of transferring local metering data received from the meters over an RF local area network (LAN), over the public WAN systems to the water, gas, and or electric utilities' backend and billing systems.
The home gateway is capable of communicating and networking via RF to other nearby home gateways as a backup in the event that the public WAN connection to the home gateway fails. Home gateways may communicate to each other using Sensus FlexNet, Zigbee, IEEE 802.15.4, Wi-Fi protocol standards but are not limited to them.
The present disclosure relates to a system and method for communicating energy or water consumption related information from a plurality of RF enabled peripheral devices in a home, such as utility meters, thermostats, appliances and load controllers. The system includes a home gateway, which is a device that enables wireless RF peripheral devices in a home to seamlessly communicate to a backhaul public WAN network, such as the internet.
The home gateway contains a RF multi-band software defined radio. The radio is fully programmable and configurable so that it is capable of emulating, transmitting, and receiving any of a plurality of RF protocols. The radio is capable of multi-band operation so that it can simultaneously communicate with peripheral devices that operate on significantly different frequencies and/or protocols. The multi-band radio is capable of operating over multiple channels such that the radio can communicate over portions of different radio spectrums. The home gateway radio is capable of full-duplex operation, which enables it to simultaneously transmit and receive RF messages. The home gateway radio is also capable of half-duplex operation so that it either only transmits or receives RF messages at the same time. The home gateway supports commonly used interfaces for communicating to the public WAN network. These interfaces are used to pass data back and forth between the peripherals and the backend over public WAN networks. The backend may be located at various monitoring locations, such as at a utility provider, a security company or any other location that could monitor the status of a home.
The home gateway supports a two-step business process. In the first step, virtually any present day AMI infrastructure can be used to garner immediate benefits to utilities. In the second step, the home gateway allows connectivity to the water, gas and electric meters and other AMI devices by means of the home gateway. The system also supports future peripherals that do not exist today due to the flexibility of the software defined radio of the home gateway.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings:
FIG. 1 is a schematic overview of the communication between a home gateway and a plurality of devices located within the home, as well as the communication between several of the devices and an advanced meter infrastructure (AMI) system;
FIG. 2 is a schematic overview of the communication between a home gateway and the AMI system, as well as the communication between the home gateway in one home and another home gateway in a nearby home;
FIG. 3 is an operational block diagram illustrating the components of the home gateway for communicating utilizing multiple RF protocols;
FIG. 4 is a more detailed block diagram illustrating the operation of the home gateway for communicating using multiple RF protocols; and
FIGS. 5 a - 5 c are schematic overviews similar to FIG. 1 illustrating alternate types of communication between an AMI system and the home gateway, including an enhanced gateway.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a home gateway 1 in a typical application where various dissimilar peripheral devices are communicating with the home gateway 1 . In the embodiment shown in FIG. 1 , the home gateway 1 is a Universal Software Defined Home Gateway (USDHG) with its major components illustrated.
The home gateway 1 is capable of communicating to any RF enabled water, gas, electric meter 2 , over any third party AMI RF protocol. This includes but is not limited to protocols from CellNet, L&G, Elster, Itron, etc.
The electric meter 3 is also capable of communicating with the home gateway 1 along with an electric load controller 4 . The communication link between the electricity meter 3 and the load controller 4 can take place using different RF protocols. In the embodiment illustrated, the electric meter 3 is a Sensus RF enabled iConA meter that communicates using a proprietary FlexNet protocol. However, other types of electricity meters 3 are contemplated as being within the scope of the present disclosure.
A generic display peripheral device 5 may send data to the home gateway 1 using the FlexNet protocol while a programmable controllable thermostat (PCT) 6 may communicate to the home gateway via the Zigbee protocol. Both of the communication protocols set forth above with respect to the display device 5 and the programmable controllable thermostat 6 are set forth for illustrative purposes only, since various other types of communication protocols could be utilized to communicate between the home gateway 1 and the various devices.
Any smart home appliance (or application) 7 may communicate with the gateway via the Q-wave standard. As an example, the home appliances 7 may include a refrigerator, stove, dishwasher, washer or dryer or other types of appliances that are RF enabled to communicate operating information regarding the appliance. Again, other types of RF protocols are contemplated to facilitate communication between the home appliances 7 and the home gateway 1 .
A GSM RF modem 8 may communicate to the gateway using the GSM standard. In the embodiment shown in FIG. 1 , the modem 8 is shown incorporated within an automobile. However, it should be understood that the modem 8 could be incorporated within any type of device and communicate back to the home gateway 1 using a conventional communication protocol.
As illustrated in FIG. 1 , components of an AMI system 11 are also shown communicating to several of the devices 3 - 6 . This communication typically takes place utilizing an AMI protocol, such as a FlexNet RF protocol, between a utility gateway 9 typically mounted to a tower 13 . In the embodiment shown in FIG. 1 , the utility gateway 9 is a Sensus FlexNet TGB (Tower Gateway Box). However, various different other types of AMI systems 11 could be utilized while operating within the scope of the embodiment shown in FIG. 1 . The gateway 9 communicates with each of the devices 3 - 6 through an RF local network such that the utility gateway 9 can receive energy consumption information or issue load control commands utilizing the RF communication protocol. The AMI system 11 shown in FIG. 1 is a currently available AMI system from Sensus Metering Systems and is sold under the FlexNet name.
FIG. 2 illustrates the home gateway 1 in a field application scenario in which the home gateway 1 is communicating with the utility gateway 9 , such as a Sensus FlexNet TGB, as well as other nearby home gateways 1 a , 1 b . Electric, water, and gas RF meters 2 , 3 , and various dissimilar peripheral devices 7 and the thermostat 6 are concurrently communicating to the home gateway 1 utilizing various RF protocols.
The home-to-home RF links between the home gateways 1 may use the FlexNet RF protocol, Wi-Fi, and/or Zigbee but are not limited to them. As illustrated in FIG. 2 , if the home gateway 1 is unable to communicate over a wide area network (WAN) 19 , such as if an internet connection to the home gateway 1 is lost or interrupted, it is contemplated that the home gateway 1 may communicate to one of the home gateways 1 a , 1 b located within RF communication range. In such an embodiment, the home gateway 1 would communicate information to and from the various devices 4 - 7 . The information collected from the devices within the home would be transferred by RF communication protocol to one of the other home gateways 1 a , 1 b . The receiving home gateway 1 a or 1 b could then, in turn, communicate over the wide area network to the utility, assuming that the link to the LAN from the home gateway 1 a or 1 b is in tact. In this manner, the home gateway 1 can communicate over a WAN even though the connection between the home gateway 1 and the WAN is disturbed.
Referring back to FIG. 1 , the home gateway 1 is shown as including a universal multi-band DSP defined radio 12 , a protocol emulator 14 , a power supply 16 , as well as a communication module 18 for communicating with the public WAN 19 . The multi-band radio 12 is capable of operating over multiple channels such that the radio can communicate over various portions or chunks of different radio spectrums. In the embodiment shown in FIG. 1 , all of the components 12 - 18 are illustrated as being included within a single housing 20 . However, it is contemplated that the various modules 12 - 18 could be included in different components that would communicate to each other through conventional communication techniques.
Although the home gateway 1 is shown in FIG. 1 as being located separate from the various devices 2 - 8 , it is contemplated that the home gateway 1 could be incorporated into any one of the devices shown in FIG. 1 . As an example, the home gateway could be incorporated into the programmable thermostat 6 or within the electricity meter 3 . In such an embodiment, the operational components of the home gateway 1 would be incorporated into the specific device such that the device would not only carry out its designated function, but would also act as the home gateway. As an example, if the home gateway 1 were incorporated into the programmable thermostat 6 , the programmable thermostat 6 would still carry out all of the functions of the thermostat. In addition, the thermostat 6 would act as the home gateway to receive information from the various devices and relay the information to a utility either over the AMI system 11 or the public WAN 19 .
Referring now to FIG. 3 , thereshown is a top level functional block diagram for the home gateway radio 12 . The radio 12 includes an antenna 22 that will be broadband such that it has reasonable performance parameters at all the required RF bands such as 900 MHz licensed, 900 MHz ISM, 2.4 GHz ISM, etc.
A multi-band duplexer 24 allows the RF signals to be received at various RF bands simultaneously. The duplexer will also facilitate full duplex operation of the radio 12 where incoming RF signals can be received at the same time as RF transmissions occur.
A RF band pass filter 26 with a passband at a first desired RF frequency range is used to filter out excess RF noise and limit out of band interference. The signal from the filter 26 is received by a Low Noise Amplifier (LNA) 28 that is used to amplify the received RF signal while limiting the added noise level to a minimum.
The received RF signal will be downconverted in frequency to some lower Intermediate Frequency (IF) by the RF downconverter 30 . The down converted signal from the converter 30 is received in an analog to digital converter 32 that takes the downconverted analog baseband or IF signal and digitizes it into a stream of ones and zeroes in the digital domain.
In the embodiment shown in FIG. 3 , the multi-band duplexer 24 feeds a pair of channels that each are centered around a different RF frequency. In the embodiment shown in FIG. 3 , the radio 12 includes two RF bands. However, it is contemplated that the radio 12 could include additional bands each having different RF frequencies. In the embodiment shown in FIG. 3 , the second band includes an RF band pass filter 26 a , an amplifier 28 a , a down converter 30 a and an analog to digital converter 32 a .
A multi-threaded demodulator 34 demodulates the digitized RF received signals received simultaneously from the multiple RF downconverters 30 , 30 a , which are centered at different RF frequencies. The demodulation of the RF signals is achieved using Digital Signal Processing (DSP) techniques.
A Multi-Threaded Protocol Data Format Decoder 36 similarly decodes the unique protocol packet data using DSP techniques. The demodulated and decoded RF packet data from various dissimilar protocols is passed along to the backend using WAN type interfaces shown by reference number 38 . In the embodiment shown in FIG. 3 , the different types of WAN interfaces can include a modem card, a DSL connection, cable modem or conventional telephone modem. In any event, the WAN interface 38 allows the radio 12 to communicate to the backend using a WAN interface.
In addition to receiving information, the radio 12 is also capable of communicating information from the radio to various devices utilizing various different RF protocols. As illustrated in FIG. 3 , raw data that is required to be transmitted is encoded in the Protocol Data Format Generator block 40 based on the specific required RF standard or protocol. Similarly block 42 imposes baseband modulation on the packetized data. These functions are achieved using DSP techniques.
The digital to analog converter (D/A) 44 takes the in phase (I) and quadrature (Q) encoded and modulated digital baseband data from DSP blocks 40 and 42 and converts the data to analog baseband or IF signals.
Block 46 serves to upconvert the IF or baseband analog I and Q signals to the required RF transmission frequencies. This may include a quadrature modulator allowing various RF modulation schemes such as BPSK, QPSK, FSK to be implemented without the need to change hardware.
The RF power amplifier (PA) 48 serves to amplify the modulated RF signal. The output RF power of the PA will also be programmable such that it meets the output requirements of the specific RF protocol currently being transmitted.
Block 49 may be a combination of various RFICs, ASICs, DSP, and FPGA ICs used to modulate and demodulate RF Signals into digital bits. Some of the RF transmit, receive, modulation, and demodulation functions may be fulfilled, for example, by RF ICs such as the Analog Devices Part No. AD9874, Texas Instruments Part Nos. CC1020 or CC1101, or the AXSEM AX5042. However, other devices could be utilized.
The block diagram in FIG. 4 illustrates a typical implementation of the home gateway 1 . As discussed, the antenna 22 will be broadband such that it has reasonable performance parameters at all the required RF bands such as 900 MHz licensed, 900 MHz ISM, 2.4 GHz ISM, etc.
The multi-band duplexer 24 allows the RF signals to be received at various RF bands simultaneously. The duplexer will also facilitate full duplex operation of the radio where incoming RF signals can be received at the same time as RF transmissions occur.
A RF band pass filter 26 with a passband at the desired RF frequency range is used to filter out excess RF noise and limit out of band interference.
A Low Noise Amplifier (LNA) 28 is used to amplify the received RF signal while limiting the added noise level to a minimum.
The received RF signal will be downconverted in frequency to some lower Intermediate Frequency (IF) by the mixer 50 and Frequency synthesizer 52 . The synthesizer will be frequency agile such that all channels in the desired RF band can be downconverted.
The IF filter 54 is used to reject any harmonic and intermodulation products that may be created by the downconversion process.
The A/D block 32 is an analog to digital converter that takes the downconverted filtered analog IF signal and digitizes it into a stream of ones and zeroes such that the DSP module 56 can post process the received message in the digital domain using digital signal processing techniques.
Other RF bands, that are very different in frequency, will require a dedicated RF downconversion chain. This is represented by path 58 . Therefore, for example, the 2.4 GHz ISM band will be downconverted by the path 60 whereas the 900 MHz band will be downconverted by path 62 . Differences between the separate downconverter chains include different RF filter center frequencies, different synthesizer frequencies, and potentially unique IF frequencies. Although only two paths ( 60 , 62 ) are shown, the system could include additional paths having different filter frequencies.
In the transmit section, digital to analog converters (D/A) 64 and 66 take the in phase (I) and quadrature (Q) encoded and modulated digital baseband data from DSP 56 and convert them to analog baseband or IF signals. IF filters 68 and 70 function to reject harmonics and spurs produced by the digital to analog conversion process.
Blocks 72 and 74 serve to upconvert the IF or baseband analog I and Q signals to the required RF transmission frequencies. Block 72 also serves as a quadrature modulator allowing various RF modulation schemes such as BPSK, QPSK, FSK to be implemented.
The RF power amplifier (PA) 76 serves to amplify the modulated RF signal. The output RF power of the PA will also be programmable such that it meets the output requirements of the specific RF protocol currently being transmitted. The transmit output RF filter 78 serves to remove any harmonic energy created by the amplification process.
The DSP module 56 shown in FIG. 4 is an integrated circuit or a set of ICs that utilizes Digital Signal Processing techniques to demodulate the received RF packets. The DSP chip(s) within the DSP module 56 are programmed with unique firmware code sets to allow the DSP module 56 to demodulate and decode various types of over the air protocols over multiple bands, such as IEEE 802.15.4, Sensus FlexNet, and GSM to name a few, simultaneously. The DSP IC(s) also function to encode and modulate the I and Q digital outputs for RF transmission. The Xilinx Spartan or Vertix family of FPGA ICs, for example, may be used for these functions.
The microcontroller block 80 is responsible for configuration and control of the software radio physical and MAC layers via the DSP module 56 , as well as processing all other layers of the communication stacks. It is also responsible for multiple protocol processing for the software radio and any third party interfaces. The Atmel AVR ATMega32 microprocessor, for example, could serve these functions.
The firmware and configuration of the software radio can be updated through any of the third party interfaces. The Flash Memory block 82 contains enough memory to facilitate the storage of the current operational image and configuration, as well as the image and configuration to be uploaded. The flash memory block 82 is in communication with the DSP module 56 such that the DSP module 56 can access information protocols that allow the software radio 12 communicate with the various types of devices located near the home gateway. In addition to the access provided to the DSP module 56 , the flash memory block 82 is coupled to the microcontroller 80 , which in turn receives information through the third party interface modules 88 . In this manner, software programming can be uploaded to the flash memory block 82 and accessed by the DSP module 56 to configure operation of the software radio. In this manner, the software radio 12 can be updated to communicate with various different devices as the devices are placed in communication range with the home gateway.
There will likely be multiple clock references required to be piped to the DSP/FGPA IC module 56 so that the ideal sample rates are possible for the various RF protocols that need to be modulated and demodulated. This is represented by block 84 and typically is implemented as a VC-TCXOs or OCXOs operating at various frequencies.
Block 86 represents the various power supply voltages that will need to be provided to different sections of the printed circuit board. These circuits may include linear voltage regulators, buck and/or boost converters, and power management ICs.
The software defined home gateway shown schematically in FIG. 1 and in more detail in FIG. 4 includes independent programmable radio channels. The software defined home gateway 1 supports multiple simultaneous communication technologies and can be configured to support new technologies as they become available. The software defined home gateway 1 includes memory and communication modules that allow various different types of communication to the home gateway such that the home gateway can be configured to communicate with various different types of devices using software controlled communication techniques. These techniques can be currently available or can be modified as the technology develops or different devices are utilized with the home gateway.
FIGS. 5 a - 5 c are schematic illustrations of three different phases of the possible development of the software based home gateway of the present disclosure. In the first embodiment shown by FIG. 5 a , the electricity meter 3 is shown including the home gateway 1 . The electricity meter 3 communicates to the utility gateway 9 using the AMI system 11 . Further, the home gateway 1 communicates using a wide area network 90 . In this manner, the software within the home gateway can be updated for communication to various other devices located in an area near the home gateway 1 .
In the embodiment shown in FIG. 5 b , the home gateway 1 is shown as a separate device that communications with the various devices using various different communication protocols. Further, the home gateway is connected to the WAN 90 to receive software upgrades as is desired. In this embodiment, the home gateway 1 is a separate device having its own power supply connection 92 . In the embodiment illustrated, the home gateway I is a set top box that can communicate both to the devices 4 - 7 as well as to the AMI system 11 .
In the third embodiment shown in FIG. 5 c , the home gateway 1 can receive a separate card 102 that provides the required communication such that the home gateway 1 can function as desired.
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A system and method for communicating energy or water consumption related information from a plurality of RF enabled peripheral devices in a home, such as utility meters, thermostats, appliances and load controllers. The system includes a home gateway that enables wireless RF peripheral devices in a home to communicate to a WAN network, such as the internet. The home gateway contains a RF multi-band software defined radio that is fully programmable and configurable so that it is capable of emulating, transmitting, and receiving any of a plurality of RF protocols over multiple RF channels. The home gateway supports commonly used interfaces for communicating to the public WAN network. The system also supports future peripherals that do not exist today due to the flexibility of the home gateway.
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[0001] CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0002] This application is a continuation of U.S. Ser. No. 09/741,843 filed on Dec. 22, 2000, which is a continuation of U.S. Ser. No. 09/127,902 filed on Aug. 3, 1998, now U.S. Pat. No. 6,187,287, which is a continuation of U.S. Ser. No. 08/690,102 filed on Jul. 31, 1996, now U.S. Pat. No. 5,789,554, which is a continuation of U.S. Ser. No. 08/289,576 filed on Aug. 12, 1994, now abandoned. This application claims only subject matter disclosed in the parent applications and therefore presents no new matter.
BACKGROUND OF THE INVENTION
[0003] The invention relates generally to immunoconjugates for diagnostic and therapeutic uses in cancer. In particular, the invention relates to recombinantly produced chimeric and humanized monoclonal antibodies directed against B-cell lymphoma and leukemia cells, which antibodies can be covalently conjugated to a diagnostic or therapeutic reagent without loss of antibody binding and internalization function and with reduced production of human anti-mouse antibodies.
[0004] Non-Hodgkins lymphoma (NHL) and chronic lymphocytic leukemia are B-cell malignancies that remain important contributors to cancer mortality. The response of these malignancies to various forms of treatment is mixed. They respond reasonably well to chemotherapy, and, in cases where adequate clinical staging of NHL is possible, as for patients with localized disease, satisfactory treatment may be provided using field radiation therapy (Hall et al., Radiology for the Radiologist, Lippincott, Philadelphia, 1989, pp 365-376). However, the toxic side effects associated with chemotherapy and the toxicity to the hematopoietic system from local, as well as whole body, radiotherapy, limits the use of these therapeutic methods. About one-half of the patients die from the disease (Posner et al., Blood, 61: 705 (1983)).
[0005] The use of targeting monoclonal antibodies conjugated to radionuclides or other cytotoxic agents offers the possibility of delivering such agents directly to the tumor site, thereby limiting the exposure of normal tissues to toxic agents (Goldenberg, Semin. Nucl. Med., 19: 332 (1989)). In recent years, the potential of antibody-based therapy and its accuracy in the localization of tumor-associated antigens have been demonstrated both in the laboratory and clinical studies (see., e.g., Thorpe, TIBTECH, 11: 42 (1993); Goldenberg, Scientific American, Science & Medicine, 1: 64 (1994); Baldwin et al., U.S. Pat. Nos. 4,925,922 and 4,916,213; Young, U.S. Pat. No. 4,918,163; U.S. Pat. No. 5,204,095; Irie et al., U.S. Pat. No. 5, 196,337; Hellstrom et al., U.S. Pat. Nos. 5,134,075 and 5,171,665). In general, the use of radio-labeled antibodies or antibody fragments against tumor-associated markers for localization of tumors has been more successful than for therapy, in part because antibody uptake by the tumor is generally low, ranging from only 0.01% to 0.001% of the total dose injected (Vaughan et al., Brit, J. Radiol., 60: 567 (1987)). Increasing the concentration of the radiolabel to increase the dosage to the tumor is counterproductive generally as this also increases exposure of healthy tissue to radioactivity.
[0006] LL-2 (EPB2) is a highly specific anti-B-cell lymphoma and anti-lymphocytic leukemia cell murine monoclonal antibody (mAb) that is rapidly internalized by such cells and that can overcome some of the aforementioned difficulties (Shih et al,. Int, J. Cancer, 56: 538 (1994)). LL2, which is of the IgG2a antibody type, was developed using the Raji B-lymphoma cell line as the source af antigen (Pawlak-Byczkowska et al., Cancer Res., 49: 4568 (1989)). Murine LL2 (mLL2) is known to react with an epitope of CD22 (Belisle et al., Proc Amer. Assn. Clin. Res., 34: A2873 (1993)). CD22 molecules are expressed in the cytoplasm of progenitor and early pre-B cells, and appear in the cell surface of mature B-cells.
[0007] By immunostaining of tissue sections, mLL2 was shown to react with 50 of 51 B-cell lymhomas tested. mLL2 is a highly sensitive means of detecting B-cell lymphoma cell in vivo, as determined by a radioimmunodetection method (Murthy et al., Eur. J. Nucl. Med., 19: 394 (1992)). The Fab′ fragment of mLL2 labeled with 99m Tc localized to 63 of 65 known lesions in Phase II trial patients with B-cell lymphoma (Mills et al., Proc. Amer. Assn. Cancer Res., 14: A2857 (1993)). In addition, 131 I-labeled mLL2 was therapeutically effective in B-cell lymphoma patients (Goldenberg et al., J. Clin. Oncol., 9: 548 (1991)). mLL2 Fab′ conjugated to the exotoxin PE38KDEL induced complete remissions of measurable human lymphoma xenografts (CA-46) growing in nude mice (Kreitman et al., Cancer Res., 53: 819 (1993)).
[0008] The clinical use of mLL2, just as with most other promising murine antibodies, has been limited by the development in humans of a HAMA response. While a HAMA response is not invariably abserved following injection of mLL2, in a significant number of cases patients developed HAMA following a single treatment with mLL2. This can limit the diagnostic and therapeutic usefulness of such antibody conjugates, not only because of the potential anaphylactic problem, but also as a major portion of the circulating conjugate may be complexed to and sequestered by the circulating anti-mouse antibodies. This is exemplified by one study in which about 30% of the patients developed low level HAMA response following a single injection of about 6 mg of mLL2 131 I-IgG and nearly all developed a strong HAMA response with additional injections. On the other hand, with mLL2 Fab′ labeled with 99m Tc, no HAMA response was observed. Such HAMA responses in general pose a potential obstacle to realizing the full diagnostic and therapeutic potential of the mLL2 antibody.
[0009] Although, as noted above, the use of fragments of mLL2, such as F(ab′) 2 and Fab′, partially alleviate/circumvent these problems of immunogenicity, there are circumstances in which whole IgG is more desirable, such as when induction of cellular immunity is intended for therapy, or where an antibody with enhanced survival time is required.
[0010] In order to maximize the value of the mLL2 IgG antibody as a therapeutic or diagnostic modality and increase its utility in multiple and continuous administration modalities, it is an object of this invention to produce a mouse/human chimeric mAb (cLL2) and humanized mAb (hLL2) related to mLL2 that retain the antigen-binding specificity of mLL2, but that elicit reduced HAMA in a subject receiving same.
[0011] It is another object of this invention to provide DNA sequences encoding the amino acid sequences of the variable regions of the light and heavy chains of the cLL2 and hLL2 mAbs, including the complementarity determining regions (CDR).
[0012] It is also an object of this invention provide conjugates of the hLL2 and cLL2 mAbs containing therapeutic or diagnostic modalities.
[0013] It is a further object of this invention to provide methods of therapy and diagnosis that utilize the humanized and chimeric mAbs of the invention.
[0014] These objects have been achieved by the invention described below in the specification and appended claims.
SUMMARY OF THE INVENTION
[0015] In one aspect of the invention, there is provided a cLL2 mAb related to mLL2 mAb, in which the murine light (VK) and heavy (VH) chain variable regions are joined to the human constant light (kappa) and heavy (IgG 1 ) chains.
[0016] This chimeric mAb retains the B-lymphoma and leukemia cell targeting and internalization properties of the parental mLL2.
[0017] In another aspect of the invention, there is provided a hLL2 mAb related to mLL2 mAb, in which the complementarity-determining regions (CDRs) of the light and heavy chains of the mLL2 mAb are joined to the framework (FR) sequence of human VK and VH regions, respectively, and subsequently to the human kappa and IgG 1 constant region domains, respectively. This humanized antibody retains the B-lymphoma and leukemia cell targeting and internalizaiton characteristics of the parental mLL2 mAb, and can exhibit a lowered HAMA reaction.
[0018] In still another aspect, there is provided isolated polynucleotides comprising DNA sequences encoding the amino acid sequences of the variable light and heavy chains, respectively, of the hLL2 and cLL2 mAbs.
[0019] In an additional aspect, there is provided the amino acid sequences of the CDRs of the VK and VH chains.
[0020] In yet another aspect, there are provided conjugates in which the hLL2 or cLL2 mAb is covalently bonded to a diagnostic or therapeutic reagent.
[0021] In still another aspect, there are provided methods whereby the aforementioned mAb conjugates can be used to diagnose or treat B-cell lymphomas and lymphocytic leukemias.
[0022] These and other aspects and embodiments of the invention will become apparent by reference to the following specification and appended claims.
DESCRIPTION OF THE FIGURES
[0023] FIG. 1 is a comparison of the murine with the humanized LL2 VK ( FIG. 1A ) and VH ( FIG. 1B ) domains. Only hFR sequences (designated as REIHuVK and EUHuVH) different than mFR sequences (designated as murine) are shown, and designated by asterisks. More residues in these positions were retained in the humanized structure. CDRs are boxed. FR residues showing CDR contacts by computer modeling are underlined.
[0024] FIG. 2 shows vicinal relationships of the LL2 CDRs to their framework regions (FRs). Separate energy-minimized models for the VL and VH domains of mLL2 were constructed, and all FR residues within a radius of 4.5 Å or any CDR atom were identified as potential CDR-FR contacts. CDRs of the light (L1,L2, and L3, FIG. 2A ) and heavy (H1, H2, and H3, FIG. 2B )) chains are shown as “ball and stick” representations superimposed on their respective, space-filling FRs.
[0025] FIG. 3 shows the light chain (FIG 3 A) staging (VKpBR) and mammalian expression (pKH) vectors, and the heavy chain ( FIG. 3B ) staging (VHpBS) and mammalian expression (pG1g) vectors.
[0026] FIG. 4 shows the double-stranded DNA and amino acid sequences of the LL2 VK domain ( FIG. 4A ) and the LL2 VH domain ( FIG. 4B ). Amino acid sequences encoded by the corresponding DNA sequences are given as one letter codes. CDR amino acid sequences are boxed. The Asn-glycosylation site located in FR1 of LL2VK ( FIG. 4A ) is shown as the underlined NVT sequence.
[0027] FIG. 5A shows the double stranded DNA and corresponding amino acid residues of the hLL2 VK domain. CDR amino acid sequences are boxed. The corresponding data for the VH domain is shown in FIG. 5B .
[0028] FIG. 6 is a schematic diagram representation of the PCR/gene synthesis of the humanized VH region and the subcloning into the staging vector, VHpBS.
[0029] FIG. 7 shows SDS-PAGE analysis of mLL2 and cLL2 antibodies under non-reducing (lanes 6-8) and reducing (lanes 3-5, light and heavy chains) conditions. Lanes 3 and 6 include a control antibody.
[0030] FIG. 8 shows SDS-PAGE analysis of different versions of cLL2 and hLL2 antibodies under reducing (lanes 3-5) and non-reducing (lanes 6-8) conditions.
[0031] FIG. 9 shows SDS-PAGE anaylsis on mix-and-match cLL2 and hLL2 antibodies under reducing (lanes 3-6) and non-reducing (lanes 7-10) conditions, cLL2 serves as the control.
[0032] FIG. 10 . shows the results of a comparative Raji cell competitive antibody binding assay involving mLL2 and cLL2 antibodies competing for binding to cells against tracer radiolabeled mLL2.
[0033] FIG. 11 shows the results of a comparative Raji cell competitive antibody binding assay in which mixed humanized/chimeric LL2s were compared to cLL2 ( FIG. 11A ), and two versions of hLL2 compared to cLL2 ( FIG. 11B ).
[0034] FIG. 12 shows a comparison of antibody internalization:surface binding ratios as a function of time for cLL2, cLL2 (Q to V mutagenesis), hLL2 and mLL2 antibodies.
[0035] FIG. 13 shows an SDS-PAGE analysis of mLL2 and cLL2 after deglycosylation by endoglycosidase F.
[0036] FIG. 14 shows the effect of deglycosylation of mLL2 on its binding affinity to Raji cells.
DETAILED DESCRIPTION OF THE INVENTION
[0037] cDNAs encoding the VL and VH regions of the mLL2 mAb have been isolated and separately recombinantly subcloned into mammalian expression vectors containing the genes encoding kappa and IgG 1 constant regions, respectively, of human antibodies. Cotransfection of mammalian cells with these two recombinant DNAs expressed a cLL2 mAb that, like the parent mLL2 mAb, bound avidly to, and was rapidly internalized by, B-lymphoma cells.
[0038] The CDRs of the VK and VH DNAs have been similarly recombinantly linked to the framework (FR) sequences of the human VK and VH regions, respectively, which are subsequently linked, respectively, to the human kappa and IgG 1 constant regions, so as to express in mammalian cells as described above hLL2.
[0039] In this specification, the expressions “cLL2” or “cLL2 mAb” are intended to refer to the chimeric monoclonal antibody constructed by joining or subcloning the murine VK and VH regions to the human constant light and heavy chains, respectively. The expressions “hLL2” or “hLL2 mAB” are intended to refer to the humanization of the chimeric monoclonal antibody by replacing the murine FR sequences in cLL2 with that of human framework regions.
[0040] Covalent conjugates between cLL2 and hLL2 mAbs and a diagnostic or chemotherapeutic reagent, formulated in pharmaceutically acceptable vehicles (see, e.g., Remington's Pharmaceutical Sciences, 18th ed., Mack Publishing Co., Easton, Pa., 1990) can be prepared that have the advantages, compared to prior art antibody conjugates, of B-cell lymphoma-specific and leukemia cell-specific targeting, rapid internalization into target cells, rapid liberation of the diagnostic or chemotherapeutic reagent intracellularly (thereby increasing effectiveness of the reagent), and a potential reduction of the HAMA response in the human patient.
[0041] As the VK-appended carbohydrate moiety of the cLL2 mAb is shown herein not to be involved in binding to B-lymphoma cells, it is preferred to use conjugates in which the reagent is bound to the antibody through such carbohydrate moieties, such as through oxided carbohydrate derivatives. Methods for the production of such conjugates and their use in diagnostics and therapeutics are provided, for expample, in Shih et al., U.S. Pat. No. 5,057,313, Shih et al., Int. J. Cancer 41: 832 (1988), and copending, commonly owned Hansen et al., U.S. Ser. No. 08/162,912, the contents of which are incorporated herein by reference. Direct linkage of the reagent to oxidized carbohydrate without the use of a polymeric carrier is described in McKearn et al., U.S. Pat. No. 5,156,840, which is also incorporated by reference.
[0042] A wide variety of diagnostic and therapeutic reagents can be advantageously conjugated to the antibodies of the invention. These include: chemotherapeutic drugs such as doxorubicin, methotrexate, taxol, and the like; chelators, such as DTPA, to which detectable labels such as fluorescent molecules or cytotoxic agents such as heavy metals or radionuclides can be complexed; and toxins such as Pseudomonas exotoxin, and the like. Several embodiments of these conjugates are described in the examples below.
[0043] Cell lines and culture media used in the present invention include LL2 (EPB-2) hybridoma cells (Pawlak-Byczkowska et al. 1989 above), Sp2/0-Ag14 myeloma cells (ATCC, Rockville, Md.) and Raji cells. These cells are preferably cultured in Dulbecco's modified Eagle's Medium (DMEM) supplemented with 10% FCS (Gibco/BRL, Gaithersburg, Mass.), 2mM L-glutamine and 75 μg/ml gentamicin, (complete DMEM). Transfectomas are grown in Hybridoma Serum Free Medium, HSFM, (Gibco/BRL, Gaithersburg, Mass.) containing 10% of FCS and 75 μg/ml gentamicin (complete HSFM) or, where indicated, in HSFM containing only antibiotics. Selection of the transfectomas may be carried out in complete HSFM containing 500 μg/ml of hygromycin (Calbiochem, San Diego, Calif.). All cell lines are preferably maintained at 37° C. in 5%CO 2 .
[0044] An important aspect of this invention is that antibody variable domains can be modeled by computer modeling (see, for example, Dion, in Goldenberg et al. eds., Cancer Therapy With Radiolabeled Antibodies, CRC Press, Boca Raton, Fla., 1994) which is incorporated by reference. In general, the 3-D structure for both the mLL22 and hLL2 mAbs are best modeled by homology. The high frequency of residue identities (75.0 to 92.3%) between the deduced primary sequences of mLL2 light chain FR regions and human REI (VK) facilitates this approach because of the availability of crystallographic data from the Protein Data Bank (PDR Code 1REI, Bernstein et al., J. Mol. Biol. 112: 535 (1977)), which is incorporated by reference. Similarly, antibody EU (VH) sequences can be selected as the computer counterparts for FR1 to FR3 of the mLL2 heavy chain; FR4 was based on NEWM. As X-ray coordinate data is currently lacking for the EU sequence. NEWM structural data (PDR Code 3FAB) for FRs 1 to 4 can be used, and amino acid side groups can be replaced to correspond to mLL2 or EU (hLL2) as needed. The CDR of the light chain can be modeled from the corresponding sequence of 1MCP (L1 and L2) and 1REI (L3). For heavy chain CDRs, H1 and H2 can be based on 2HFL and 1MCP, respectively, while H3 can be modeled de novo. Wherever possible, side group replacements should be performed so as to maintain the torsion angle between Cα and Cβ. Energy minimization may be accomplished by the AMBER forcefield (Weiner et al, J. Amer. Chem. Soc. 106: 765 (1984) using the convergent method. Potentially critical FR-CDR interactions can be determined by initially modeling the light and heavy variable chains of mLL2. All FR residues within a 4.5 Å radius of all atoms within each CDR can thereby be identified and retained in the final design model of hLL2.
[0045] Once the sequences for the hLL2 VK and VH domains are designed, CDR engrafting can be accomplished by gene synthesis using long synthetic DNA oligonucleotides as templates and short oligonucleotides as primers in a PCR reaction. In most cases, the DNA encloding the VK or VH domain will be approximately 350 bp long. By taking advantage of codon degeneracy, a unique restriction site may easily be introduced, without changing the encoded amino acids, at regions close to the middle of the V gene DNA sequence. For example, at DNA nucleotide positions 157-162 (amino acid positions 53 and 54) for the hLL2 VH domain, a unique AvrII site can be introduced while maintaining the originally designed amino acid sequence ( FIG. 4B ). Two long non-overlapping single-stranded DNA oligonucleotides (˜150 bp) upstream and downstream of the AvrII site (see, for example, oligo A and oligo B, Example 3 below) can be generated by automated DNA oligonucleotide synthesizer (Cyclone Plus DNA Synthesizer, Milligen-Biosearch). As the yields of full length DNA oligonucleotides such as oligos A and B may be expected to be low, they can be amplified by two pairs of flanking oligonucleotides (oligo Seq. ID Nos. 7 and 8 for oligo A; oligo Seq. ID Nos. 9 and 10 for oligo B, Example 3) in a PCR reaction. The primers can be designed with the necessary restriction sites to facilitate subsequent subcloning. Primers for oligo A and for oligo B should contain overlapping sequence at the AvrII site so that the resultant PCR product for oligo A and B, respectively, can be joined in-frame at the AvrII site to form a full length DNA sequence (ca 350 bp) encoding the hLL2 VH domain. The ligation of the PCR products for oligo A (restriction-digested with PstI and AvrII) and B (restriction-digested with AvrII and BstEII) at the AvrII site and their subcloning into the PstII/BstEII sites of the staging vector, VHpBs, can be completed in a single three-fragment-ligation step (See, for example, Example 3). The subcloning of the correct sequence into VHpBS can be first analyzed by restriction digestion analysis and subsequently confirmed by sequencing reaction according to Sanger et al., Proc. Natl. Acad. Sci. USA 74: 5463 (1997).
[0046] The HinkIII/BamHI fragment containing the Ig promoter, leader sequence and the hLL2 VH sequence can be excised from the staging vector and subcloned to the corresponding sites in a pSVgpt-based vector, pG1g, which contains the genomic sequence of the human IgG constant region, an Ig enhancer and gpt selection marker, forming the final expression vector, hLL2pG1g. Similar strategies can be employed for the construction of the hLL2 VK sequence. The restriction site chosen for the ligation of the PCR products for the long oligonucloetides (oligos C and D, see examples below) can be NruI in this case.
[0047] The DNA sequence containing the Ig promoter, leader sequence and the hLL2 VK sequence can be excised from the staging vector VKpBR by treatment with BamH1/HindIII, and can be subcloned into the corresponding sites of a pSVhyg-based vector, pKh, which contains the genomic sequence of human kappa chain constant regions, a hygromycin selection marker, an Ig and a kappa enhancer, forming the final expression vector, hLL2pKh.
[0048] As humanization sometimes results in a reduction or even loss of antibody affinity, additional modification might be required in order to restore the original affinity (See, for example, Tempest et al., Bio/Technology 9: 266 (1991); Verhoeyen et al., Science 239: 1534 (1988)), which are incorporated by reference. Knowing that cLL2 exhibits a binding affinity comparable to that of its murine counterpart (see Example 5 below), defective designs, if any, in the original version of hLL2 can be identified by mixing and matching the light and heavy chains of cLL2 to those of the humanized version. SDS-PAGE analysis of the different mix-and-match humanized chimeric LL2 under non-reducing (the disulfide L-H chain connections remain intact) and reducing condition (the chains separate, permitting analyses of the relationships of the different types of light and heavy chains on the properties of the molecule). For example, migrtation as multiple bands or as a higher apparent molecular size can be due to the presence of a glycan group at the N-linked glycosylation site found at the FR1 region of the murine VK domain of LL2. For another example, a discrete band migrating at about 25 kDa is the expected molecular size for a non-glycosylated light chain.
[0049] In general, to prepare cLL2 mAb, VH and VK chains of mLL2 can be obtained by PCR cloning using DNA products and primers. Orlandi et al., infra, and Leung et al., infra. The VK PCR primers may be subcloned into a pBR327 based staging vector (VKpBR) as described above. The VH PCR products may be subcloned into a similar pBluescript-based staging vector (VHpBS) as described above. The fragments containing the VK and VH sequences, along with the promoter and signal peptide sequences, can be excised from the staging vectors using HindIII and BamHI restriction endonucleases. The VK fragments (about 600 bp) can be subcloned into a mammalian expression vector (for example, pKh) conventionally. pKh is a pSVhyg-based expression vector containing the genomic sequence of the human kappa constant region. an Ig enhancer, a kappa enhancer and the hygromucin-resistant gene. Similarly, the about 800 bp VH fragments can be subcloned into pG1g, a pSVgpt-based expression vector carrying the genomic sequence of the human IgG1 constant region, an Ig enhancer and the xanthine-guanine phosphoribosyl transferase (gpt) gene. The two plasmids may be transfected into mammalian expression cells, such as Sp2/0-Ag14 cells, by electroporation and selected for hygromycin resistance. Colonies surviving selection are expanded, and supernatant fluids monitored for production of cLL2 mAb by an ELISA method. A transfection efficiency of about 1-10×10 6 cells is desirable. An antibody expression level of between 0.10 and 2.5 μg/ml can be expected with this system.
[0050] RNA isolation, cDNA synthesis, and amplification can be carried out as follows. Total cell RNA can be prepared from a LL2 hybridoma cell line, using a total of about 10 7 cells, according to Sambrook et al., ( Molecular Cloning: A Laboratory Manual, Second ed., Cold Spring Harbor Press, 1989), which is incorporated by reference. First strand cDNA can be reverse transcribed from total RNA conventionally, such as by using the SuperScript preamplification system (Gibco/BRL., Gaithersburg, Md.). Briefly, in a reaction volume of 20 μl, 50 ng of random primers can be annealed to 5 μg of RNAs in the presence of 2 μl of 10×synthesis buffer [200 mM Tris-HCl (pH 8.4), 500 mM KCl, 25 mM MgCl 2 , 1 mg/ml BSA], 1 μl of 10 mM dNTP mix, 2 μl of 0.1 M DTT, and 200 units of SuperScript reverse transcriptase. The elongation step is initially allowed to proceed at room temperature for 10 min followed by incubation at 42° C. for 50 min. The reaction can be terminated by heating the reaction mixture at 90° C. for 5 min.
[0051] The VK and VH sequences of cLL2 or hLL2 can amplified by PCR as described by Orlandi et al., ( Proc. Natl. Acad. Sci., USA, 86: 3833 (1989)) which is incorporated by reference. VK sequences may be amplified using the primers CK3BH and VK5-3 (Leung et al., BioTechniques, 15: 286 (1993), which is incorporated by reference), while VH sequences can be amplified using the primer CH1B which anneals to the CH1 region of murine 1gG, and VHIBACK (Orlandi et al., 1989 above). The PCR reaction mixtures containing 10 μl of the first strand cDNA product, 9 μl of 10× PCR buffer [500 mM KCl, 100 mM Tris-HCl (pH 8.3), 15 mM MgC12, and 0.01% (w/v) gelatin] (Perkin Elmer Cetus, Norwalk, Conn.), can be subjected to 30 cycles of PCR. Each PCR cycle preferably consists of denaturation at 94° C. for 1 min, annealing at 50° C. for 1.5 min, and polymerization at 72° C. for 1.5 min. Amplified VK and VH fragments can be purified on 2% agarosse (BioRad, Richmond, Calif.). See Example 3 for a method for the synthesis of an oligo A (149-mer) and an oligo B (140-mer) on an automated Cyclone Plus DNA synthesizer (Milligan-Biosearch) for use in constructing humanized V genes.
[0052] PCR products for VK can be subcloned into a staging vector, such as a pBR327-based staging vector VKpBR that contains an Ig promoter, a signal peptide sequence and convenient restriction sites to facilitate in-frame ligation of the VK PCR products. PCR products for VH can be subcloned into a similar staging vector, such as the pBluescript-based VHpBS. Individual clones containing the respective PCR products may be sequenced by, for example, the method of Sanger et al., Proc. Natl. Acad. Sci., USA, 74: 5463 (1977) which is incorporated by reference.
[0053] The DNA sequences described herein are to be taken as including all alleles, mutants and variants thereof, whether occurring naturally or induced.
[0054] The two plasmids can be co-transfected into an appropriate cell, e.g., myeloma Sp2/0-Ag14, colonies selected for hygromycin resistance, and supernatant fluids monitored for produciton of cLL2 or hLL2 antibodies by, for example, an ELISA assay, as described below.
[0055] Transfection, and assay for antibody secreting clones by ELISA, can be carried out as follows. About 10 μg of hLL2pKh (light chain expression vector) and 20 μg of hLL2pG1g (heavy chain expression vector) can be used for the transfection of 5×10 6 SP2/0 myeloma cells by electroporation (BioRad, Richmond, Calif.) according to Co et al., J. Immunol., 148: 1149 (1992) which is incorporated by reference. Following transfection, cells may be grown in 96-well microtiter plates in complete HSFM medium (GIBCO, Gaithersburg, Md.) at 37° C., 5% CO 2 . The selection process can be initiated after two days by the addition of hygromycin selection medium (Calbiochem, San Diego, Calif.) at a final concentration of 500 μg/ml of hygromycin. Colonies typically emerge 2-3 weeks post-electroporation. The cultures can then be expanded for further analysis.
[0056] Transfectoma clones that are positive for the secretion of chimeric or humanized heavy chain can be identified by ELISA assay. Briefly, supernatant samples (100 μl) from transfectoma cultures are added in triplicate to ELISA microtiter plates precoated with goat anti-human (GAH)-IgG, F(ab′) 2 fragment-specific antibody (Jackson ImmunoResearch, West Grove, Pa.). Plates are incubated for 1 h at room temperature. Unbound proteins are removed by washing three times with wash buffer (PBS containing 0.05% polysorbate 20). Horseradish peroxidase (HRP) conjugated GAH-IgG, Fc fragment-specific anitbodies (Jackson ImmunoResearch, West Grove, Pa.) are added to the wells, (100 μl of antibody stock diluted ×10 4 , supplemented with the unconjugated antibody to a final concentration of 1.0 μg/ml). Following an incubation of 1 h, the plates are washed, typically three times. A reaction solution, [100 μl, containing 167 μg of orthophenylene-diamine (OPD) (Sigma, St. Louis, Mo.), 0.025% hydrogen peroxide in PBS], is added to the wells. Color is allowed to develop in the dark for 30 minutes. The reaction is stopped by the addition of 50 μl of 4 N HCl solution into each well before measuring absorbance at 490 nm in an automated ELISA reader (Bio-Tek instruments, Winooski, Vt.). Bound chimeric antibodies are than determined relative to an irrelevant chimeric antibody standard (obtainable from Scotgen, Ltd., Edinburg, Scotland).
[0057] Antibodies can be isolated from cell culture media as follows. Transfectoma cultures are adapted to serum-free medium. For production of chimeric antibody, cells are grown as a 500 ml culture in roller bottles using HSFM. Cultures are centrifuged and the supernatant filtered through a 0.2 micron membrane. The filtered medium is passed through a protein A column (1×3 cm) at a flow rate of 1 ml/min. The resin is then washed with about 10 column volumes of PBS and protein A-bound antibody is eluted from the column with 0.1 M glycine buffer (pH 3.5) containing 10 mM EDTA. Fractions of 1.0 ml are collected in tubes containing 10 μl of 3 M Tris (pH 8.6), and protein concentrations determined from the absorbancies at 280/260 nm. Peak fractions are pooled, dialyzed against PBS, and the antibody concentrated, for example, with the Centricon 30 (Amicon, Beverly, Mass.). The antibody concentration is determined by ELISA, as before, and its concentration adjusted to about 1 mg/ml using PBS. Sodium azide, 0.01% (w/v), is conveniently added to the sample as preservative.
[0058] Comparative binding affinities of the mLL2, cLL2 and hcLL2 antibodies thus isolated may be determined by direct radioimmunoassay. mLL2 can be labeled with 131 I or 125 I using the chloramine T method (see, for example, Greenwood et al., Biochem. J., 89: 123 (1963) which is incorporated by reference). The specific activity of the iodinated antibody is typically adjusted to about 10 μCi/μg. Unlabeled and labeled antibodies are diluted to the appropriate concentrations using reaction medium (HSFM supplemented with 1% horse serum and 100 μg/ml gentamicin). The appropriate concentrations of both labeled and unlabeled antibodies are added together to the reaction tubes in a total volume of 100 μl. A culture of Raji cells is sampled and the cell concentration determined. The culture is centrifuged and the collected cells washed once in reaction medium followed by resuspension in reaction medium to a final concentration of about 10 7 cells/ml. All procedures are carried out in the cold at 4° C. The cell suspension, 100 μl, is added to the reaction tubes. The reaction is carried out at 4° C. for 2 h with periodic gentle shaking of the reaction tubes to resuspend the cells. Following the reaction period, 5 ml of wash buffer (PBS containing 1% BSA) is added to each tube. The suspension is centrifuged and the cell pellet wahed a second time with another 5 ml of wash buffer. Following centrifugation, the amount of remaining radioactivity remaining in the cell pellet is determined in a gamma counter (Minaxi, Packard Instruments, Sterling, Va.).
[0059] The Raji cell surface antigen binding affinities of mix-and-match and fully humanized antibodies can be compared to that of cLL2 using various concentrations of mLL2 F(ab′) 2 fragments devoid of the Fc portion as competitors, as evaluated by flow cytometry assay. Residual surface-bound LL2 antibodies carrying the human Fc portions (cLL2 and mix-and-match LL2) can be detected by a FITC-labeled anti-human Fc specific antibody in a flow cytometry assay. Where mix-and-match LL2 antibodies exhibit antigen-binding affinities similar to that of cLL2, it can be concluded that the original designs for the humanization of both the light and heavy chains reatin the mLL2 immunoreactivity.
[0060] The internalization of mLL2, cLL2 and hLL2 antibodies into target cells can be followed by fluorescence labeling, essentially according to the procedure of Pirker et al., J. Clin. Invest., 76: 1261 (1985), which is incorporated by reference. Cultured Raji cells are centrifuged and the cells resuspended in fresh medium to a concentration of about 5×10 6 cells/ml. To each well of a 96-well microtiter plate, 100 μl of the cell suspension is added. The antibodies, 40 μg/ml, in a volume of 100 μl are added to the reaction wells at timed intervals so as to terminate all reations simultaneously. The plate is incubated at 37° C. in a CO 2 cell culture incubator. Unbound antibodies are removed by washing the cells three times with cold 1% FCS/PBS at the end of the incubation. The cells are then treated with 1 ml of Formaid-Fresh [10% formalin solution (Fisher, Fair Lawn, N.J.)] for 15 min at 4° C. After washing, antibodies present either on the cell surface or inside the cells are detected by treatment with FITC-labeled goat anti-mouse antibody (Tago, Burlingame, Calif.), or FITC-labeled goat anti-human antibody (Jackson ImmunoResearch, West Grove, Pa.), depending on whether the antibody being assayed for is murine, chimeric, or humanized, respectively. Fluorescence distribution are evaluated using a BH-2 flourescence microscope (Olympus, Lake Success, N.Y.).
[0061] The rate of antibody internalization can be determined according to Opresko et al., ( J. Biol. Chem., 262: 4116 (1987)), using radioiodinated antibody as tracer. Briefly, radiolabeled antibodies (1×10 4 cpm) are incubated with Raji cells (1×10 6 cells/ml) at 4° C. for 2 h in 0.5 ml of DMEM medium containing 1% human serum. Following the reaction interval, non-specifically bound antibodies are removed by washing three times with 0.5 ml of DMEM medium. To each of the reaction tubes 0.5 ml of DMEM medium is added and the suspension incubated at 37° C. for the determination of internalization. At timed intervals, triplicates of cells are removed and chilled immediately in an ice bath to stop further internalization. Cells are centrifuged at 1000×g for 5 min at 4° C. The supernatant is removed and counted for radioactivity. The surface-bound radioactivity is removed by treatment with 1 ml 0.1 M acetate/0.1 M glycine buffer at pH 3.0 for 8 min. inh the cold. Radioactivity removed by the acid treatment, and that remaining associated with the cells, are determined. The ratio of the CPM internalization /CPM surface is plotted versus time to determine the rate of internalization from the slope.
[0062] Detailed protocols for oligonucleotide-directed mutagenesis and related techniques for mutagenesis of cloned DNA are well-known. For example, see Sambrook et al. and Ausubel et al. above.
[0063] Asn-linked glycosylation sites may be introduced into antibodies using conventional site-directed oligonucleotide mutagenesis reactions. For example, to introduce an Asn in position 18 of a kappa protein, one may alter codon 18 from AGG to AAC. To accomplish this, a single stranded DNA templated containing the antibody light chain sequence is prepared from a suitable strain of E. coli (e.g., dut 31 ung−) in order to obtain a DNA molecule containing a small number of uracils in place of thymidine. Such a DNA template can be obtained by M13 cloning or by in vitro transcription using a SP6 promoter. See, for example, Ausubel et al., eds., CURRENT PROTOCOLS IN MOLECULAR BIOLOGY, John Wiley & Sons, NY, 1987. An oligonucleotide containing the mutated sequence is synthesized conventionally, annealed to the single-stranded template and the product treated with T4 DNA polymerase and T4 DNA ligase to produce a double-stranded DNA molecule. Transformation of wild type E. coli (dut 30 ung 30 ) cells with the double-stranded DNA provides an efficient recovery of mutated DNA.
[0064] Alternatively, an Asn-linked glycosylation site can be introduced into an antibody light chain using an oligonucleotide containing the desired mutation as the primer and DNA clones of the variable regions for the VL chain, or by using RNA from cells that produce the antibody of interest as a template. Also see, Huse, in ANTIBODY ENGINEERING: A PRACTICAL GUIDE, Boerrebaeck, ed., W. H. Freeman & Co., pp 103-120, 1992. Site-directed mutagenesis can be performed, for example, using the TRANSFORMER™ kit (Clontech, Palo Alto, Calif.) according to the manufacturer's instructions.
[0065] Alternatively, a glycosylation site can be introduced by synthesizing an antibody chain with mutually priming oligonucleotides, one such containing the desired mutation. See, for example, Uhlmann, Gene 71: 29 (1988); Wosnick et al., Gene 60: 115 (1988); Ausubel et al., above, which are incorporated by reference.
[0066] Although the general description above referred to the introduction of an Asn glycosylation site in position 18 of the light chain of an antibody, it will occur to the skilled artisan that it is possible to introduce Asn-linked glycosylation sites elsewhere in the light chain, or even in the heavy chain variable region.
[0067] The representative embodiments described below are simply used to illustrate the invention. Those skilled in these arts will recognize that variations of the present materials fall within the broad generic scope of the claimed invention. The contents of all references mentioned herein are incorporated by reference.
EXAMPLE 1
Choice of Human Frameworks and Sequence Design for the Humanization of LL2 Monoclonal Antibody
[0068] By comparing the murine variable (V) region framework (FR) sequences of LL2 to that of human antibodies in the Kabat data base (Kabat et al., Sequences of Proteins of Immunological Interest, 5th ed., U.S. Department of Health and Human Services, U.S. Government Printing Office, Washington, D.C.), which is incorporated by reference, the human REI ( FIG. 1A , Sequence ID No. 1) and EU ( FIG. 1B , Sequence ID No. 2) sequences were found to exhibit the highest degree of sequence homology to the FRs of VK and VH domains of LL2, respectively. Therefore, the REI and EU FRs were selected as the human frameworks onto which the CDRs for LL2 VK and VH were grafted, respectively. The FR4 sequence of NEWM, however, rather than that of EU, was used to replace the EU FR4 sequence for the humanization of LL2 heavy chain. Based on the results of computer modeling studies ( FIGS. 2A and 2B ), murine FR residues having potential CDR contacts, which might affect the affinity and specificity of the resultant antibody, were retained in the design of the humanized FR sequences ( FIG. 1 ).
[0069] Two versions of humanized heavy chain were constructed. In the first version (hLL2-1), the glutamine (Q) at amino acid position 5 (Kabat numbering) was introduced to include a PstI restriction site to facilitate its subcloning into the staging vector ( FIG. 3 ). This murine residue was converted, by oligo-directed mutagenesis, to the human EU residue valine (V) in hLL2-2. It should be noted that in the original murine kappa chain variable sequence, a potential N-linked glycosylation site was identified at positions 18-20 ( FIG. 1 ) and was used for carbohydrate addition. This glycosylation site was not included in the REI FR sequence used for LL2 light chain humanization.
[0070] See Example 3 for more oligonucleotide detail.
EXAMPLE 2
PCR Cloning and Sequence Elucidation for LL2 Heavy and Light Chain Variable Regions
[0071] The variable regions for both heavy (VH) and light (VK) chains of mLL2 (IgG2a) were obtained by PCR cloning using DNA primers as described in general above and in greater detail in Example 3, below. As PCR is prone to mutation, the variable region sequence of multiple individual clones for either the heavy or light chains was determined for six clones and confirmed to be identical prior to use for the construction of the chimeric antibody.
[0072] The PCR products for VK were subcloned into a pBR327-based staging vector, VKpBR, which contained an Ig promoter, a signal peptide sequence and convenient restriction sites to facilitate in-frame ligation of the VK PCR products ( FIG. 3A ). The PCR products for VH were subcloned into a similar pBluescript-based staging vector, VHpBS ( FIG. 3B ).
[0073] As noted above, at least six individual clones containing the respective PCR products were sequenced according to the method of Sanger et al., 1977, above. All were shown to bear identical sequences and their respective sequences were elucidated, as shown in FIG. 4A for LL2 VK (Sequence ID NO. 3) and FIG. 4B for LL2 VH (Sequence ID NO. 4). No defective mutations were identified within the sequences encoding the VK and VH regions. Comparison of the PCR-amplified variable region sequences of LL2 with the Kabat database (Kabat et al., above) suggested that the VK and VH sequences of LL2 belong to subgroup 5 and 2B, respectively. Important residues such as Cys for intra-domain disulfide linkage were retained at appropriate positions.
[0074] In the FR1 framework region of VK, an N-linked carbohydrate attachment site, Asn-Val-Ser, was identified at position 18-20 ( FIG. 4A ), suggesting that the VK of LL2 might be glycosylated. As will be detailed below, SDS-PAGE analysis under reducing conditions demonstrated that this Asn glycosylation site is indeed utilized for carbohydrate addition. The presence of the glycosylation site in the variable region does not, however, appear to affect the immunoreactivity of the antibody. A comparison of the immunoreactivity of mLL2 with that of cLL2 in a competitive RIA showed that the two antibodies have nearly identical activities.
EXAMPLE 3
PCR/Gene Synthesis of the Humanized V Genes
[0075] The designed sequence for the hLL2 VH domain, the construction of the hLL2 VH domain by long oligonucleotides and PCR, and the staging vector VHpBS containing the hLL2 VH domain are summarized in the sketch shown in FIG. 6 .
[0076] For the construction of the hLL2 VH domain, oligo A (149-mer) and oligo B(140-mer) were synthesized on an automated CYCLONE PLUS™ DNA synthesizer (Milligen Bioresearch).
[0077] Oligo A (Sequence ID No. 7 below) represents the minus strand of the hLL2 VH domain complementary to nt 24 to 172.
Sequence ID No. 7 5′-TAT AAT CAT TCC TAG GAT TAA TGT ATC CAA TCC ATT CCA GAC CCT GTC CAG GTG CCT GCC TGA CCC AGT GCA GCC AGT AGC TAG TAA AGG TGT AGC CAG AAG CCT TGC AGG AGA CCT TCA CTG ATG ACC CAG GTT TCT TGA CTT CAG CC-3′
[0078] Oligo B (Sequence ID No. 8 below) represents the minus strand of the hLL2 VH domain complementary to nt 180 to 320.
Sequence ID No. 8 5′-CCC CAG TAG AAC GTA ATA TCC CTT GCA CAA AAA TAA AAT GCC GTG TCC TCA GAC CTC AGG CTG CTC AGC TCC ATG TAG GCT GTA TTG GTG GAT TCG TCT GCA GTT ATT GTG GCC TTG TCC TTG AAG TTC TGA TT-3′
[0079] Oligos A and B were cleaved from the support and deprotected by treatment with concentrated ammonium hydroxide. After the sample were vacuum-dried (SpeedVac, Savant, Farmingdale, N.Y.) and resuspended in 100 μl of water, incomplete oligomers (less than 100-mer) were removed by centrifugation through a CHROMOSPIN-100™ column (Clonetech, Palo Alto, Calif.) before the DNA oligomers were amplified by PCR. All flanking primers for the seperate amplifications and PCR cloning of oligos A and B were purified by SDS-PAGE essentially according to the methods of Sambrook et al., 1989, above. From the CHROMASPIN-purified oligo A, 1 μl of sample stock was PCR-amplified in a reaction volume of 100 μl by adding 5 μl of 5 μM of oligo Sequence ID No. 9:
5′-CCA GCT GCA GCA ATC AGG GGC TGA AGT CAA GAA ACC TG-3′
and oligo Sequence ID No. 10:
5′-AAG TGG ATC CTA TAA TCA TTC CTA GGA TTA ATG-3′
in the presence of 10 μl of 10×PCR Buffer (500 mM KCl, 100 mM Tris.HCL buffer, pH 8.3, 15 mM MgCl 2 ) and 5 units of AMPLITAQ™ DNA polymerase (Perkin Elmer Cetus, Norwalk, Conn.). This reaction mixture was subjected to 30 cycles of PCR reaction consisting of denaturation at 94° C. for 1 minute, annealing at 50° C. for 1.5 minutes, and polymerization at 72° C. for 1.5 minutes.
[0082] Oligo B was PCR-amplified by the primer pairs Sequence ID No. 11:
5′-TAA TCC TAG GAA TGA TTA TAC TGA GTA CAA TCA GAA CTT CAA GGA CCA G-3′
and Sequence ID No. 12:
5′-GGA GAC GGT GAC CGT GGT GCC TTG GCC CCA GTA GAA CGT AGT AA-3′under similar conditions.
[0084] Double-stranded PCR-amplified products for oligos A and B were gel-purified, restriction-digested with PstI/AvrII (PCR product of oligo A) and BstEII/AvrII (PCR product of oligo B), and sucloned into the complementary PstI/BstEII sites of the heavy chain staging vector, VHpBS. The humanized VH sequence was subcloned into the pG1g vector, resulting in the final human IgG1 heavy chain expression vector, hLL2pG1g.
[0085] For constructing the full length DNA of the humanized VK sequence, oligo E (150-mer) and oligo F (121-mer) were synthesized as described above.
[0086] Oligo E Sequence ID No. 13:
5′-CCT AGT GGA TGC CCA GTA GAT CAG CAG TTT AGG TGC TTT CCC TGG TTT CTG GTG GTA CCA GGC CAA GTA GTT CTT GTG ATT TGC ACT GTA TAA AAC ACT TTG ACT GGA CTT ACA GCT CAT AGT GAC CCT ATC TCC AAC AGA TGC GCT CAG-3′
[0087] represents the minus strand of the humanized VK domain complementary to nt 31 to 180, and this sequence was PCR-amplified by oligo Sequence ID No. 14:
5′-GAC AAG CTT CAG CTG ACC CAG TCT CCA TCA TCT CTG AGC GCA TCT GTT GGA G-3′
[0088] and oligo Sequence ID No. 15
5′-AGA GAA TCG CGA AGG GAC ACC AGA TTC CCT AGT GGA TGC CCA GTA-3′.
[0089] Oligo F Sequence ID No. 16:
5′-GCA CCT TGG TCC CTC CAC CGA ACG TCC ACG AGG AGA GGT ATT GGT GAC AAT AAT ATG TTG CAA TGT CTT CTG GTT GAA GAG AGC TGA TGG TGA AAG TAA AAT CTG TCC CAG ATC CGC TGC C-3′
represents the minus strand of the humanized LL2 VK domain complementary to nt 208 to 327, and was PCR amplified by oligo Sequence ID No. 17:
5′-GAC AAG CTT TCG CGA TTC TCT GGC AGC GGA TCT GGG ACA G-3′
and oligo Sequence ID No. 18:
5′-GAC CGG CAG ATC TGC ACC TTG GTC CCT CCA CCG-3′.
[0092] Gel-purified PCR products for oligos E and F were restriction-digested with PvuII/NruI and NruI/BglIII, respectively. The two PCR fragments E and F were then joined at the NruI site and ligated to the complementary PvuI/BcII sites of the light chain staging vector, VKpBR. The humanized VK sequence was subcloned into vector pKh to form the final human kappa chain expression vector, hLL2pKh.
[0093] To express the humanized antibodies, about 10 μg of linearized hLL2pKh and 20 μg of linearized hLL2pG1g were used to transfect 5×10 6 SP2/0 cells by electroporation. The transfectomas were selected with hygromycin at 500 μg/ml and secreted antibody was purified on a 1×3 cm column of protein A. After concentrating the purified antibody by Centricon 30 centifugation, antibody concentration was determined by ELISA. The final concentration of the antibody was adjusted to 1 mg/ml in PBS buffer containing 0.01% (w/v) sodium azide as a preservative.
[0094] FIG. 1 (Sequence ID Nos. 1 and 2), there is compared the amino acid sequence between murine and humanized LL2 VK domains ( FIG. 1A ) and between murine and humanized LL2 VH domains ( FIG. 1B ). In the VK chain, human REI framework sequences were used for all FRs. In the VH chain, human EU framework sequences were used for FR 1-3, and NEWM sequences were used for FR-4. Only human FR sequences that are different from that of the mouse are shown. Asterisks indicate murine FR sequences that are different form that of the human FR at corresponding positions. Murine residues at these positions were retained in the humanized structure. CDRs are boxed.
[0095] In FIG. 4A (Sequence ID No. 3) there are shown the double stranded DNA and corresponding amino acid sequences (shown by single letter code) of the humanized LL2 VK domain. CDR 1-3 amino acid sequences are boxed. The corresponding display for VH is shown in FIG. 4B (Sequence ID No. 4).
[0096] In FIG. 5A (Sequence ID No. 5) and FIG. 5B (Sequence ID No. 6) there are shown double-stranded DNA sequences and amino acid sequences of humanized LL2 VK and LL2 VH, respectively. Amino acid sequences are shown by the single-letter code, and CDR amino acid sequences are boxed.
EXAMPLE 4
Construction, Expression and Purification of Chimeric LL2 Antibodies
[0097] The fragments containing the VK and VH sequences of LL2, together with the promoter and signal peptide sequences, were excised from LL2VKpBR and LL2VHpBS, respectively, by double restriction digestion with HindIII and BamHI. The about 600 bp VK fragments were then subcloned into the HindIII/BamHI site of a mammalian expression vector, pKh ( FIG. 3A ). pKh is a pSVhyg-based expression vector containing the genomic sequence of the human kappa constant region, an Ig enhancer, a kappa enhancer and the hygromycin-resistant gene. Similarly, the ca. 800 bp VH fragments were subcloned into the corresponding HindIII/BamHI site of pG1g ( FIG. 3B ), a pSVgpt-based expression vector carrying the genomic sequence of the human IgG1 constant region, an Ig enhancer and the xanthine-guanine phosphoribosyltransferase (gpt) gene. The final expression vectors are designated as LL2pKh and LL2pG1g, respectively.
[0098] The two plasmids were co-transfected into Sp2/0-Ag14 cells by electroporation and selected for hygromycin resistance. Supernatants from colonies surviving selection were monitored for chimeric antibody secretion by ELISA assay (see above). The transfection efficiency was approximately 1-10×10 6 cells. The antibody expression level, in a terminal culture, was found to vary in the range between <0.10 and 2.5/μg/ml.
[0099] FIG. 7 shows the results of analyzing protein A-purified mLL2 (lanes 4 and 7) and cLL2 (lanes 5 and 8) by SDS-PAGE under reducing and non-reducing conditions, respectively. HMW stands for high molecular weight protein markers, and LMW for light molecular weight markers. The light chains of both mLL2 and cLL2 (lanes 4 and 5) migrated primarily as a doublet band, with a higher than expected apparent molecular weight. As the human kappa constant region of cLL2 is know to contain no potential glycosylation site, it can be inferred that the potential glycosylation site identified in the FR1 region of LL2 VK domain was utilized.
[0100] FIG. 8 shows the results of analyzing different versions of hLL2 and cLL2 antibodies by SDS-PAGE under reducing and non-reducing conditions. As before, LMW and HMW are molecular weight markers. Lanes 3 and 6 are cLL2 antibodies. Lanes 4 and 7 are hLL2 with seven murine FR residues in the VH domain (hLL2-1). Lanes 5 and 8 are hLL2 with 6 murine FR residues in the VH domain (hLL2-2). The humanized light chains migrated more rapidly and as more discrete bands compared to chimeric light chains.
[0101] FIG. 9 shows the results of SDS-PAGE analysis on mix-and-match and cLL2 and hLL2 antibodies under both reducing and non-reducing conditions. Lanes 1 and 2 are molecular weight markers. Lanes 3 and 7 are cLL2. Lanes 4 and 8 are mix-and-match with a humanized light and chimeric heavy chain [(hL/cH)LL2]. Lanes 5 and 9 are chimeric light and humanized heavy (Version 1) chains [(cL/hH)LL2-1]. Lanes 6 and 10 are chimeric light and a humanized heavy (version 2) chains [(cL/hH)LL2-2]. The humanized LL2 version 1 contains 7 murine FR residues in the VH domain, while version 2 contains 6 murine FR residues in the VH domain. It is noteworthy that the position of the light chain of (hL/cH)LL2 (lane 4) is different from that of the others, suggesting that there is no carbohydrate attachment to the humanized LL2 light chain.
EXAMPLE 5
Binding of cLL2 Antibody to Raji Cell Surface Antigens
[0102] A competition cell binding assay was carried out to assess the immunoreactivity of cLL2 relative to the parent mLL2. Using 131 I-labeled mLL2 (0.025 μg/ml) as a probe, Raji cells were incubated with the antibodies and the relative binding to the cells determined from the amount of cell-bound labeled mLL2 (see above). As shown by the competition assays described in FIG. 10 , both mLL2 and cLL2 antibodies exhibited similar binding activities.
[0103] The results were confirmed by a second competition assay based on flow cytometry. Briefly, using Raji cells as before and varying the concentration of one antibody relative to other, as before, the amount of bound mLL2 or cLL2 was determined with FITC-labeled anti-mouse Fc or anti-human Fc antibodies followed by analysis using flow cytometry.
EXAMPLE 6
Binding of hLL2 Antibodies to Raji Cells
[0104] In experiments similar to those of Example 5, the antigen binding affinities of the three different combinations of mix-and-match or humanized LL2 were compared with that of cLL2 in the flow cytometry assay.
[0105] Briefly, 1 μg of cLL2, mix-and-match LL2, hLL2-1 or hLL2-2 antibodies were incubated with 10 8 Raji cells in the presence of varying concentrations of mLL2 F(ab′) 2 fragments (as competitor) in a final volume of 100 μl of PBS buffer supplemented with 1% FCS and 0.01% sodium azide. The mixture was incubated for 30 minutes at 4° C., and washed three times with PBS to remove unbound antibodies. By taking advantage of the presence of human Fc portions in the antibodies, the binding levels of the antibodies were assessed by adding a 20×diluted FITC-labeled goat anti-human IgG1, Fc fragment-specific antibodies (Jackson ImmunoResearch, West Grove, Pa.). The cells were washed three times with PBS, and fluorescence intensities measured by a FACSCAN fluorescence activated cell sorter (Becton-Dickinson, Bedford, Mass.). The results are shown in FIG. 11A .
[0106] Using the same methods, cLL2 was compared to two versions of hLL2 ( FIG. 11B ).
[0107] The results shown in FIGS. 11A and B demonstrate that the immunoreactivity of cLL2 is similar or identical to that of humanized or mix-and-match antibodies. Taken together with the comparison of cLL2 with mLL2 ( FIG. 10 ), the authenticity of the sequences for chimeric and humanized VK and VH obtained is established, and the functionality of cLL2 and hLL2 confirmed.
EXAMPLE 7
Internalization of mLL2 and cLL2 by Raji Cells
[0108] One of the unique characteristics of the LL2 antibody is its rapid internalization upon binding to Raji cells (Shih et al., 1994 above). Murine LL2 after internalization is likely to be rapidly transferred to the Golgi apparatus and from there to the lysosomes, the organelle responsible for the degradation of a wide variety of biochemicals (Keisari et al., Immunochem., 10: 565 (1973)).
[0109] Rates of antibody internalization were determined according to Opresko et al., 1987 above. The ratio of CPM intracellular /CPM surface was determined as a function of time.
[0110] Rates of LL2 antibody internalization were determined by incubating radiolabeled LL2 antibody (1×10 6 cpm) with 0.5×10 6 Raji cells in 0.5 ml of DMEM buffer containing 1% human serum for 2 hrs. at 4° C. Excess human serum was included to saturate Raji cell surface Fc receptors in order to exclude or minimize non-antigen-specific internalization mediated through the Fc receptors. Unbound radiolabeled LL2 antibodies were removed from the cells by washing three times with 0.5 ml portions of DMEM at 4° C. Cells were then incubated at 37° C., and, at timed intervals, aliquots of the cell suspension were transferred to ice in order to stop internalization. The cells in these aliquots were isolated by centrifugation at 1,000×g for 5 mins. at 4° C., and surface bound radiolabeled LL2 stripped off cells with 1 ml of 0.1 M glycine acetate buffer, pH 3, for 8 mins. at 4° C. Radioactivity thus obtained (CPM surface) and radioactivity remaining in the cells (CPM intracellular) were determined. Rates of internalization were calculated from the slope of the plot of intracellular:surface radioactivity ratios as a function of time.
[0111] As shown in FIG. 12 , mLL2, cLL2, cLL2Q and hLL2 antibodies were internalized at a similar rate (Ke=0.107 (mLL2) to 0.1221 (cLL2Q, NVT to QVT mutation). Those numbers suggested that approximately 50% of the surface-bound antibody could be internalized in 10 min. The results show that neither chimerization nor humanization nor deglycosylation by mutagenesis of mLL2 antibodies impair rates of internalization.
[0112] The pattern of internalization for mLL2, cLL2 and hLL2 was also monitored by fluorescence microscopy on a time-course basis using a FITC-labeled second antibody probe as described in the specification. Internalization of both antibodies was observed in at the earliest time point measurable. At 5 minutes, antibodies were seen both on the cell surface and internalized in areas immediately adjacent to the membrane as cytoplasmic micro-vesicles. At 15 min. post-incubation, the fine dots dispersed around the intramembrane began to merge into a group of granules, at locations believed to be the Golgi apparatus. As more antibodies were being internalized after 30 min. of incubation, redistribution of the grouped antibodies to scattered locations, probably the lysosomes in which the antibodies were degraded, was observed. At 2 hrs post-incubation, most of the antibodies were found inside the cell. Only strong surface staining was observed when LL2 was incubated for 20 min on ice. Both mLL2 and cLL2 were internalized with a similar pattern. The internalization of LL2 was associated specifically with antigent-antibody binding, as the irrelevant control humanized antibody demonstrated only dull surface staining.
[0113] A103 antibody (an IgG2a antibody that binds to the surface of all human epithelial cells but does not internalize efficiently (Mattes et al., Hybridoma, 2: 253 (1983)) showed strong membrane staining at up to 2 h, while the anti-transferrin receptor antibody (5F9) internalized rapidly, just as did LL2.
EXAMPLE 8
Role of Glycosylation Site in FR1 Region of LL2 VK Sequence
[0114] Of particular inventive interest is the identification of an Asn-glycosylation site at position 18-20 within the FR1 region of the LL2 NVT light chain sequence ( FIG. 4A ). As shown above, SDS-PAGE analysis under reducing condition suggests that the Asn glycosylation site is utilized for carbohydrate addition.
[0115] In this example, the influence of the carbohydrate moiety at position 18-20 on the functional acitivities of the light chains was examined.
[0116] Murine and chimeric LL2 light chains were treated with (+) or without (−) endoglycosidase F conventionally, and the antibody products examined by SDS-PAGE under reducing and non-reducing conditions ( FIG. 13 ). There was no distinction between the antibody types as to electrophoretic behavior. In both cases, deglycosylation reduced the rate of migration of the light chain.
[0117] The effect of deglycosylation on the binding affinity to Raji cells of the mLL2 antibody is shown in FIG. 14 . Removing carbohydrate by endoglycosidase F was without influence on the binding activity.
[0118] A mutation was introduced at position 18 of the light chain so that the Asn was replaced with Gln to produce LL2Q VK FR1. SDS-PAGE analyses demonstrated that the NVT to QVT mutation abolished glycosylation of the antibody. Comparison of the Raji cell binding affinity for cLL2 with and without light chain VK glycosylation demonstrated that the carbohydrate moiety was without influence on binding of the antibody to these cells.
[0119] It can be concluded that the presence of the carbohydrate site in the variable region does not affect the immunoreactivity of the antibody. Computer modeling studies suggested that the VK carbohydrate moiety in LL2 is remotely positioned from the CDRs and forms a “cap” over the bottom loops of the FR-associated β-barrels supporting the CDRs.
[0120] Humanization without inclusion of the original glycosylation site resulted in a CDR-grafted LL2 antibody with immunoreactivity comparable to that of its murine counterpart.
[0121] These characteristics indicate that the glycosylation site can be used for conjugating therapeutic or diagnostic agents to LL2 without compromising the ability of the antibody to bind and internalize in B-lymphoma or leukemia cells.
EXAMPLE 9
Conjugation of LL2 at its Carbohydrate-bearing Site
[0122] The apparent lack of involvement of the variable region carbohydrate moiety in the functional activities of mLL2, cLL2and hLL2 mAbs indicates that this moiety could profitably be used as the site of attachment of cytotoxic or detection agents such as radionuclides or toxins, and thereby avoid potential interference with the binding of the conjugate to a cell surface.
[0123] Using procedures described in Shih et al., U.S. Pat. No. 5,057,313 (which is incorporated by reference) for preparing antibody conjugates through an oxidized carbohydrate moiety of the antibody and a primary alkylamino group of a polymeric carrier to which are covalently one or more of a variety of drugs, toxins, chelators and detectable labels, a doxorubicin-dextran-LL2 antibody fragment devoid of appended glycans was produced containing multiple copies of the drug. The carbohydrate moieties of the cLL2 VK FR1 region involved were those covalently bound to the Asn glycosylation site.
[0124] In one synthesis, dextran (18-40 kDa) was converted to an amino dextran by oxidation of the dextran by NaIO 4 , Schiff base formation with NH 2 —CH 2 —CHOH—CH 2 —NH 2 , and reduction with NaBH 4 . The amino dextran was then condensed with doxorubicin (DOX) in the presence of succinic anhydride and 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide to produce DOX-aminodextran. The latter was then condensed with an aldehydic group on LL2 VK FR-1 produced by oxidizing the carbohydrate moiety of the antibody fragment with NaIO 4 .
[0125] In one preparation of DOX-LL2, the number of moles of DOX attached to dextran was 14 moles per mole dextran, and the number of moles of doxorubicin per mole F(ab′)2 was 8.9. The immunoreactivity in the Raji cell binding assay above was about 80% of control values.
[0126] This conjugation system is not limited to the mLL2 antibody. In a comparative study, 15-19 moles of DOX/mole of cLL2 were bound.
[0127] The conjugation possibilities are not limited to the use of a carrier dextran as in the example above. For example, the carbohydrate moiety of the LL2 VK FR1 region can be oxidized to produce aldehydic groups. These in turn can be reacted with an amino group on any drug to produce a Schiff base which, upon reduction, produces multiple copies of the drug stably linked to the antibody via alkyamine groups.
[0128] For example, where the drug is aminohexyl DTPA (a chelating agent), there is produced a LL2 covalently bound to a chelator. The chelator can be used to deliver to target tissues, for example, a radionuclide or paramagnetic metal ion, with a potential for diagnostic and therapeutic uses. DTPA-LL2 conjugates were produced containing 5.5 moles of the chelator/mole of antibody which, in turn, chelated 47.3% of Y-90 and 97.4% In-111.
[0129] It should be emphasized that the above-described examples merely describe several specific embodiments of the invention, and applicants do not intend to be limited as to scope of claims by these specific examples.
[0130] Applicants also incorporate by reference all publications and patents cited in the specification.
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A chimeric LL2 monoclonal antibody is described in which the complementarity determining regions (CDRs) of the light and heavy chains of the murine LL2 anti-B-lymphoma, anti-leukemia cell monoclona lantibody has been recombinantly joined to the human kappa and IgG 1 constant region domains, respectively, which retains the immunospecificity and B-cell lymphoma and leukemia cell internalization capacity of the parental murine LL2 monoclonal antibody, and which has the potential of exhibiting reduced human anti-mouse antibody production activity. A humanized LL2 monoclonal antibody is described in which the CDRs of the light and heavy chains have been recombinantly joined to a framework sequence of human light and heavy chains variable regions, respectively, and subsequently linked to human kappa and IgG 1 constant region domains, respectively, which retains the immunospecificity and B-lymphoma and leukemia cell internalization capacities of the parental murine and chimeric LL2 monoclonal antibodies, and which has the potential for exhibiting reduced human anti-mouse antibody production activity. Vectors for producing recombinant chimeric and humanized chimeric monoclonal antibodies are provided. Isolated DNAs encoding the amino acid sequences of the LL2 variable light and heavy chain and CDR framework regions are described. Conjugates of chimeric and humanized chimeric LL2 antibodies with cytotoxic agents or labels find use in therapy and diagnosis of B-cell lymphomas and leukemias.
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BACKGROUND
The invention relates to a drive system for chain sprockets of chain drives, preferably for driving chain scraper conveyors or chain-drawn ploughs for underground mining, with a drive assembly formed of an asynchronous motor and a gear mechanism, the gear mechanism being designed as an overload and load equalisation gear unit having a controllable multiple-disk clutch for overload equalisation with which multiple-disk clutch the force flow between the asynchronous motor and the chain sprocket can be disconnected.
A drive system of this type is known from DE 40 24 830 A1 or U.S. Pat. No. 5,551,902 for example. In the known chain drive, unregulated three phase a.c. asynchronous motors are used. With the downstream arranged overload and load compensation gearing, during operation of the drive system load compensation between the main drive and the auxiliary drive of the coal plough or chain scraper conveyor is brought about in order to optimise the operation of the coal plough or chain scraper conveyor and to prevent unfavourable loading conditions for the chain. In the case of the drive system in DE 40 24 830 A1 an auxiliary motor is assigned to the overload and load sharing gearing which can be switched on and off when the asynchronous motor is at a standstill in order to tension the chain. At the same time, in order to tension the chain in the drive connection between the asynchronous motor and the overload and load compensation gear mechanism, a blocking device which blocks the asynchronous motor from turning is provided.
In place of unregulated three phase a.c. asynchronous motors (rotary current asynchronous motors), pole reversing asynchronous motors (DE 37 41 762 A1) and computer-controlled three phase a.c. asynchronous motors (U.S. Pat. No. 6,008,605) have been proposed, in which for each motor the individual torque-revolution characteristic curve is stored in an assigned computer. By means of a revolution counter, when the motors are in operation the current revolutions are permanently determined in a potential-separated manner in order to regulate the motor by way of comparing the current revolutions with the individual revolutions according to the characteristic curve. Due to the proportionality of revolutions and torque, with appropriate rotary current asynchronous electric motors the given torque can be adjusted.
In underground mining, efforts are being made to use three phase a.c. motors with frequency converters, known as frequency converter motors, as electric drives. With frequency converter motors constant adjustment of the revolutions is possible. The rough underground ambient conditions, with dust, moisture and corrosion, as well as the statically determined coupling of the frequency converter motor with the overload gearing cause problems for the use of frequency converter motors which have hitherto prevented the broad possibilities of using frequency converter motors. However, one use of frequency converter motors is known in which a rotary elastic and breakthrough-proof claw coupling is arranged between the overload coupling and the frequency converter motor. The intermediate claw coupling considerably increases the space required for the drives in the underground working faces so that correspondingly assembled drive system can only be used in an underground working face if there is sufficient space available. Furthermore, when using frequency converters on chain drives there are still considerable difficulties in achieving the breakaway effect required for starting a loaded chain scraper conveyor or releasing a plough jammed in the working face.
SUMMARY
The aim of the invention is to create a drive system for chain sprockets of chain drives in which revolution and torque control of the asynchronous motors is possible and in which the required breakaway effect can be exerted on the chain sprocket and thereby the chain.
In accordance with the invention this task is achieved in that the asynchronous motor comprises a frequency converter motor and in the drive assembly a two-gear toothed wheel gear mechanism with a start gear and normal gear is placed between the motor shaft and the gear mechanism. By way of the intermediate two-gear toothed wheel gear mechanism all the advantages of a frequency converter can be exploited in underground drive system and at the same time, through changing from the normal gear to the starting gear position, it is possible to increase the torque for the breakaway effect in an overproportional manner. A further advantage of the toothed wheel gear mechanism with the two gear positions is that chain tensioning systems, as otherwise provided by auxiliary motors or other devices in the state of the art, can be dispensed with.
In a preferred embodiment the toothed wheel gearing is designed as a forward gear mechanism so that it is arranged between the frequency converter motor and the overload gear mechanism. In a particularly preferred embodiment the toothed wheel gear mechanism has a returning transmission gear mechanism with a gear transmission of 1:3 to 1:4 as the starting gear, so that the drive torque delivered in the starting gear is approximately two to four times the nominal torque.
The toothed wheel or forward gear mechanism preferably also has a drive side central wheel borne in a rotating manner on the drive shaft and a output side central wheel borne in a rotating manner on the drive shaft, between which a control gear is connected in a torsion-stable manner to the drive shaft, whereby the control wheel can be coupled by means of a gearing system either to the drive-side or output-side central wheel. In order to simplify controlling the gear mechanism, both central wheels and the control wheel have an aligned and adjacent toothed section with identical toothing. The gear system can then comprise, in particular, a control hub which can be slid over the toothed sections of two adjacent toothed wheels of the forward gear mechanism in order to lock the adjacent wheels together so that they rotate together. In a preferred embodiment the control hub is moved by means of a gear fork, which can be displaced parallel to the gear shaft axis by means of a gear rod. In particular, the toothed wheel gear mechanism can be designed so that operation of the control system and therefore changing the gear position can also take place under load.
The gear shaft may be borne on the gear mechanism casing on the output side and may be supported on the motor drive side by the drive side toothed wheel, which is borne on the gear mechanism casing in a rotating manner. Particularly preferred is a transmission gearing for the start gear position including a secondary shaft borne in a rotating manner on the gear casing, which has a first gear toothing engaging in the drive side central wheel and second gear toothing engaging in the output central wheel. At least the first gear toothing can be part of a single wheel connected in a torsion-stable manner to the secondary shaft in order to facilitate assembly of the toothed wheel gear mechanism and the secondary shaft. The toothed wheel or forward gear mechanism is expediently designed as a spur gear. It is particularly advantageous if the drive-side central wheel is designed as a bushing and/or is provided on the inside with a hub connection for the motor shaft. By way of this embodiment a radial displacement of the motor shaft of the frequency converter motor can be easily intercepted. The frequency converter motor and the toothed wheel gear mechanism can also be arranged in a common casing, whereby the central wheel on the motor drive side is arranged on the motor shaft or is part of the motor shaft, so that an additional bearing can be saved if necessary.
It is desirable to minimise the maximum space required for underground chain drives and to improve a statically determined connection of the frequency converter motor to the toothed wheel gear mechanism. Therefore, in the case of a frequency converter motor which is provided with a stator with stator windings, a rotor and a frequency converter switch, and a motor shaft, the motor shaft is borne in a rotating manner on the motor flange side and rear of the motor casing, and which motor shaft is preferably designed as a hollow shaft, the axial boring of which is penetrated by a torsion rod which is coupled in a moving manner only at the rear end of the hollow shaft.
In a preferred embodiment, in the frequency converter motor according to the invention, the torque rod passes trough the axial boring and/or the motor case in a contact-free manner on the motor flange side, i.e. there is no bearing provided for the torsion rod on the motor flange side and no support on the hollow shaft. By way of this measure, and without an intermediate torsionally elastic coupling, statically determined coupling can be achieved between the motor and the downstream drive system, even when due to manufacturing inaccuracies or assembly imprecision there is no exact alignment of the motor shaft with the input shaft of the downstream drive system. For the drive coupling between the motor and the downstream drive system it is particularly advantageous to be able to push the torsion rod into the hollow shaft from its rear end and through the hollow shaft.
Expediently the motor flange side end of the torsion rod is provided with a pinion gear, toothing or a shaft connection, the external diameter of which is smaller than the minimum internal diameter of the axial boring in order to allow the torsion rod to be passed through from the rear end of the hollow shaft, which is always accessible even when the motor is assembled. The rear end of the torsion rod can expediently be provided with a spur gear, a hub connection or hub connection toothing, the external diameter of which is greater than the motor flange side of the torsion rod and the internal diameter of the axial boring.
As additional safety for the motor used in underground mining, it is recommended to create a breakage point on the rear end of the torsion rod and to arrange fastening means for assembly/dismantling aids for the torsion rod between the breakage point and the motor flange side of the hollow shaft, so that even after a breakage of the torsion rod at the breakage point dismantling of all the parts of the torsion rod can be carried out without the motor having to be loosened on the motor flange side of the downstream drive system. The fastening means can, in particular, include an axial threaded boring in the face side of the torsion rod.
In frequency converter motors it is particularly preferable if the frequency converter control is integrated into the frequency converter motor, more particularly arranged in a control box integrated into the motor casing. In a preferred embodiment the torsion rod projects from the motor casing with its motor flange side end or the motor flange side pinion gear. The motor flange side end of the torsion rod can be coupled with the input shaft of the toothed wheel or forward gear mechanism in a statically determined manner. By coupling the motor to the two-gear toothed gear mechanism, the torque required for the breakaway effect can be easily attained without significantly increasing the required assembly space for the chain drive by switching the toothed wheel or forward gear mechanism into the starting gear position.
BRIEF DESCRIPTION OF DRAWINGS
Further advantages and embodiments of the invention are set out in the following description of an example of embodiment set out schematically in the drawings. In the drawings:
FIG. 1 shows a simplified, schematic view of an underground extraction device with two chain drives with frequency converter motors
FIG. 2 shows a cross-section of a frequency converter motor coupled to a forward gear mechanism, and
FIG. 3 shows in a diagram the motor torque attainable with the frequency converter motor and the forward gear mechanism.
DETAILED DESCRIPTION
FIG. 1 shows two chain drives, designated 50 , for driving an endless chain 2 running around both sprockets 1 of the chain drives 50 . In the case of a face or drift conveyor designed as a chain scraper conveyer, the chain 2 is a scraper chain band and in the case of a plough system, the chain is a plough chain which moves the coal plough, which is not shown, along the working face. The chain sprockets 1 turn the chain 2 around and are each driven with drive units with which they connected via the chain wheel shaft 3 in a torsion-stable manner. The drive units of both chain drives 50 comprise an electric rotary current asynchronous motor, designed as a frequency converter motor 10 with an integrated control box 11 for controlling the frequency converter and connected to an overload protection and load equalisation gear mechanism 4 with an intermediately arranged forward gear mechanism 30 . The overload protection and load equalisation gear mechanism 4 is, more particularly, designed as a planetary gear mechanism with two planet positions, whereby a hydraulically operated disk coupling is assigned to the hollow wheel of one of the planet gears in order to achieve load-free starting of all motors 10 , to be able to effect load equalisation between the two drive units 50 , and, in the case of blockages of the chain 2 to release the drive connection between the motors 10 and the chain sprockets 1 . The assembly and corresponding functioning of the overload and load equalisation gear mechanism is known, for example, from DE 43 16 798 A1.
FIG. 2 shows a longitudinal section through the frequency converter motor 10 and the forward gear mechanism 30 . The frequency converter motor 10 has a motor casing 12 with an integrated control box ( 11 , FIG. 1 ) for controlling the frequency converter. Inside the motor casing 12 is a stator 13 with stator windings 14 , whereby arranged at a distance of an air gap inside the stator 13 is the rotor 15 of the frequency converter motor 10 with which motor shaft designed as a hollow shaft 16 is connected in a torsion-stable manner. The fundamental assembly of a rotary current asynchronous motor designed as a frequency converter motor is known to a person skilled in the art, so that a more detailed description of the electrical method of operation of the frequency converter motor 10 is not given here. The hollow shaft 16 is borne both at the rear end 17 and the motor flange end 18 via bearings 19 , 20 in a rotating manner on the rear bearing plate 21 and the motor flange plate 22 respectively and is provided with an axial boring 23 , in which a torsion rod 24 is arranged, which passes completely through the axial boring 23 and projects at the motor flange side end 18 of the hollow shaft 16 with a drive pinion 25 from the axial boring 23 and the motor casing 12 . On the rear end of the torsion rod 24 there is a further pinion 26 which is provided with appropriate toothing and engages in a torsion-stable manner in counter-toothing 27 on the internal circumference of the rear end 17 of the hollow shaft. Between the counter toothing 27 and the pinion 26 of the torsion rod 24 there can be transitional play in order to facilitate the assembly of the torsion rod 24 through an opening which can be closed with a closing lid 28 in the rear bearing plate 21 of the motor casing 23 . The external diameter of the pinion 25 is preferably slightly smaller and the outer diameter of the pinion 26 is preferably slightly larger than the internal diameter D i of the axial boring 23 . In the area of the pinion 26 a nominal breakage point 29 is formed on the torsion rod 24 by way of a shearing groove, whereby a threaded boring 8 arranged on axis A of the torsion rod 24 extends beyond the nominal breakage point 29 in the direction of the gear side pinion 25 of the torsion rod 24 so that even in the event of breakage of the torsion rod 24 in the area of the nominal breakage point 29 a dismantling tool (not illustrated) can be screwed into the threaded boring 8 and the torsion rod 24 pulled out of the axial boring 23 . As the torsion rod 24 is only coupled to the hollow shaft 16 at its rear end 17 and supported relative to the hollow shaft 16 , alignment errors between the casing 12 of the frequency converter motor 10 and, respectively, axis A of the hollow shaft 16 and the casing 31 of the forward gear mechanism 30 can be compensated for. There is therefore no necessity to arrange a coupling, such as a torsion elastic claw coupling, between the frequency converter motor 10 and the forward gear mechanism 30 .
In the shown example of embodiment the forward gear mechanism 30 is designed as a two-gear toothed wheel gear mechanism whereby switching between a starting gear position and a normal gear position is carried out by way of a control ring or a control hub 32 . In the lateral view in FIG. 2 the control hub 32 is shown in the lower half in the starting gear position and in the upper half in the normal gear position as will be explained.
The two-gear toothed wheel gear mechanism 33 of the forward gear mechanism 30 designed as a returning transmission gear mechanism has a gear shaft 34 which on the output side is borne in the output side bearing plate 36 by means of bearing 35 . The gear shaft 34 extends on the frequency converter motor 10 to close to the pinion 25 of the torsion rod 24 with a gap remaining between the pinion 25 and the gear shaft 34 . On the motor side end of the gear shaft 34 a drive-side central wheel 37 of the toothed wheel gear mechanism 33 is borne, which in this case is designed as a bushing, and the section of the central wheel 37 provided with gear toothing 39 is borne in a rotating manner on the free end of the gear shaft 34 by way of bearing 40 . The central wheel 37 tapers vis-à-vis the section with the spur gear toothing 39 to a connection section 41 , which has toothing 42 on its inner circumference and is, or can be, connected as a hub in a torsion-stable manner to the pinion 25 of the torsion rod 24 . On its outer circumference the connection section 41 has a cylindrical band 43 which is borne by way of bearing 44 on the motor-side bearing plate 45 , which is an integral part of the gear casing 31 . Axially displaced vis-à-vis the gear shaft 34 there is a secondary shaft 46 borne in a rotating manner on both bearing plates, whereby the secondary shaft 46 has a cam 47 with gear toothing 48 as well as a shaft section on which, for example, a single wheel 49 with gear toothing 51 is borne in a torsion-stable manner by means of a feather key connection. As further components the toothed wheel gear mechanism 33 has a control wheel 52 with spur gear toothing 53 connected in a torsion-stable manner to the gear shaft, as well as an output side central wheel 54 with spur gear toothing 55 , which is supported by means of bearing 56 in a freely rotating manner on the gear shaft 34 .
In the normal gear position in which the control hub 32 , which is movable over the control shaft 57 and the control fork 58 firmly connected thereto, connects a section of the gear toothing 53 of the control wheel 52 with a section of the gear toothing 39 of the drive side central wheel 57 , the control wheel 52 and therefore the gear shaft 34 rotates at the same speed as the torsion rod 24 connected to the central wheel 37 . This position of the control hub 32 therefore corresponds to the normal gear position of the gear box 33 with a gear transmission of 1:1.
The toothed wheel transmission gearing brought about by the engaging spur wheel and gear toothing 39 , 51 , 48 and 55 of the toothed wheels and pinions 37 , 49 , 47 and 54 respectively has a slow transmission ratio of 1:4 in the starting gear position in the shown embodiment. The starting gear position is only active if the control hub 32 , as shown in the lower half of FIG. 2 , is in the left position in contact with the flank 59 of the output side central wheel 54 . In this position the control hub 32 simultaneously covers a section of the gear toothing 53 of the control wheel 52 and a toothed section 60 on the output side central wheel 54 which is formed on a collar 61 of the central wheel 54 projecting in the direction of the electric motor 10 . The position of the control hub 32 and the coupling of the toothed sections 60 and 53 causes the speed of the central wheel 54 to be transmitted to the control wheel 52 and therefore to the gear shaft 34 . In contrast to this, as has already been set out above, in the normal gear position the control hub 32 engages with the gear toothing 39 of the drive side central wheel 37 and the toothing 53 of the control wheel 52 in such a way that the gear shaft rotates at the same speed as the torsion rod 24 of the frequency converter motor 10 .
The starting gear position brought about by the two-gear toothed wheel gear mechanism is only initiated if a breakaway effect is to be achieved with the frequency converter motor 10 and the chain drive 50 in order to start the loaded chain scraper conveyor or to release the plough. As shown schematically in the diagram in FIG. 3 , in the starting gear position the motor torque M d brought about on the output side by the combination of frequency converter motor 10 and toothed wheel gear mechanism 33 and/or forward gear mechanism 20 increases to the breakaway torque Md A which in this case is around four times the nominal motor torque Md N . The starting gear position can only initiated at low revolutions or low chain speeds V k .
This invention is not limited to the illustrated example of embodiment. The use of a frequency converter motor with a hollow shaft and torsion rod forms the preferred embodiment of the invention. The toothed wheel transmission gear mechanism and the frequency converter motor can also be arranged in a common casing, whereby the drive-side central wheel then coincides with the motor shaft so that one of the two bearings 20 , 44 can be dispensed with. In this embodiment it is obviously also unnecessary to form the motor shaft as a hollow shaft with a torsion rod.
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A drive system for chain sprockets 1 of chain drives, more particularly for driving chain scraper conveyors or chain-drawn ploughs for underground mining, with a drive assembly formed of an asynchronous motor and a gear mechanism 4 , the gear mechanism 4 being designed as overload gearing and having a controllable multiple-disk clutch for overload equalisation with which the force flow between the asynchronous motor and the chain sprocket can be disconnected. The asynchronous motor comprises a frequency converter motor 10 and in the drive assembly between the motor shaft and the gear mechanism 4 a two-gear toothed wheel gear mechanism is arranged as a forward gear mechanism, with a starting gear position and a normal gear position, with which in the starting gear position the breakaway effect required for starting the loaded chain scraper conveyor or for releasing the plough can be attained.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a nonprovisional of, and claims priority to, and the benefit of U.S. Provisional Application No. 61/918,224, entitled “SYSTEM AND METHOD FOR LATERAL TRANSFER PLATE HAVING A PUNCHED TAB,” filed on Dec. 19, 2013, which is hereby incorporated by reference in its entirety.
FIELD
[0002] The present disclosure relates to prefabricated building panels for use in structures, and walls external to structures, such as outdoor privacy walls and the like. More particularly, the present disclosure relates to a method and system for providing prefabricated building panels that provide improved structural integrity, distributed loads, and thermal performance among other attributes.
BACKGROUND
[0003] Recent changes in the construction industry have led to an increased use by builders of prefabricated building components manufactured offsite. Despite its many benefits, however, builders have not fully embraced prefabricated building components using alternatives to conventional wood framing. For example, even though steel framing has many advantages over conventional wood framing, there has been reluctance in residential construction, and some types of commercial construction, to use components made from steel, rather than wood, due in part to the belief that steel is more costly. Dimensioned lumber prices, however, are highly volatile. An insulated steel frame panel system that is cost competitive to conventional wood framing, incorporates recognized and readily available components, and that is easily and quickly assembled and installed, has many advantages over conventional wood framing and would be embraced by the building industry and building owners.
[0004] A number of panels have been designed that incorporate foam insulation for improved thermal performance These panels, however, often incorporate nonstandard light gage steel framing members (e.g., U.S. application Ser. No. 11/825,562 to Miller, U.S. application Ser. No. 11/282,351 to Onken et al., U.S. patent application Ser. No. 11/068,609, to Rue, U.S. Patent Application Publication No. 2011/0047912 to Armijo, U.S. application Ser. No. 11/361,189 to Bowman) and often require the manufacture of the panel within a mold, (e.g., Rue and U.S. Pat. No. 5,799,462, to McKinney). Others envision the insertion of framing members in larger channels or voids in the foam or that require an adhesive to lubricate the stud insertion and/or to adhere the stud in the foam (e.g., Miller).
[0005] New building codes recognize the importance of eliminating thermal bridging. Newer codes require a layer of continuous insulation unless a wall assembly can demonstrate an acceptable level of thermal performance without it. The layer of continuous insulation creates new building challenges, among which are fastening and exterior finish details, moisture control, and the ratio of rigid continuous insulation to batt or other air permeable insulation in the wall cavity.
[0006] Since a structural panel by nature generally requires support on both the exterior and interior of the panel, some panelized systems use nonstandard steel framing members in order to create sufficient strength in the steel member to avoid multiple connecting bridges through the panel. For example, the nonstandard framing member in Miller has additional bends in the steel framing member to provide additional strength. While such efforts can help avoid thermal bridging, the use of a nonstandard framing member generally requires extensive and expensive testing to demonstrate compliance with building codes, including structural analyses and fire testing under superimposed loads if the foam is intended to serve any primary structural support purpose. A panelized system that minimizes thermal bridging but which emphasizes the use of conventional steel framing members will be more economical to manufacture and will ensure more rapid acceptance by the building industry.
[0007] Other building panel systems that incorporate nonstandard light gage steel members and foam insulation have addressed thermal bridging in various ways, but generally are designed in ways that will also require substantial structural (and other) testing to gain acceptance by the building industry and building code officials. Also, they generally require a manufacturing process that is complex and not economical. These factors have generally limited the commercial practicability of these approaches.
[0008] In traditional construction, cable/utility runs in walls are not well integrated with the framing. Groupings of tubing (such as PEX plumbing), electrical, data, voice, and audio wiring are often commingled or loose in a common area within a cable/utility run wall cavity. These cables, wires and tubing are generally secured in wood framing using secondary means (such as staples, nails, clips, and tacks), which may puncture the cables, wires and/or tubing upon coupling to the wall. In steel framing, similar attachment means are used such as tie wire, clips, hangars, and mechanical fasteners, each of which may also puncture or abrade the cables, wires, and/or tubing. Moreover, the channel/utility run often results in an opening for thermal, sound, and vibration inefficiencies. In a solid panel system, planning for the placement of cable and utility run is an important feature.
SUMMARY
[0009] These above disclosed needs are successfully met via the disclosed system and method.
[0010] In accordance with various aspects, a method and system for providing panels with improved thermal, acoustic, and vibration characteristics is disclosed. In accordance with various embodiments of the present disclosure a method and system for providing precision cuts to tight tolerances to allow insertion of conventional framing members in exoskeletal panels of variable design length, width, and thickness, in a desired axis (such as the X, Y or Z axis in a Cartesian coordinate system) without use of a lubricant or securing adhesive is disclosed, and without the use of cumbersome and limiting EPS panel molding processes. In this way, conventional materials may be used in a non-standard application. Thus, stringent building codes based on conventional shaped and formed materials, such as C shaped studs, may be fashioned into a panel using precision cut grooves.
[0011] In accordance with various embodiments of the present disclosure, to distribute loads across the exoskeleton, a lateral transfer plate and/or stud tie track is disclosed for use in these exoskeletal panels integrated with a foam core, permitting the framing to be staggered and providing the same or different stud spacing on each side of the panel. Further, a method and system for the lateral transfer plate to be used as integrated fireblocking in such panels is disclosed.
[0012] In accordance with various embodiments of the present disclosure a panel comprising a polymeric insulated core comprising a steel exoskeleton of steel studs, and a lateral transfer plate comprises an opening to receive a first stud, wherein the opening corresponds to the shape of the first stud is disclosed. Further, in accordance with additional embodiments of the present disclosure, the lateral transfer plate may include an optional flange configured to be fastened to the first stud. The lateral transfer plate may include a punched tab configured to be fastened to the first stud. The panel is constructed from parts in accordance with AISI S200 requirements. Moreover, the lateral transfer plate may be configured to be integrated into a furring wall panel in which a plurality of studs are arranged in a row. The lateral transfer plate may be configured to share the load between the interior and exterior staggered studs, act as mid-height blocking/bracing to reduce the unbraced length of the stud, and/or provide supplemental bracing that would generally be supplied in part by sheathing.
[0013] In accordance with additional embodiments of the present disclosure, a panel comprising a first polymeric insulated core and a contiguous precision cut groove cut out of the core configured to receive a first steel stud, wherein the precision cut groove corresponds to the shape of the first stud is disclosed. The first steel stud may be a conventional steel stud. The conventional steel stud may be a C shaped conventional steel stud comprising a web, a flange and a lip. The C shaped stud may be oriented in any suitable orientation; however, in an embodiment, the stud is oriented such that a long side of the C shaped stud is oriented orthogonal to the face of the panel. This C shaped stud is traditionally slid into position from the top or bottom edge of the panel.
[0014] Such systems, methods, and panels can be used for and by builders of prefabricated building components, commercial buildings, residential building, storage or containment structures, exterior sound barrier/privacy walls, mobile structures, and other types of walls and enclosures. Such systems, methods and panels can suitably distribute loads, improve thermal performance, vibration dampening, structural integrity, and provide fire-blocking capability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A more complete understanding of the present disclosure may be derived by referring to the detailed description and claims when considered in connection with the Figures, where like reference numbers refer to similar elements throughout the Figures, and:
[0016] FIG. 1A is a plan view of the lateral transfer plate according to an exemplary embodiment;
[0017] FIG. 1B depicts a side view of a “C” shaped lateral transfer plate according to an exemplary embodiment
[0018] FIG. 1C depicts a side view of a “Z” shaped lateral transfer plate according to an exemplary embodiment;
[0019] FIG. 1D is a top cut away view of a template prior to bending to form one or more flanges into either a C shaped lateral transfer plate, a Z shaped lateral transfer plate, or an L shaped lateral transfer plate and prior to punching or cutting the penetrations for the stud profiles according to an exemplary embodiment;
[0020] FIG. 1E is a wall panel section showing a C shaped lateral transfer plate integrated in a panel according to an exemplary embodiment;
[0021] FIG. 1F is a wall panel section showing a Z shaped lateral transfer plate integrated in a panel according to an exemplary embodiment;
[0022] FIG. 1G depicts a side view of an “L” shaped lateral transfer plate according to an exemplary embodiment,
[0023] FIG. 2A is a plan view of a wall panel assembly according to an exemplary embodiment;
[0024] FIG. 2B is a side view of a stud tie track profile according to an exemplary embodiment;
[0025] FIG. 2C is a side cut away view of a wall panel with stud tie track integrated into the panel comprising a lap joint according to an exemplary embodiment;
[0026] FIG. 2D is a side view of a wall panel with an integrated stud tie track according to an exemplary embodiment;
[0027] FIG. 3A is a side view of a slip transfer plate according to an exemplary embodiment;
[0028] FIG. 3B is an isometric view of the slip transfer plate showing the stud profile penetrations and the slip fastener slots in the flanges according to an exemplary embodiment;
[0029] FIG. 3C is a side view of a wall panel with a slip transfer plate according to an exemplary embodiment;
[0030] FIG. 4 is a side cut away view of integrated fireblocking according to an exemplary embodiment;
[0031] FIG. 5 is a side cut away view of a fire resistance rated wall panel system with integrated fireblocking according to an exemplary embodiment;
[0032] FIGS. 6A-6C depict a top cut away view of a wall panel comprising a formed chase (utility run) and a multipurpose chase (utility run) with studs oriented in both the X axis orientation and Y axis orientation according to an exemplary embodiments;
[0033] FIG. 7 is a side cut away view of a wall panel with a split steel track, integrated acoustical sound/fire material, and integrated side air gap according to an exemplary embodiment;
[0034] FIG. 8 is a top cut away view of a corner assembly of adjoining wall panels according to an exemplary embodiment;
[0035] FIGS. 9A and 9B are segmented side cut away views of a matrix of interlocking panels according to an exemplary embodiment.
[0036] FIG. 10A depicts a three dimensional view of flangeless lateral transfer plate comprising a stud attachment tab according to an exemplary embodiment;
[0037] FIG. 10B depicts a three dimensional view of the flangeless lateral transfer plate of
[0038] FIG. 10A according to an exemplary embodiment;
[0039] FIG. 10C depicts a plan view of the flangeless lateral transfer plate of FIGS. 10A and 10B according to an exemplary embodiment;
[0040] FIG. 10D depicts a section view of the flangeless lateral transfer plate of FIGS. 10A through 10C according to an exemplary embodiment;
[0041] FIG. 10E depicts a plan view of the flangeless lateral transfer plate of FIGS. 10A and 10B with attached metal strapping according to an exemplary embodiment;
[0042] FIG. 10F depicts a section view of the flangeless lateral transfer plate of FIGS. 10A through 10C with attached metal strapping according to an exemplary embodiment
[0043] FIG. 11A depicts a three dimensional view of lateral transfer plate comprising a stud attachment tab according to an exemplary embodiment;
[0044] FIG. 11B depicts a three dimensional view of the lateral transfer plate of FIG. 11A according to an exemplary embodiment;
[0045] FIG. 12A depicts a three dimensional view of lateral transfer plate comprising a stud attachment tab according to an exemplary embodiment;
[0046] FIG. 12B depicts a three dimensional view of the lateral transfer plate of FIG. 12A according to an exemplary embodiment;
[0047] FIG. 13A depicts a three dimensional view of lateral transfer plate comprising a stud attachment tab according to an exemplary embodiment;
[0048] FIG. 13B depicts a three dimensional view of the lateral transfer plate of FIG. 13A according to an exemplary embodiment;
[0049] FIG. 14A depicts a three dimensional view of lateral transfer plate comprising a stud attachment tab according to an exemplary embodiment;
[0050] FIG. 14B depicts a three dimensional view of the lateral transfer plate of FIG. 14A according to an exemplary embodiment;
[0051] FIG. 15A depicts a three dimensional view of lateral transfer plate comprising a stud attachment tab according to an exemplary embodiment; and
[0052] FIG. 15B depicts a three dimensional view of the lateral transfer plate of FIG. 15A according to an exemplary embodiment.
[0053] FIG. 16A depicts a three dimensional view of lateral transfer plate comprising a stud attachment tab according to an exemplary embodiment; and
[0054] FIG. 16B depicts a three dimensional view of the lateral transfer plate of FIG. 16A according to an exemplary embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0055] The present systems, apparatus and methods are described herein in terms of various functional components and various processing steps. It should be appreciated that such functional components may be realized by any number of hardware or structural components configured to perform the specified functions. For example, the present disclosure may employ various foam core portions in varying densities or foam types, and conventional stud framing members and the like whose structure, dimension, gage, and composition may be suitably configured for various intended purposes. In addition, the present systems, apparatus and methods described herein may be practiced in any application where building panels are desired, and the examples herein are merely for exemplary purposes, as the systems, apparatus and methods described herein can be applied to any similar application.
[0056] A simple prefabricated building product that incorporates conventional light gage steel framing members in a manner that minimizes thermal bridging sufficiently to meet energy efficiency requirements without the need for a separate layer of continuous insulation provides significant advantages over prior systems. To gain acceptance, such a system should be cost competitive to manufacture and install. For example, in accordance with various embodiments, a method and system for providing building panels 150 with an improved steel exoskeleton that makes efficient use of conventional steel components while meeting load requirements is described. Such systems, methods and panels 150 can be used for and by builders of prefabricated building components, commercial buildings, residential building, storage structures, exterior sound barrier walls, mobile structures, and other types of walls and enclosures.
[0057] In various embodiments, one or more panels 150 may include a core 151 made of an insulating material, preferably, expanded polystyrene (EPS) ranging in density from about 0.75 pcf to about 3.0 pcf. Importantly, the panels 150 may include an exoskeleton of stiffeners (studs 120 ); each spaced, such as to national and international building code requirements at 24-inches on center (24″ OC) or 16-inches on center (16″ OC), to form a rigid support framework. The studs 120 may be made of galvanized steel, in various gages according to structural and building code requirements, such as AISI S200.
[0058] The result is a prefabricated panel system that incorporates conventional light gage steel framing members in an exoskeletal design that minimizes thermal bridging, but permits the manufacture of panels to a building's specifications without the requirement of a complex and limiting panel molding process. A panel system which is economical to manufacture, and meets energy efficiency requirements without a layer of continuous insulation outside the panel. A panel design that allows the insertion of conventional steel framing members within foam profiles cut to tight tolerances such that the framing member may be inserted without lubricant or adhesive, yet fits snugly within the panel after insertion and the exposed steel is flush with the surfaces of the foam in the panel is achieved. For instance, using the present system a conventional stud, which generally comprise a web, a flange and a lip, may be inserted into a precision fit in grooves. Additionally, according to various embodiments, a system and panel which distributes loads across the exoskeleton and addresses or eliminate unbraced flanges in order that the exoskeletal wall will distribute loads efficiently and meet building requirements without the use of heavier than normal steel gage members is achieved.
[0059] Historically, EPS panel makers have attempted to use non-conventional steel studs (which lack the web, a flange and a lip of a conventional steel stud) as they have encountered problems inserting these conventional steel studs into EPS cut-outs. Other makers have employed a cumbersome, inflexible, and expensive molding process.
[0060] Unlike in conventional wood or steel framing, the studs 120 do not extend from the exterior surface to the interior surface. Instead, the studs 120 forming the exoskeleton are each inserted in grooves 170 precision cut in the foam core to mirror the shape and form of the stud 120 . As used herein, to mirror refers to substantially track, correspond to, complement and/or follow, such as by approximating the contours and/or exterior shape of an element. Accordingly, conduction across the studs 120 from the exterior to the interior, and vice versa, does not occur because the studs 120 do not extend through the panels 150 , thereby minimizing thermal bridges through the panel 150 . In an exemplary embodiment, the panels 150 may have a top track 180 and a bottom track 190 , which may be attached prior to or during panel 150 installation. These tracks ( 180 , 190 ) may be made from steel, such as conventional steel track. The panel bottom tracks 190 are attachable to a floor, such as a concrete floor, using suitable fasteners. The panel top tracks 180 are attachable to a ceiling using suitable fasteners. Any suitable mating or attachment method can be used to join adjacent panels 150 . Accordingly, workers can build a wall, for example by connecting a series of panels 150 together, and fastening the bottom 190 and top tracks 180 .
[0061] In accordance with an exemplary embodiment, an exemplary system 100 and panel 150 includes an integrated lateral transfer plate 160 . This integrated lateral transfer plate 160 can be made of light gage steel, such as 18 gage cold formed steel, or it can be made of other materials, such as carbon fiber that provide lower thermal conductivity combined with the material properties required to provide the desired load transfers, such as in the lateral direction and, in some applications, fire retardant properties. The stud 120 profiles 168 may be punched or cut into the plate 160 so that the steel studs 120 are inserted through the plate 160 . The foam core 151 for the panel 150 may be configured with pre-cut precision grooves 170 for the studs 120 such that the foam core 151 may be integrated into the panel 150 assembly that contains the lateral transfer plate 160 . In an embodiment, the lateral transfer plate 160 contains flanges of any suitable dimension. For instance, the flanges may be between about ¾″ high to 6″ high or greater, depending on the application (“about” in this context means plus or minus 33% of the dimensional range). The flanges may be fastened to the studs 120 on each side of the panel 150 exoskeleton with screws or may be welded in some applications, such as through contact welding. The lateral transfer plate 160 with stud 120 profile penetrations can take any suitable shape, such as a “C” shape (See FIG. 1E ), much like the shape of standard light gage steel track, or it may take a “Z” shape (See FIG. 1F ) or an “L” shape in certain applications. Referring to the figures, the C shaped lateral transfer plate 160 is illustrated in FIG. 1B . For instance, FIG. 1B depicts a side view of a “C” shaped lateral transfer plate with a width of “X”, depending on the thickness of the wall panel, and an attachment flange 163 and 166 on opposite sides, with the length of “Y” and “Z” variable from about ¾″ to 6″ or more according to an exemplary embodiment, depending on the application. FIG. 1C depicts a side view of a “Z” shaped lateral transfer plate with a width of “X”, depending on the thickness of the wall panel, and an attachment flange 163 and 166 on opposite sides, with the length of “Y” and “Z” variable from about ¾″ to 6″ or more according to an exemplary embodiment, depending on the application. FIG. 1G depicts a side view of an “L” shaped lateral transfer plate with a width of “X”, depending on the thickness of the wall panel, and an attachment flange 163 and a straight attachment extension 167 on the opposite side, with the length of “Y” and “Z” variable from about ¾″ to 6″ or more according to an exemplary embodiment, depending on the application. In various embodiments, the lateral transfer plate 160 may be integrated into a furring wall panel in which the studs 120 are arranged in a single row. One flange of the plate 160 may be fastened to the interior of an exterior wall, such as a mass wall comprising concrete or CMU, to provide an insulated interior furring wall. A portion of the flange in such plate 160 may be cut away so that the fastening points become separate tabs and not a continuous flange. The lateral transfer plate 160 may be configured to share the load between the interior and exterior staggered studs 120 , act as mid-height blocking/bracing to reduce the unbraced length of the stud 120 , and/or provide supplemental bracing that would generally be supplied in part by sheathing.
[0062] In an exemplary embodiment, the integrated lateral transfer plate 160 may permit the gage of the steel studs 120 used in the panel's exoskeleton to be reduced from what would be requisite without the lateral transfer plate 160 , but enable the panel 150 to still meet or exceed the required loads. The lateral transfer plate 160 may also allow consistent stud 120 spacing in the panels, such as at 24″ on center, for a variety of wall panel applications. The lateral transfer plate 160 may also have one or both of its flanges made longer to enable the lateral transfer plate 160 to serve as an exterior or interior ledger in some applications, such as a ledger to which an exterior deck or other exterior horizontal building component may be affixed. The lateral transfer plate 160 may be created in various shapes to match the profile of associated wall components. For example, a lateral transfer plate 160 that mirrors the shape and dimensions of an “L” or “Z” shaped corner component 200 in this panel system 100 can simplify the production and installation of the plate 160 in a wall corner by eliminating the need for two separate plates 160 and by avoiding cutting, mitering, and overlapping of two separate corner plates. In some applications, the lateral transfer plate 160 may have an extension 167 that overlaps the lateral transfer plate 160 in the adjacent wall panel 150 to give the lateral transfer plate 160 continuity in the horizontal plane (See 169 in FIG. 1A ), or the lateral transfer plate 160 may abut the adjacent lateral transfer plate 160 without overlap.
[0063] Historically, panel designs ignored integrated fireblocking. Here, the lateral transfer plate 160 may have a fire retardant layer above or below the lateral transfer plate 160 to enable the lateral transfer plate 160 with fireblock configuration to be used in a wall where fireblocking is desired, such as an exterior nonbearing wall in a multi-floor building. In accordance with an exemplary embodiment, one or more panels 150 comprising a lateral transfer plate 160 , and/or a lateral transfer plate 160 with fireblocking configuration are applicable to a multi-story assembly such as for use in balloon framing construction or a curtain wall assembly.
[0064] Another exemplary embodiment creates a slip transfer plate 165 placed at the top of an infill wall panel 150 to improve the structural integrity of the exoskeleton. The studs 120 in the exoskeleton are fastened to the slip transfer plate 165 through slotted 310 flanges in the plate 165 , which allow for vertical movement of the floorplate 320 above the panel. The top of the studs 120 may protrude through the stud 120 profile penetrations 168 cut or punched in the slip transfer plate 165 . The slip transfer plate 165 may be created in various shapes to match the profile of associated wall components. For example, a slip transfer plate 165 that mirrors the shape and dimensions of an “L” or “Z” shaped corner component in this panel system 100 can simplify the production and installation of the plate 165 atop a wall corner by eliminating the need for two separate plates and by avoiding cutting, mitering, and/or overlapping of two separate slip transfer plates 165 .
[0065] In accordance with another exemplary embodiment to maximize the structural integrity of the steel exoskeleton and eliminate unbraced flanges, a groove 170 is cut at one or both ends of a panel 150 and a stud tie track 125 of cold formed light gage steel is inserted into the groove 170 in such a way that the stud tie track 125 is contiguous to the inside flange of each steel stud 120 that forms the wall panel 150 exoskeleton. The stud tie track 125 is then fastened to each contiguous stud 120 with appropriate fasteners, such as self-tapping screws or in some applications may be welded to the contiguous studs 120 , such as through contact welding. The stud tie track 125 ensures that the metal studs 120 will remain affixed to the panels 150 during shipping, handling, and installation. The stud tie track 125 also improves the structural strength of the panel 150 by bracing the flanges to resist torsional forces on the studs 120 . In some applications, sill anchor bolts will protrude through the bottom plate 190 or track and fit inside the stud tie track 125 . In an exemplary embodiment, tying studs 120 on each side of the exoskeleton together produces structural and cost benefits, such as permitting the use of lighter gages of steel stud 120 members in more standardized gages and spacing.
[0066] In an exemplary embodiment, an exemplary system 100 and panel 150 includes an integrated lateral transfer plate 160 that may be made from steel or, in certain applications, may be made from another material providing similar or better structural and/or thermal qualities, such as carbon fiber, fiberglass, or HDPE. In one embodiment of the lateral transfer plate 160 , a light gage steel template such as that shown in FIG. 1D is created. For example, as shown in FIG. 1D , a top cut away view of a light gage steel rolled stock template prior to bending the stock along a flange bending line 162 to form one or more flanges into either a C shaped lateral transfer plate, a Z shaped lateral transfer plate, or an L shaped lateral transfer plate, and prior to punching or cutting the penetrations 168 for the stud profiles is depicted according to an exemplary embodiment. Penetrations 168 , such as penetrations mirroring the shape of the stud 120 profiles used in the panel 150 are cut or punched in the template as shown in FIGS. 1B , 1 C, and 1 G. Flanges 161 , 163 , or 167 on the lateral transfer plate 160 are created from the template by bending or other means, as shown on FIGS. 1B , 1 C, and 1 G. The lateral transfer plate 160 can be designed with an integrated extension 167 that will overlap (See FIG. 1A , 169 ) the shear transfer plate on the adjacent panel 150 , as shown in FIG. 1A . Fire retardant material can be added above or below the lateral transfer plate 160 to create a fireblocking configuration that suitably permits the use of the lateral transfer plate 160 in walls in which fireblocking is desired and/or required, including curtain walls in a multi-floor building. In accordance with an exemplary embodiment, one or more wall panels comprising a lateral transfer plate 160 in a fireblocking configuration are applicable to a multi-panel assembly such as for use in balloon framing or multistory building with curtain walls. In accordance with another exemplary embodiment, one or more wall panels comprising a lateral transfer plate 160 are applicable to a single story or multistory wall panel assembly without fireblocking added to the lateral transfer plate 160 in applications in which fireblocking is not desired.
[0067] A fire retardant such as one or more spray, coating, caulking, foil tape, elastomeric, gypsum board, mineral wool, or other material may be introduced above or below the lateral transfer plate 160 . In an embodiment, a fire retardant material is placed on the lateral transfer plate 160 before the stud 120 profile penetrations 168 are cut or punched. In some embodiments, any gaps around the stud 120 penetrations 168 are sealed with fire retardant material, which may be the same or different fire retardant material used on the horizontal surface of the lateral transfer plate 160 .
[0068] Turning to FIG. 1E , a wall section of a panel 150 with an integrated lateral transfer plate 160 shows that the flanges on the lateral transfer plate 160 are secured to the studs 120 , which may be via a fastener, contact or other welding, clipping or snapping mechanism, adhesive tape, or other means of securing the lateral transfer plate 160 to the studs 120 . Stated another way, FIG. 1E depicts a wall panel section showing a C shaped lateral transfer plate 101 integrated in the panel with the light gage steel exoskeleton of studs and track according to an exemplary embodiment. In accordance with an embodiment, and with reference to FIG. 1A , a plan view of the lateral transfer plate 160 with examples of the stud profile penetrations 168 to be cut or punched is depicted. Also, an example of an optional extension of the lateral transfer plate to overlap 169 the lateral transfer plate on an adjacent panel according to an exemplary embodiment; a part of the lateral transfer plate 160 may overlap the lateral transfer plate 160 on the adjacent wall panel 150 . Such overlap may be unsecured, or may be secured by a fastener, contact or other form of welding, or an appropriate adhesive or sealant.
[0069] According to various embodiments, as shown in FIG. 1F , a wall panel section showing a Z shaped lateral transfer plate 102 integrated in the panel with the light gage steel exoskeleton of studs and track, in which embodiment one flange may be longer to serve as a ledger (not depicted).
[0070] According to various embodiments, with reference to FIGS. 2A-2D the presently disclosed system and wall panel assembly may comprise a stud tie track. For instance, FIG. 2A depicts a plan view wall panel assembly with an exploded view of a portion of the panel that contains a light gage metal stud tie track secured to the studs with fasteners. FIG. 2B depicts a side view of a stud tie track profile. FIG. 2C depicts a side cut away view of a wall panel with stud tie track integrated into the panel, which panel has an illustrative lap joint. FIG. 2D depicts a side view of a wall panel with an integrated stud tie track and without any bottom track.
[0071] In accordance with another exemplary embodiment, the top track 180 on panels 150 comprising an infill wall may be replaced by a fire-resistive slip transfer plate 165 such as that depicted in FIG. 3A and FIG. 3B . For instance, FIG. 3A depicts a side view of a slip transfer plate with light gage metal studs protruding through the plate according to an exemplary embodiment. FIG. 3A further depicts dimensions A, B, C, and D. Dimension A represents the exterior slip flange dimension. Dimension B represents the interior slip flange dimension. Dimension C represents the slab attachment flange dimension. Dimension D represents the width of wall panel dimension. Furthermore, FIG. 3A illustrates a light gage metal stud protruding through metal stud profile penetration 168 and the top of EPS foam insulation 151 . Dimensions A, B, C, D are further depicted in FIG. 3B . FIG. 3B depicts an isometric view of the slip transfer plate showing the stud profile penetrations and the slip fastener slots in the flanges according to an exemplary embodiment.
[0072] The slip transfer plate 165 improves the structural integrity of the panel 150 by tying the inner and outer steel studs 120 of the exoskeleton together. The slip transfer plate 165 attaches to the studs through slotted metal flanges in the plate 165 , which flanges allow for vertical movement of the floorplate above the panel 150 that may be caused by thermal, seismic, wind loading, or any other load.
[0073] In accordance with another exemplary embodiment, the foam panel core above the lateral transfer plate 160 has precision grooves 170 pre-cut to hold and receive the studs 120 comprising the exoskeleton, and the foam panel 150 core above the lateral transfer plate 160 is integrated with the studs 120 that extend above the lateral transfer plate 160 in a manner that the studs 120 are securely fit in the pre-cut grooves 170 such that the lateral transfer plate 160 becomes integrated within the foam core of the wall panel 150 .
[0074] Studs 120 may be inserted from the top and/or bottom of the panel 150 retained in the precision cut groove 170 , cut to substantially mirror the exterior and interior of the stud 120 . In this fashion, multiple panels 150 or core material may be coupled to a single stud 120 . For instance, a thirty foot long stud 120 may be used to couple three 10 foot wide sections of core material (panels 150 ) together. In the panel 150 embodiment that incorporates one or more lateral transfer plates 160 , the foam core above the lateral transfer plate 160 has precision cut grooves 170 to match the stud 120 profiles and such foam core is integrated with the portion of the panel 150 containing the lateral transfer plate 160 in a manner that the protruding studs 120 integrate into such grooves 170 . This procedure may be repeated on the same panel 150 to create a panel 150 of any length with more than one lateral transfer plate 160 .
[0075] The stud tie track 125 is formed from cold formed steel such that each flange of the stud tie track 125 will be contiguous to the inside web of each stud 120 forming the wall panel's 150 steel exoskeleton, as depicted in FIGS. 2B and FIG. 2D . In one example embodiment, this steel is 20 gage. In one example embodiment, stud tie rack 125 has a channel approximately 1 inch deep. The stud tie track 125 is placed in a pre-cut precision groove 170 in an end of the wall panel 150 and fastened to the studs 120 with suitable fasteners, such as self-tapping screws or other means of fastening such as welding with contact welding. The stud tie track 125 holds the studs 120 securely in the wall panel 150 to prevent movement of the studs 120 during assembly, shipping, and installation of the wall panel 150 . Upon installation of a wall panel 150 , the stud tie track 125 braces the interior flanges and increases the ability of the steel studs 120 to resist torsional forces, thereby improving the structural integrity of the wall panel 150 . In one embodiment, the fasteners or anchor bolts that fasten the steel bottom plate to the foundation fit within the stud tie track 125 .
[0076] In accordance with one aspect of the present invention, an exemplary system and panel includes an integrated fireblocking configuration that suitably permits the use of an exemplary panel 150 method and system in walls in which fireblocking is desired and/or required, including in a multi-floor building. For instance, with reference to FIG. 4 , a side cut away view of integrated fireblocking according to an exemplary embodiment is depicted.
[0077] In accordance with an exemplary embodiment, one or more panels 150 comprising a fireblocking configuration are applicable to a multi-panel 150 assembly such as for use in balloon framing construction. In accordance with another exemplary embodiment, one or more panels 150 comprising a fireblocking configuration are applicable to potential or real gaps in fire protection formed along or through the panel 150 (in any axis, such as vertical or horizontal). For instance, the fireblocking configuration may be applied in the case of a soffit or beam enclosure.
[0078] For example, with reference to FIG. 4 , a side view of a wall system with integrated fireblocking construction is depicted. At or in the near proximity of the location where fireblocking is desired, a first panel 150 portion is configured for joining to a second panel 150 portion. The first panel 150 and second panel 150 portions may comprise a complete panel 150 size or they may comprise less than a complete panel 150 size. In some embodiments, the location where fireblocking is desired is within about 1.5 inches (plus or minus 0.75″) of the bottom of the intersection of a floor to a wall panel 150 (e.g. bottom track 190 ), with the panel 150 oriented in a plane 90 degrees from the axis of the panel 150 construction (as shown).
[0079] This configuration for joining may comprise altering the surface properties of the first panel 150 to mate with a receiving second panel 150 by any suitable configuration, such as by establishing a joint and receiving well (as shown). Alternatively, tongue and groove, rounded, jagged, flat and combinations thereof are contemplated for this joint configuration. Alternatively, fireblocking could be supported by the use of plates, foils, and angles, as appropriate.
[0080] A fire retardant such as one or more spray 450 , coating, caulking, foil tape, elastomeric, or other material may be introduced into the joint and/or applied to one or more joint members. In some embodiments, this spray may be 3M Firedam spray applied to both mating surfaces during manufacture, or field applied, as appropriate. This fire retardant may be applied over the entire joint and/or receiving well surface(s). In some embodiments, a first fire retardant is applied to the first panel 150 edge (e.g. joint) and a second fire retardant is applied to the second panel 150 edge, (e.g. receiving well). In an embodiment, the first and second panel 150 portions are placed in position and the fire retardant is sprayed into a gap between the joint members (first and second panel 150 portions). The gap between joint members may be any suitable distance. In some embodiments, this gap is between about 0.25 inches and about 1.25 inches. In another embodiment, this gap between the joint and the receiving well is about 0.5 inches.
[0081] In another embodiment, insulation is positioned between the joint and receiving well, such as mineral wool batt insulation 410 sandwiched and encapsulated between two metal foil sheets in a continuous roll seam in a manner that the configuration of the joint creates a structural component. Alternatively, a formed steel plate may be fastened to the studs to support the integrated fireblocking. This insulation may improve the acoustic (sound transmission class) and/or fire safety of the wall panel system.
[0082] In various embodiments, a second fire retardant, such as an aluminum foil tape 420 , is applied over the fireblocking joint on the panel face. The second fire retardant may be suitably applied to continuously cover the fireblocking joint on the interior and exterior face of the panel 150 . An exterior layer of sound, vapor, and/or noncombustible cladding 440 , such as a drywall, plasterboard, cement board, gypsum board and/or the like may be applied to either side of the panel 150 , such as by securing to one or more studs 120 . An exterior cladding over flashing 430 may be secured to the exterior layer. In some embodiments, additional layers of vapor, sound and/or fire resistant materials may be coupled between the exterior layer and the exterior cladding over flashing 430 .
[0083] Turning to FIG. 5 , a segmented side cut away view of a fire resistance rated wall panel system is depicted. As shown in the top of FIG. 5 , one surface of a track is secured to a ceiling via a fastener, such as a steel slip channel 510 or steel clip secured by a power driven fastener 520 . A joint surface of a panel 150 (e.g. top edge of the panel) is configured to be secured into the track. Between the track and the top joint surface of the panel 150 a fire retardant, such as one or more spray, coating, caulking, foil tape, elastomeric, or other material may be introduced into the joint and/or applied to the top joint surface and/or the track. This fire retardant may be applied over the entire joint surface. In some embodiments, a first fire retardant is applied to the top joint surface and a second fire retardant is applied to the track. In an embodiment, the panels 150 are placed in position and the fire retardant is sprayed into a gap between the joint members (track and top edge surface). As shown in FIG. 5 , a fire stop spray and/or fire retardant may coat the intersection of the top exterior and interior face of the panel 150 and the track and surrounding surfaces. This fire stop spray and/or fire retardant may expand (and/or in some cases harden) when exposed to high temperature creating an additional structural element and/or enhancing protection from smoke and fire. In various embodiments, a structural element and/or fire retardant may be coupled to the fireblocking configuration disclosed herein and/or surrounding surfaces to further retain the passive fire protection system elements from weakening due to fire, heat, or from instant cooling, impact, and erosion effects of active fire protection, such as from water delivered via fire hose, sprinklers or fire extinguishers. In some embodiments, this coating of fire stop spray and/or fire retardant is applied such that there is at least a 2″ overlap ( FIG. 5 ; Dimension F) at the joint, though overlap can vary. According various embodiments, insulation may be applied to the joint surface, such as mineral wool batt insulation. According various embodiments, the sheathing is replaced by two light gage metal skin panels adhered together, with the inner metal panel coated with an intumescent paint or similar fire resistant coating in order to create a fire resistant wall assembly without the use of gypsum board.
[0084] As shown in the bottom of FIG. 5 , one surface of a track may be secured to a floor via a fastener, such as a steel slip channel or steel clip secured by a power driven fastener 520 (e.g. at bottom track 190 ). A joint surface of a panel is configured to be secured into the track. Between the track and the bottom joint surface of the panel a fire retardant, such as one or more spray, coating, caulking, foil tape, elastomeric, or other material may be introduced into the joint and/or applied to the bottom joint surface and/or the track. This fire retardant may be applied over the entire joint surface. In some embodiments, a first fire retardant is applied to the bottom joint surface and a second fire retardant is applied to the track. In an embodiment, the panels are placed in position and the fire retardant is sprayed into a gap between the joint members (track and bottom edge surface). As shown in FIG. 5 , a fire stop spray and/or fire retardant may coat the intersection of the bottom exterior and interior face of the panel 150 and the track and surrounding surfaces. In some embodiments, this coating of fire stop spray and/or fire retardant is applied such that there is at least a two inch overlap at the joint. In another embodiment, insulation is applied to the joint surface, such as mineral wool batt insulation. A horizontal multipurpose chase with interlocking expanded plug 215 (described in greater detail below) is also depicted in FIG. 5 .
[0085] Cable and/or utility runs have been addressed in a rudimentary fashion by makers of building panels. In accordance with another aspect of the present invention, an exemplary system 100 and panel 150 is configured to provide a utility run (chase/channel 210 ) with precision cut grooves 170 for retaining cables, wires and tubing. In accordance with an exemplary embodiment, an exemplary panel 150 includes a multi-purpose EPS chase 210 with interlocking EPS plug 215 configured to provide compression channels 210 in the panel 150 . The channels 210 are suitably sized to hold low voltage electrical wires, PEX plumbing, and the like. The interlocking EPS plug 215 may be sized to fit in the chase 210 . This plug may increase the thermal efficiency by avoiding a larger thermal short.
[0086] In accordance with an embodiment and with reference to FIG. 6B , a precision cut chase 210 is depicted. This chase 210 may be formed using a computer numerical control (CNC) machine (described in greater detail below). This chase 210 may be formed in any desired axis of the panel. As shown, in various embodiments, the depth of the utility run 210 can be greater than the depth of the studs 120 in the panel so as to prevent the studs 120 from impeding utility runs 210 . Additionally, the chase 210 can be at a depth to facilitate the use of the knockouts in the studs 120 . In various embodiments, the interior surface of the chase 210 is precision cut to comprise one or more channels 212 for securely receiving at least one of a tube (such as PEX plumbing), electrical, data, voice, and/or audio wiring. Stated another way, these channels 212 are integral to the core formed by removing core material. Each channel 212 within the chase 210 may be cut at a pre-selected size to substantially mirror the portion of the exterior of a tube, electrical, data, voice, and/or audio wiring desired to be retained by each channel 212 . These tubes, wires and/or cables may be press fit into place within each channel 212 . Additionally, the disclosed utility chase 210 configuration with an EPS rib separating each component provides shielding between data and electrical wires in the same chase 210 , which may reduce or eliminate the need for mechanical devices to achieve this shielding. Also, eliminating the entanglement of electrical wiring reduces secondary electromagnetic fields caused by crisscrossed wires.
[0087] Each channel 212 may be suitably spaced within the chase 210 such that there is a gap between each tube, wire or cable. Each channel 212 may be marked to assist with installation and coordination of the tubes, wires and/or cables installed therein. Though FIG. 6B depicts 5 individual channels 212 (all of a similar size) within the chase 210 it should be appreciated that any suitable number of channels 212 formed in any suitable respective size may be formed in the chase 210 .
[0088] In according with various embodiments, an interlocking EPS plug 215 may be inserted into the chase 210 . This configuration may provide compression channels 212 in the panel 150 . The interlocking EPS plug 215 fits back in the chase 210 and increases the thermal efficiency by avoiding a larger thermal short. In some embodiments, the plug 215 is formed from a portion of the material removed while cutting the chase 210 from the core material. This method may both minimize waste material and ensure a tight fit in the chase 210 . The plug 215 is shown with a flat or substantially rectangular cross sectional shape, however it should be appreciated that the plug 215 may be cut with surface features to substantially mirror the portion of the exterior of a tube, electrical, data, voice, and/or audio wiring desired to be retained by each channel 212 . The EPS plug 215 may be cut with tabs extending from the side surface such that the extending tabs provide for a securable semi-permanent or permanent pressure fit in the chase 210 . Moreover, the chase 210 may be cut with ridged sidewalls to retain a plug 215 comprising extending tabs (as shown).
[0089] The chase 210 with precision cut channels 212 may be substantially rectangular (as shown) or may be curved (not depicted). Also depicted, in FIGS. 6B-6D a multipurpose chase 210 without precision cut channels 212 may be formed in the panel in any desired axis of the panel 150 . In accordance with an embodiment, this multipurpose chase 210 may be precision cut to any desired shape or diameter in the core. This chase 210 may be formed in any desired axis of the panel 150 . This chase 210 may be a straight run or may be oriented in any desired direction, such as having a bend and run from horizontal to vertical. As shown, in various embodiments, the depth of the utility run (e.g. chase 210 ) is greater than the depth of the studs 120 in the panel 150 so as to prevent the studs 120 from impeding utility runs.
[0090] Also, with reference to FIGS. 6A-6C , precision cut stud grooves 170 , such as hot wire cuts, are depicted. In various embodiments, a hot wire cut may be made in a panel to substantially mirror the exterior surface of a stud 120 , such as a “C” shaped stud 120 in either or both of the X axis (See 610 ) or Y axis (See 620 ) orientations. This hot wire cut may be made by any suitable hot wire cutting tool; however, in an embodiment that achieves the desired precision the hot wire cutting tool is a CNC foam cutting machine with which the operator employs optimal combinations of cutting parameters and methods to achieve tight tolerances around the stud 120 profile. For example, FIG. 6A illustrates a top cut away view of an exemplary wall panel comprising a formed chase (utility run) and a multipurpose chase (utility run) with studs oriented in both the X axis orientation 610 and Y axis orientation 620 . FIG. 6C depicts a top cut away view of an exemplary wall panel comprising a formed chase (utility run) and a multipurpose chase (utility run) with studs oriented in the X axis orientation 610 . FIG. 6B depicts a top cut away view of an exemplary wall panel comprising a formed chase (utility run) and a multipurpose chase (utility run) with studs oriented in the Y axis orientation 620 .
[0091] The CNC foam cutting machine may allow for end-to-end panel design. This end-to-end design is highly automated using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a postprocessor, and then loaded into the CNC machines for production. The complex series of steps needed to produce any panel is highly automated and produces a part that closely matches the original CAD design. For instance, in one embodiment, automated measurements of a room layout via a room measuring device, such as a laser, may be made and transmitted and/or input, directly or indirectly through intervening processing, to the CNC machine for production. Alternatively, a program for automatically producing panel 150 configurations from a CAD design may be automatically translated into the machine code to cut the panels on a CNC machine.
[0092] Principles of the present disclosure may suitably be combined with principles for a panel system and method of manufacture as disclosed in U.S. patent application Ser. No. 12/715,288 filed on Mar. 1, 2010 and entitled, “CONSTRUCTION SYSTEM USING INTERLOCKING PANELS.”
[0093] A C shaped conventional stud 120 is depicted, in part, because it is more commonly used in the industry; however any shape of stud that meets load requirements may be envisioned (in that regard, C-shaped conventional studs may even appear to pose more difficulty to precision fit in grooves due to the small “lip” configuration, but can be readily utilized in accordance with methods and systems disclosed). The studs 120 may be formed, such as with a bending or cold steel forming machine, to proprietary specifications and a precision cut 170 may be made in the panel 150 to substantially mirror these proprietary specifications/tolerances. Moreover, this stud 120 forming machine may by itself, or in combination with another machine, mechanically insert the formed studs 120 into the precision cut grooves.
[0094] In an embodiment, a large block of EPS material may cut into multiple panels 150 by using a specialized hot wire cutting device preprogrammed with specific instructions where cuts should be made. The travel path of the hot wire may be fine-tuned such that minimal waste is created and avoiding a larger thermal short. The hot wire cutting machine may have more than one cutting element to cut multiple panels substantially simultaneously and/or to make multiple cuts in a single panel substantially simultaneously. The hot wire cutting device may travel/make cuts along any desired axis and/or direction. Also the panel 150 being cut may move in any desired axis/direction while being cut.
[0095] As discussed herein, studs 120 may be inserted from the top and/or bottom of the panel 150 retained in the precision cut groove 170 , cut to substantially mirror the exterior and/or interior of the stud 120 . In this fashion multiple panels 150 or core material may be coupled to a single stud 120 . For instance a thirty foot long stud 120 may be used to couple three 10 foot wide sections of core material (panels) together. Similarly, a matrix of sections of core material may be coupled together using channels/grooves 170 and studs 120 in multiple axis. For instance, to create a wall, floor, ceiling, or roof (see FIG. 9A and FIG. 9B ) panels 150 with an EPS core can be created in any length or width up to the length or width of the appropriate stud 120 , and multiple panels 150 may be interlocked using various interlocking edge configurations precision cut in the foam core. Each of FIG. 9A and FIG. 9B depicts a matrix of interlocking panels 150 according to various embodiments.
[0096] As will be appreciated by one of ordinary skill in the art, the system for creating panels 150 and forming precision cuts 170 in panels based upon plans existing only as prints or existing as electronic CAD drawings may be embodied as a method, device for making the cuts, and/or a computer program product. Additionally, a scanning device may scan the profile of a steel stud 120 or steel track or other building component and convert the scanned image to the machine code used by the CNC machine to cut the corresponding groove 170 or other profile in the EPS. Accordingly, the aspects of the present disclosure may take the form of an entirely non-transitory software embodiment, an entirely hardware embodiment, or an embodiment combining aspects of both software and hardware. Furthermore, the present invention may take the form of a computer program product on a non-transitory computer-readable storage medium having computer-readable program code means embodied in the storage medium. Any suitable computer-readable storage medium may be utilized, including hard disks, CD-ROM, optical storage devices, magnetic storage devices, flash card memory and/or the like.
[0097] Historically, building panels exhibited poor thermal, vibration, and acoustic characteristics. In accordance with another aspect of the present disclosure, and with reference to FIG. 7 , an exemplary system and panel 150 is configured for various other acoustical and thermal improvements. For instance, FIG. 7 is a side cut away view of an exemplary wall panel with a split steel track 710 , integrated acoustical sound/fire material, and integrated side air gap 720 for improved thermal, fire, and acoustical properties. In accordance with an exemplary embodiment, a system 100 or panel 150 can comprise a split steel track 710 with integral gasket 730 , such as a foam gasket, configured to create integral sound, vibration, and thermal break at the track. This track may be attachable to a ceiling or a floor. In various embodiments, the track 710 is secured via a power driven fastener 520 through the gasket. A steel runner 530 , steel clip, steel angle 740 or other steel connector, in the case of a floor or ceiling respectively, may be screwed 540 to the track at one or more studs 120 . A continuous bead of sealant 750 (such as acoustical/thennal/joint sealant) may be applied to the joint surface of the panel and the complementary steel track. This sealant may be applied to any joint in the system, such as the joint of the face of the panel and the chase plug. An air gap 720 between a vapor, sound and/or fire barrier and the panel creates a higher sound and vibration rating.
[0098] In accordance with another embodiment, and with reference to FIG. 8 , a corner system 200 is depicted. FIG. 8 depicts a top cut away view of a corner assembly of adjoining wall panels. In this system, an interlocking outside corner steel structural element (stud or other steel support), and an inside corner steel structural element (stud or other steel support) is depicted, as shown, these structural elements may be conventional studs. One or more sections of core material may be precision cut to receive the outside corner and inside corner structural elements.
[0099] The integral corner depicted in FIG. 8 may eliminate the thermal bridging associated with conventional construction. The corner system 200 , comprising an integral corner, also allows for the continuity of horizontal utility chases that are difficult or impossible to facilitate in conventional construction. The corner system 200 , comprising an integral corner also creates a uni-directional shear connection not created in conventional corner construction methods. This corner system 200 , comprising an integral corner, may also eliminate voids and leaks and to combat a building thermal envelope being compromised as it is in conventional construction methods.
[0100] FIG. 8 also depicts a precision cut integral interlocking EPS joint 810 . This joint and receiving well does not require secondary fasteners to couple a first panel 150 and a second panel 150 together. In various embodiments, an edge of a first panel 150 is fashioned with a precision cut 170 joint configuration and a second panel 150 is fashioned with a precision cut receiving well sized to substantially mirror the outer surface of the joint such that the two panels 150 may be pressure fit together. Though not necessary, retaining elements may be fashioned on the receiving well and/or the joint surface to securely hold the two panels 150 together.
[0101] According to various embodiments, FIGS. 10A-10D depict a lateral transfer plate 960 . The lateral transfer plate 960 may be fashioned with punched stud attachment tab 970 corresponding with stud 930 profile penetrations 920 . The tabs 970 may be integrally formed and punched and/or cut from a flat surface of the lateral transfer plate 960 substantially perpendicular to the orientation of length of stud 930 . For instance, the tabs 970 may be formed by cutting two (or three in the case of a lateral transfer plate 960 having a flange) sides of a rectangle from the lateral transfer plate 960 . The tab 970 may then be bent approximately 90 degrees along the remaining edge of the rectangle. Tab 970 may be formed from a recess configured to accept a stud 930 and/or from any flat surface of the lateral transfer plate 960 .
[0102] The stud attachment tabs 970 may mirror and/or be substantially the same dimensions as the profile penetrations 920 . According to various embodiments the stud attachment tabs 970 may be smaller than the profile penetrations 920 . The stud attachment tabs 970 may be cut into any desired shape, but as shown in FIGS. 10A-15B , are generally rectangular. As variously depicted by the figures, the stud attachment tabs 970 may be fastened to the web of the stud (with renewed reference to FIGS. 10A-10B ), the flange of the stud (with brief reference to FIGS. 12 A- 12 B)., or tabs can be punched/cut so that there is a tab for each of the web and the flange of the stud 930 (with brief reference to FIGS. 16A-16B ).
[0103] The height of the stud attachment tab 970 may be approximately equivalent to the width of profile penetrations 920 and/or the width of stud 930 . The width of the stud attachment tab 970 is approximately equivalent to the depth of profile penetrations 920 and/or the width of stud 930 . As depicted in FIGS. 10A-10D , tab 970 may be fastened to the stud 930 as desired. The tabs 970 may be fastened to the studs 930 with screws, rivets, contact welding, or with adhesive tape, such as 3M VHB tape.
[0104] A thermal isolator may be positioned between the tab 970 and the stud 930 . The thermal isolator may be configured to lessen the thermal transfer from the lateral transfer plate 960 to the studs 930 . The thermal isolator may be any desired dimension. For instance, the thermal isolator may be less than or equal to about 1 / 8 ″ thick. The thermal isolator between the tab 970 and the stud 930 is configured to provide a break in the metal to metal thermal path. From a thermal perspective, the lateral transfer plate 960 is configured to lessen thermal transfer from one side to the other. For instance, lateral transfer plate 960 introduces discontinuities configured to interrupt what was formerly a continuous metal path through the wall in conventional framing systems. Stated another way, the design of lateral transfer plate 960 is configured to impede efficient thermal transport through lateral transfer plate 960 .
[0105] Strapping, such as continuous metal strapping 940 , may be applied in the field, as desired. For instance, and with reference to FIGS. 10 E and 1 OF a lateral transfer plate 960 may be coupled to an adjacent lateral transfer plate 960 with a short length of metal strapping that overlaps the flange of each lateral transfer plate 960 and is screwed into each adjacent flange. The metal strapping that may be field applied may extend the entire length of the wall until an opening is reached, corner, or the end of the wall for a flangeless lateral transfer plate 960 (as depicted in FIG. 10F ). With the flangeless lateral transfer plate 960 , the practice of tying a first lateral transfer plate 960 to an adjacent lateral transfer plate 960 may be obviated.
[0106] According to various embodiments, FIGS. 11A-11B depict a lateral transfer plate 960 comprising a flange 1065 . Stud attachment tab 1070 may be punched forming an aperture 1020 bounded on three side by the lateral transfer plate 960 and on one side by flange 1065 . As previously described, flange 1065 may be coupled to the stud 930 and/or tab 1070 may be coupled to the stud 930 .
[0107] According to various embodiments, FIGS. 12A-12B depict a lateral transfer plate 960 comprising a stud attachment tab 1170 . Attachment tab 1170 may be configured to be attached to the web 935 of the stud 930 . The tabs 1170 may be cut such that the resultant tab 1170 extends past the stud 930 to (or past) the centerline of the lateral transfer plate 960 . In this way, the loads on the studs 930 and lateral transfer plate 960 may be transferred appropriately. As used herein, the centerline runs in the X direction and generally bisects the lateral transfer plate 960 in Y direction. Attachment tab 1170 may be any desired height. For instance, attachment tab 1170 may be equivalent to the depth of the cut out 1120 and or the width of stud 930 . According to various embodiments, the height of attachment tab 1170 may be less than the depth of the cut out 1120 and or the width of stud 930 .
[0108] According to various embodiments, FIGS. 13A-13B depict a lateral transfer plate 960 comprising a plurality of stud attachment tabs 1270 and 1275 configured to be attached to each stud 930 . As previously mentioned, studs 930 may be oriented in both the X axis orientation and Y axis orientation. For instance, as compared with FIGS. 12A and 12B the orientation of studs 930 of FIGS. 13A-13B are rotated 90 degrees. Attachment tabs 1270 and 1275 may be configured to be attached to two sides (such as the flanges) of each stud 930 . Attachment tab 1170 may be any desired height. For instance, the height of attachment tab 1270 and 1275 may be equivalent to the one half the width of recess 1120 and or the width of stud 930 . According to various embodiments, the height of attachment tab 1270 and 1275 may be less one half the width of recess 1120 and or the width of stud 930 .
[0109] According to various embodiments, FIGS. 14A-14B depict a lateral transfer plate 960 comprising a flange 1065 . Stud attachment tab 1370 may be punched forming an aperture 1325 bounded on three side by the lateral transfer plate 960 and on one side by flange 1370 . Stud attachment tab 1370 may be punched forming a recess 1320 bounded on three side by lateral transfer plate 960 .
[0110] According to various embodiments, FIGS. 15A-15B depict a lateral transfer plate 960 comprising a stud attachment tab 1470 . Stud attachment tab 1470 may be formed as part punch/cutting two sides of lateral transfer plate 960 to form recess 1420 . According to various embodiments, FIGS. 16A-16B depict a lateral transfer plate 960 comprising a stud attachment tab 1570 and 1575 . Attachment tabs 1570 and 1575 may be oriented along different planes and configured to be coupled to two surfaces of stud 930 , such as both the web and the flange of stud 930 . In this way, multiple attachment tabs 1570 and 1575 may be formed from a single punched recess 1520 .
[0111] According to various embodiments, a wall is the foam is recessed about 2.5″ on an interior side to provide a space for electrical distribution without having to make any cuts in the foam. For instance, an approximately 8″ wall, with about 5½″ of foam and about 2½″ of space for service distribution may be created. In this wall, the lateral transfer plate 960 may be any desired width, but may desirably be about 8″ wide. In this way, lateral transfer plate 960 may extend over and cover the service distribution space. The lateral transfer plate 960 may be configured for draftstopping and/or fireblocking applications. Components may be coupled to each lateral transfer plate 960 , in certain applications, to improve its fire resistance/draft resistance. The lateral transfer plate 960 may be configured to provide a vertical barrier in the wall. Lateral transfer plate 960 may comprise penetrations for vertical runs of conduit, as desired.
[0112] The present disclosure sets forth exemplary methods and systems for providing building panels with improved structural, thermal, acoustic, and fire-blocking characteristics. It will be understood that the foregoing description is of exemplary embodiments of the disclosure, and that the systems and methods described herein are not limited to the specific forms shown. Various modifications may be made in the design and arrangement of the elements set forth herein without departing from the scope of the disclosure. For example, the various components and devices can be connected together in various manners in addition to those illustrated in the exemplary embodiments, and the various steps can be conducted in different orders. These and other changes or modifications are intended to be included within the scope of the present disclosure. Accordingly, the specification is to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present disclosure. Likewise, benefits, other advantages, and solutions to problems have been described above with regard to various embodiments. However, benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the statements. As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Also, as used herein, the terms “coupled,” “coupling,” or any other variation thereof, are intended to cover a physical connection, an electrical connection, a magnetic connection, an optical connection, a communicative connection, a functional connection, and/or any other connection. Still further, as used herein, the term “about” shall mean within +/−25% of a number, unless stated otherwise. When language similar to “at least one of A, B, or C” is used in the statements, the phrase is intended to mean any of the following: (1) at least one of A; (2) at least one of B; (3) at least one of C; (4) at least one of A and at least one of B; (5) at least one of B and at least one of C; (6) at least one of A and at least one of C; or (7) at least one of A, at least one of B, and at least one of C.
[0113] In the description herein, references to “various embodiments”, “various aspects”, “an aspect”, “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.
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The present disclosure relates to prefabricated building panels for use in structures, and walls external to structures, such as outdoor privacy walls and the like. More particularly, the present disclosure relates to a method and system for providing building panels that provide improved structural integrity, distribute loads, thermal performance, among other attributes using conventional framing members.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority to, and incorporates by reference herein in its entirety, pending U.S. Provisional Patent Application Ser. No. 60/497,782, filed 26 Aug. 2003.
BACKGROUND
Industrial automation has increased in scope and refinement with time. In general, industrial automation has focused on continuous processes comprising a plurality of interacting machines. Heretofore, automation has not fully developed using automation for process improvement relating to production and/or reliability related to discrete machines in certain applications.
United States Patent Application No. 20030120472 (Lind), which is incorporated by reference herein in its entirety, allegedly cites a “process for simulating one or more components for a user is disclosed. The process may include creating an engineering model of a component, receiving selection data for configuring the component from a user, and creating a web-based model of the component based on the selection data and the engineering model. Further, the process may include performing a simulation of the web-based model in a simulation environment and providing, to the user, feedback data reflecting characteristics of the web-based model during the simulation.” See Abstract.
United States Patent Application No. 20020059320 (Tamaru), which is incorporated by reference herein in its entirety, allegedly cites a “plurality of work machines is connected by first communication device such that reciprocal communications are possible. One or a plurality of main work machines out of the plurality of work machines are connected to a server by second communication device such that reciprocal communications are possible. Each work machine is provided with work machine information detection device for detecting work machine information. The server is provided with a database which stores data for managing the work machines, and management information production device for producing management information based on the work machine information and on data stored in the database. In conjunction with the progress of work by the plurality of work machines, work machine information is detected by the work machine information detection device provided in the work machines, and that detected work machine information is transmitted to the main work machine via the first communication device. The main work machine transmits the transmitted work machine information to the server via the second communication device. The server produces management information, based on the transmitted work machine information and on data stored in the database, and transmits that management information so produced to the main work machine via the second communication device. The main work machine manages the work machines based on the management information so transmitted.” See Abstract.
SUMMARY
Certain exemplary embodiments can comprise obtaining and analyzing data from at least one discrete machine, automatically determining relationships related to the data, taking corrective action to improve machine operation and/or maintenance, automatically and heuristically predicting a failure associated with the machine and/or recommending preventative maintenance in advance of the failure, and/or automating and analyzing mining shovels, etc.
Certain exemplary embodiments comprise a method comprising at a remote server, receiving representative data obtained from a set of sensors associated with a machine, said representative data transmitted responsive to a transmission rate selected by a wirelessly receiving user; and storing said received representative data in a memory device.
Certain exemplary embodiments comprise a method comprising at an information device, receiving representative data from a memory device, said representative data generated by a set of sensors associated with a machine, said representative data transmitted responsive to a transmission rate selected by a wirelessly receiving user; and rendering at least one report responsive to said representative data.
Certain exemplary embodiments comprise receiving a plurality of values for a plurality of machine variables associated with one or more machine components; analyzing at least two variables from the plurality of machine variables, to determine a performance of the one or more machine components; and rendering a report that indicates the determined performance of the machine components
BRIEF DESCRIPTION OF THE DRAWINGS
A wide variety of potential embodiments will be more readily understood through the following detailed description, with reference to the accompanying drawings in which:
FIG. 1 is a block diagram of an exemplary embodiment of a machine data management system 1000 ;
FIG. 2 is a flow diagram of an exemplary embodiment of a machine data management method 2000 ;
FIG. 3 is a flow diagram of an exemplary embodiment of a machine data management method 3000 ;
FIG. 4 is a block diagram of an exemplary embodiment of an information device 4000 ;
FIGS. 5 a , 5 b , and 5 c are an exemplary embodiment of a partial log file layout for data associated with a mining shovel;
FIG. 6 is an exemplary user interface showing a graphical trend chart of electrical data for a crowd motor of a mining shovel;
FIG. 7 is an exemplary user interface showing a graphical rendering of gauges displaying electrical data of a crowd motor of a mining shovel;
FIG. 8 is an exemplary user interface showing a relationship between speed and torque of a crowd motor of a mining shovel;
FIG. 9 is an exemplary user interface showing a graphical rendering of gauges displaying temperatures related to a mining shovel crowd;
FIG. 10 is an exemplary user interface showing information related to driver operation of a mining shovel;
FIG. 11 is an exemplary user interface showing a graphical trend chart of electrical data for a hoist motor of a mining shovel;
FIG. 12 is an exemplary user interface showing a graphical rendering of gauges displaying electrical data for a hoist motor of a mining shovel;
FIG. 13 is an exemplary user interface showing a relationship between speed and torque of a hoist motor of a mining shovel;
FIG. 14 is an exemplary user interface showing a graphical rendering of gauges displaying temperatures related to a mining shovel hoist;
FIG. 15 is an exemplary user interface showing a graphical trend chart of electrical data related to a mining shovel;
FIG. 16 is an exemplary user interface showing information related to mining shovel operations;
FIG. 17 is an exemplary user interface showing position information related to a mining shovel;
FIG. 18 is an exemplary user interface showing a graphical rendering of gauges displaying pressures of mining shovel components;
FIG. 19 is an exemplary user interface showing a graphical rendering of gauges displaying temperatures of mining shovel components;
FIG. 20 is an exemplary user interface showing a graphical rendering of gauges displaying electrical data of hoist, crowd, and swing motors of a mining shovel;
FIG. 21 is an exemplary user interface showing a graphical trend chart of motion data related to a mining shovel;
FIG. 22 is an exemplary user interface showing a graphical trend chart of production data related to a mining shovel;
FIG. 23 is an exemplary user interface showing a graphical rendering of gauges displaying production data of a mining shovel;
FIG. 24 is an exemplary user interface providing operating statuses of mining shovel components;
FIG. 25 is an exemplary user interface showing a graphical trend chart of electrical data for a swing motor of a mining shovel;
FIG. 26 is an exemplary user interface showing a graphical rendering of gauges displaying electrical data for a swing motor of a mining shovel;
FIG. 27 is an exemplary user interface showing a relationship between speed and torque of a swing motor of a mining shovel; and
FIG. 28 is an exemplary user interface showing a graphical rendering of gauges displaying temperatures related to a mining shovel swing.
DEFINITIONS
When the following terms are used herein, the accompanying definitions apply:
Active X—a set of technologies developed by Microsoft Corp. of Redmond, Wash. Active X technologies are adapted to allow software components to interact with one another in a networked environment, such as the Internet. Active X controls can be automatically downloaded and executed by a Web browser. activity—performance of a function. analogous—logically representative of and/or similar to. analysis—evaluation. automatic—performed via an information device in a manner essentially independent of influence or control by a user. communicate—to exchange information. communicative coupling—linking in a manner that facilitates communications. component—a part. condition—existing circumstance. connection—a physical and/or logical link between two or more points in a system. For example, a wire, an optical fiber, a wireless link, and/or a virtual circuit, etc. correlating—mathematically determining relationships between two or more non-time variables. For example, correlating can comprise a gamma association calculation, Pearson association calculation, tests of significance, linear regression, multiple linear regression, polynomial regression, non-linear regression, partial correlation, semi-partial correlation multicollinearity, suppression, trend analysis, curvilinear regression, exponential regression, cross-validation, logistic regression, canonical analysis, factor analysis, and/or analysis of variance techniques, etc. cycle time—a time period associated with loading a haulage machine with an electric mining shovel. data—numbers, characters, symbols etc., that have no “knowledge level” meaning. Rules for composing data are “syntax” rules. Data handling can be automated. database—one or more structured sets of persistent data, usually associated with software to update and query the data. A simple database might be a single file containing many records, each of which is structured using the same set of fields. A database can comprise a map wherein various identifiers are organized according to various factors, such as identity, physical location, location on a network, function, etc. detect—sense or perceive. determine—ascertain. deviation—a variation relative to a standard, expected value, and/or expected range of values. digging—excavating and/or scooping. dispatch data—information associated with scheduling personnel and/or machinery. dispatcher—a person, group of personnel, and/or software assigned to schedule personnel and/or machinery. For example, a dispatcher can schedule haulage machines to serve a particular electric mining shovel. earthen—related to the earth. electrical—pertaining to electricity. electrical component—a device and/or system associated with a machine using, switching, and/or transporting electricity. An electrical component can be an electric motor, transformer, starter, silicon controlled rectifier, variable frequency controller, conductive wire, electrical breaker, fuse, switch, electrical receptacle, bus, and/or transmission cable, etc. electrical performance—performance related to an electrical component of a machine. For example, electrical performance can relate to a power supply, power consumption, current flow, energy consumption, electric motor functionality, speed controller, starter, motor-generator set, and/or electrical wiring, etc. electric mining shovel—an electrically-powered device adapted to dig, hold, and/or move earthen materials. electric mining shovel component—a part of an electric mining shovel. A part of an electric mining shovel can be a stick, a mast, a cab, a track, a bucket, a pulley, a hoist, and/or a motor-generator set, etc. electric mining shovel system—a plurality of components comprising an electric mining shovel. An electric mining shovel system can comprise an electric mining shovel, electric mining shovel operator, dispatch entity, mine in which the electric mining shovel digs, and/or material haulage machine (e.g. a mine haul truck), etc. electrical—pertaining to electricity. electrical variable—a sensed reading relating to an electrical component. For example, an electrical power measurement, an electrical voltage measurement, an electrical torque measurement, an electrical motor speed measurement, an electrical rotor current measurement, and/or an electrical transformer temperature measurement, etc. environmental variable—a variable concerning a situation around a machine. For example, in the case of an electric mining shovel, an environmental variable can be a condition of material under excavation, weather condition, and/or condition of an electrical power supply line, etc. equipment scheduling information—data associated with a plan for machinery such as locating, operating, storing, and/or maintaining, etc. expected—anticipated. export—to send and/or transform data from a first format to a second format. failed component—a part no longer capable of functioning according to design. failure—a cessation of proper functioning or performance. format—an arrangement of data for storage or display. generate—produce. graphical—a pictorial and/or charted representation. heuristic rule—an empirical rule based upon experience, a simplification, and/or an educated guess that reduces and/or limits the search for solutions in domains that can be difficult and/or poorly understood. hoist—a system comprising motor adapted to at least vertically move a bucket of a mining shovel. identification—evidence of identity; something that identifies a person or thing. inactive—idle. initialization file—a file comprising information identifying a machine and the transmission of sensor data from the machine. information—data that has been organized to express concepts. It is generally possible to automate certain tasks involving the management, organization, transformation, and/or presentation of information. information device—any general purpose and/or special purpose computer, such as a personal computer, video game system (e.g., PlayStation, Nintendo Gameboy, X-Box, etc.), workstation, server, minicomputer, mainframe, supercomputer, computer terminal, laptop, wearable computer, and/or Personal Digital Assistant (PDA), mobile terminal, Bluetooth device, communicator, “smart” phone (such as a Handspring Treo-like device), messaging service (e.g., Blackberry) receiver, pager, facsimile, cellular telephone, a traditional telephone, telephonic device, a programmed microprocessor or microcontroller and/or peripheral integrated circuit elements, an ASIC or other integrated circuit, a hardware electronic logic circuit such as a discrete element circuit, and/or a programmable logic device such as a PLD, PLA, FPGA, or PAL, or the like, etc. In general any device on which resides a finite state machine capable of implementing at least a portion of a method, structure, and/or or graphical user interface described herein may be used as an information device. An information device can include well-known components such as one or more network interfaces, one or more processors, one or more memories containing instructions, and/or one or more input/output (I/O) devices, etc. Input/Output (I/O) device—the input/output (I/O) device of the information device can be any sensory-oriented input and/or output device, such as an audio, visual, haptic, olfactory, and/or taste-oriented device, including, for example, a monitor, display, projector, overhead display, keyboard, keypad, mouse, trackball, joystick, gamepad, wheel, touchpad, touch panel, pointing device, microphone, speaker, video camera, camera, scanner, printer, haptic device, vibrator, tactile simulator, and/or tactile pad, potentially including a port to which an I/O device can be attached or connected. load—an amount of mined earthen material associated with a bucket and/or truck, etc. load cycle—a time interval beginning when a mine shovel digs earthen material and ending when a bucket of the mining shovel is emptied into a haulage machine. log file—an organized record of information and/or events. machine performance variable—a property associated with an activity of a machine. For example, in the case of an electric mining shovel, a machine performance variable can be machine position, tons loaded per bucket, tons loaded per truck, tons loaded per time period, trucks loaded per time period, machine downtime, electrical downtime, and/or mechanical downtime, etc. Machine Search Language engine—machine readable instructions adapted to query information stored in an organized manner. For example, a machine search language engine can search information stored in a database. maintenance—an activity relating to restoring and/or preserving performance of a device and/or system. maintenance activity—an activity relating to restoring and/or preserving performance of a device and/or system. maintenance entity—a person and/or information device adapted restore and/or preserve performance associated with a device or system. management entity—a person and/or information device adapted to handle, supervise, control, direct, and/or govern activities associated with a machine. material—any substance that can be excavated and/or scooped. maximum acceptable value—a greatest amount in a predetermined range. measurement—a value of a variable, the value determined by manual and/or automatic observation. mechanical component—a device and/or system associated with a machine that is not primarily associated with using, switching, and/or transporting electricity. A mechanical component can be a bearing, cable, cable reel, gear, track pad, sprocket, chain, shaft, pump casing, gearbox, lubrication system, drum, brake, wear pad, bucket, bucket tooth, cable, and/or power transmission coupling, etc. mechanical performance—performance related to a mechanical component or system. For example, mechanical performance can relate to a bearing, gearbox, lubrication system, drum, brake, wear pad, bucket, bucket tooth, cable, power transmission coupling, and/or pump, etc. mechanical variable—a sensed reading relating to a mechanical component. For example, a bearing temperature measurement, an air pressure measurement, machine load reactions, and/or lubrication system pressure measurements, etc. memory device—any device capable of storing analog or digital information, for example, a non-volatile memory, volatile memory, Random Access Memory, RAM, Read Only Memory, ROM, flash memory, magnetic media, a hard disk, a floppy disk, a magnetic tape, an optical media, an optical disk, a compact disk, a CD, a digital versatile disk, a DVD, and/or a raid array, etc. The memory device can be coupled to a processor and can store instructions adapted to be executed by the processor according to an embodiment disclosed herein. metric—a measurement, deviation, and/or calculated value related to a measurement and/or deviation, etc. Microsoft Access format—information formatted according to a standard associated with the Microsoft Corp. of Redmond, Wash. Microsoft Excel format—information formatted according to a standard associated with the Microsoft Corp. of Redmond, Wash. mine—a site from which earthen materials can be extracted. mine dispatch entity—a person and/or information device adapted to monitor, schedule, and/or control activities and/or personnel associated with an earthen materials extraction operation. mine dispatcher—an entity performing scheduling and/or monitoring of equipment and/or personnel in an earthen materials extraction operation. mine dispatch system—a collection of mechanisms, devices, instructions, and/or personnel adapted to schedule and/or monitor equipment and/or personnel in an earthen materials extraction operation. minimum acceptable value—a smallest amount in a predetermined range. min/max pointer—a graphical rendering of a low and high operating range of a process variable associated with the electric mining shovel. motion gauge—a graphical rendering of a gauge associated with an electrical mining shovel. motion strip chart—a graphical rendering of a stream of process data displayed as a function of time. motion XY plot—a graphical rendering of a stream of process data displayed as a function of a non-time variable. non-binary—represented by more than two values. For example, a weight of 45 tons is non-binary; by contrast, a value, such as zero, representing a machine in an off state can be binary if an on state is solely represented by a different single value. non-digging activities—activities not involving excavating or scooping. For example, in the case of an electric mining shovel, non-digging can comprise bank cleanup, scraping, operator training, and/or repositioning an electrical cable, etc. non-load—not related to a load or quantity of material. non-positional—not related to a physical location. notify—to advise and/or remind. operational variable—a variable related to operating a machine. For example, an operation variable can be a technique used by an operator to accomplish a task with a first machine (e.g. a path used to lift a load in an electric mining shovel bucket), technique of an operator of a second machine used in conjunction with the first machine (e.g. how a mine haul truck spots relative to the electric mining shovel), practice of scheduling machines and/or personnel by a machine dispatch entity, number of second machines assigned in conjunction with the first machine, characteristics of second machines assigned in conjunction with the first machine (e.g. size, load capacity, dimensions, brand, and/or horsepower, etc.), production time period length, operator rest break length, scheduled production time for the machine, a cycle time, and/or a material weight, etc. operator—one observing and/or controlling a machine or device. pan—to move a rendering to follow an object or create a panoramic effect. panel—a surface containing switches and dials and meters for controlling a device. part—component. performance—an assessment. Performance can be measured by a characteristic related to an activity. position—location relative to a reference point. predetermined standard—a value and/or range established in advance. processor—a hardware, firmware, and/or software machine and/or virtual machine comprising a set of machine-readable instructions adaptable to perform a specific task. A processor acts upon information by manipulating, analyzing, modifying, converting, transmitting the information to another processor or an information device, and/or routing the information to an output device. production data—information indicative of a measure relating to an activity involving operation of a machine. For example, bucket load weight, truck load weight, last truck load weight, total weight during a defined production time period, operator reaction, and/or cycle timer associated with the electric mining shovel, etc. propelled motion—a linear and/or curvilinear movement of a machine from a first point to a second point. query—obtain information from a database responsive to a structured request. real-time—substantially contemporaneous to a current time. For example, a real-time transmission of information can be initiated and/or completed within about 120, 60, 30, 15, 10, 5, and/or 2, etc. seconds of receiving a request for the information. remote—in a distinctly different location. rendered—made perceptible to a human. For example data, commands, text, graphics, audio, video, animation, and/or hyperlinks, etc. can be rendered. Rendering can be via any visual and/or audio means, such as via a display, a monitor, electric paper, an ocular implant, a speaker, and/or a cochlear implant, etc. report—a presentation of information in a predetermined format. representative data—a plurality of measurement data associated with defined times. For example, representative data can be a plurality of readings from sensor taken over a time period. reset—a control adapted to clear and/or change a threshold. save—retain data in a memory device. schedule—plan for performing work. schematic model—a logical rendering representative of a device and/or system. search—a thorough examination or investigation. search control—one or more sets of machine readable instructions adapted to query a database in a predetermined manner responsive to a user selection. select—choose. sensor—a device adapted to measure a property. For example, a sensor can measure pressure, temperature, flow, mass, heat, light, sound, humidity, proximity, position, velocity, vibration, voltage, current, capacitance, resistance, inductance, and/or electromagnetic radiation, etc. server—an information device and/or software that provides some service for other connected information devices via a network. shovel motion control variable—a sensed reading relating to motion control in a mining shovel. For example, a hoist rope length, a stick extension, and/or a swing angle, etc. source—an origin of data. For example, a source can be a sensor, wireless transceiver, memory device, information device, and/or user, etc. statistical metric—a calculated value related to a plurality of data points. Examples include an average, mean, median, mode, minimum, maximum, integral, local minimum, weighted average, standard deviation, variance, control chart range, statistical analysis of variance parameter, statistical hypothesis testing value, and/or a deviation from a standard value, etc. status—information relating to a descriptive characteristic of a device and or system. For example, a status can be on, off, and/or in fault, etc. store—save information on a memory device. subset—a portion of a plurality. time period—an interval of time. transmit—send a signal. A signal can be sent, for example, via a wire or a wireless medium. transmission rate—a rate associated with a sampling and/or transfer of data, and not a modulation frequency. Units can be, for example, bits per second, symbols per second, and/or samples per second. user—a person interfacing with an information device. user interface—any device for rendering information to a user and/or requesting information from the user. A user interface includes at least one of textual, graphical, audio, video, animation, and/or haptic elements. user selected—stated, provided, and/or determined by a user. validate—to establish the soundness of, e.g. to determine whether a communications link is operational. value—an assigned or calculated numerical quantity. variable—a property capable of assuming any of an associated set of values. velocity—speed. visualize—to make visible. visually-renderable—adapted to be rendered on a visual means such as a display, monitor, paper, and/or electric paper, etc. wireless—any means to transmit a signal that does not require the use of a wire connecting a transmitter and a receiver, such as radio waves, electromagnetic signals at any frequency, lasers, microwaves, etc., but excluding purely visual signaling, such as semaphore, smoke signals, sign language, etc. wirelessly receiving user—a user that acquires, directly or indirectly, wirelessly transmitted information. wireless transmitter—a device adapted to transfer a signal from a source to a destination without the use of wires. zoom—magnify a rendering.
DETAILED DESCRIPTION
FIG. 1 is a block diagram of an exemplary embodiment of a machine data management system 1000 . Machine data management system 1000 can comprise a machine 1100 . In certain exemplary embodiments, machine 1100 can be a mining shovel such as an electric mining shovel, blast hole drill, truck, locomotive, automobile, front end loader, bucket wheel excavator, pump, fan, compressor, and/or industrial process machine, etc. Machine 1100 can be powered by one or more diesel engines, gasoline engines, and/or electric motors, etc.
Machine 1100 can comprise a plurality of sensors 1120 , 1130 , 1140 . Any of sensors 1120 , 1130 , 1140 can measure, for example: time, pressure, temperature, flow, mass, heat, flux, light, sound, humidity, proximity, position, velocity, acceleration, vibration, voltage, current, capacitance, resistance, inductance, and/or electromagnetic radiation, etc., and/or a change of any of those properties with respect to time, position, area, etc. Sensors 1120 , 1130 , 1140 can provide information at a data rate and/or frequency of, for example, between 0.1 and 500 readings per second, including all subranges and all values therebetween, such as for example, 100, 88, 61, 49, 23, 1, 0.5, and/or 0.1, etc. readings per second. Any of sensors 1120 , 1130 , 1140 can be communicatively coupled to an information device 1160 .
Information obtained from sensors 1120 , 1130 , 1140 related to machine 1100 can be analyzed while machine 1100 is operating. Information from 1120 , 1130 , 1140 can relate to performance of at least one of the measurable parts of the electrical system, performance of at least one of the measurable parts of the mechanical system, performance of one or more operators, and/or performance of one or more dispatch entities associated with machine 1100 , etc.
The dispatch entity can be associated with a dispatch system. The dispatch system can be an information system associated with the machine. The dispatch system can collect data from many diverse machines and formulate reports of production associated with machine 1100 , personnel and/or management entities associated with the production, a location receiving the production, and/or production movement times, etc. Certain exemplary embodiments can collect information related to machine 1100 through operator input codes. Information device 1160 can comprise a user interface 1170 and/or a user program 1180 . User program 1180 can, for example, be adapted to obtain, store, and/or accumulate information related to machine 1100 . For example, user program 1180 can store, process, calculate, and/or analyze information provided by sensors 1120 , 1130 , 1140 as machine 1100 operates and/or functions, etc. User interface 1170 can be adapted to receive user input and/or render output to a user, such as information provided by and/or derived from sensors 1120 , 1130 , 1140 as machine 1100 operates and/or functions, etc.
Information device 1160 can be adapted to process information related to any of sensors 1120 , 1130 , 1140 . For example, information device 1160 can detect and/or anticipate a problem related to machine 1100 . Information device 1160 can be adapted to notify a user with information regarding machine 1100 .
Any of sensors 1120 , 1130 , 1140 , and/or information device 1160 can be communicatively coupled to a wireless transmitter and/or transceiver 1150 . Wireless transceiver 1150 can be adapted to communicate data related to machine 1100 to a second wireless receiver and/or transceiver 1200 . Data related to machine 1100 can comprise electrical measurements and/or variables such as voltages, currents, resistances, and/or inductances, etc.; mechanical measurements and/or variables such as torques, shaft speeds, and/or accelerations, etc.; temperature measurements and/or variables such as from a motor, bearing, and/or transformer, etc.; pressure measurements and/or variables such as air and/or lubrication pressures; production data and/or variables (e.g. weight and/or load related data) such as dipper load, truck load, last truck load, shift total weight; and/or time measurements; motion control measurements and/or variables such as, for certain movable machine components, power, torque, speed, and/or rotor currents; etc.
A network 1300 can communicatively couple wireless transceiver 1200 to devices such as an information device 1500 and/or a server 1400 . Server 1400 can be adapted to receive information transmitted from machine 1100 via wireless transceiver 1150 and wireless transceiver 1200 . Server 1400 can be communicatively coupled to a memory device 1600 . Memory device 1600 can be adapted to store information from machine 1100 . Memory device 1600 can store information, for example, in a format compatible with a database standard such as XML, Microsoft SQL, Microsoft Access, MySQL, Oracle, FileMaker, Sybase, and/or DB2, etc.
Server 1400 can comprise an input processor 1425 and a storage processor 1450 . Input processor 1425 can be adapted to receive representative data, such as data generated by sensors 1120 , 1130 , 1140 , from wireless transceiver 1200 . The representative data can be transmitted responsive to a transmission rate selected by a wirelessly receiving user. Storage processor 1450 can be adapted to store representative data generated from sensors 1120 , 1130 , 1140 on memory device 1600 .
Information device 1500 can be adapted to obtain and/or receive information from server 1400 related to machine 1100 . Information device 1500 can comprise a user interface 1560 and/or a client program 1540 . Client program 1540 can, for example, be adapted to obtain and/or accumulate information related to operating and/or maintaining machine 1100 . Client program 1540 can be adapted to notify a user via user interface 1560 with information indicative of a current or pending failure related to machine 1100 . Information device 1500 can communicate with machine 1100 via wireless transceiver 1200 and wireless transceiver 1150 . Information device 1500 can notify and/or render information for the user via user interface 1520 .
Information device 1500 can comprise an input processor 1525 and a report processor 1575 . In certain exemplary embodiments, input processor 1525 can be adapted to receive representative data, such as data generated by and/or derived from sensors 1120 , 1130 , 1140 . The representative data can be transmitted responsive to a data transmission rate selected by a wirelessly receiving user. Report processor 1575 can be adapted to render at least one report responsive to received and/or representative data, such as data obtained from, for example, memory device 1600 .
FIG. 2 is a flow diagram of an exemplary embodiment of a data management method 2000 for a machine. Data management method 2000 can be used for reporting, improving, optimizing, predicting, and/or analyzing operations related to activities such as mining, driving, and/or manufacturing, etc. At activity 2100 , data can be received at an information device associated with the machine. In certain exemplary embodiments, the information device can be local to the machine. The information device can be adapted to store, process, filter, correlate, transform, compress, analyze, report, render, and/or transfer the data to a first wireless transceiver, etc.
In certain exemplary embodiments, the information device can be remote from the machine. The information device can receive data transmitted via a first wireless transceiver associated with the machine and a second wireless transceiver remote from the machine. The information device can be adapted to receive the data indirectly via a memory device. The information device can be adapted to integrate information from a plurality of sources into a database. Integrating information can comprise associating data values from a plurality of sources to a common timeclock.
In certain exemplary embodiments the data can comprise an initialization file. The initialization file can be transmitted to and/or received by a server that can be remote from the machine. The initialization file can comprise identification information related to the machine. The initialization file can comprise, for example, a moniker associated with the machine, a type of the machine, an address of the machine, information related to the transmission rate of data originating at the machine, transmission scan interval, log directory, time of day to start a log file, and/or information identifying the order in which data is sent and/or identification information relating to sensors associated with the machine from which data originates.
In certain exemplary embodiments, data can be received from a machine dispatch entity that can comprise information related to the actions of a machine dispatcher, haulage machines associated with an excavation machine, equipment scheduling, personnel scheduling, maintenance schedules, historical production data, and/or production objectives, etc.
At activity 2200 , the data can be transmitted. The data can be transmitted via the first wireless transceiver to the second wireless transceiver. The second wireless transceiver can transmit the information via a wired and/or wireless connection to at least one wirelessly receiving information device to be stored, viewed, and/or analyzed by at least one wirelessly receiving user and/or information device. In certain exemplary embodiments, transmitted data can be routed and/or received by a remote server communicatively coupled to, for example, the second wireless transceiver via a network.
In certain exemplary embodiments, the data can comprise information relating to a status of the machine. The status of the machine can comprise, for example, properly operating, shut down, undergoing scheduled maintenance, operating but not producing a product, and/or relocating, etc. The status of the machine can be provided to and/or viewed by the, user via a user interface.
At activity 2300 , a transmission rate can be received at an apparatus and/or system associated with the machine and adapted to adjust transmissions from the machine responsive to the transmission rate. The transmission rate can be received from a second information device remote from the machine and/or the wirelessly receiving user. The transmission rate can be related to a transmission rate between at least the first wireless transceiver and the second wireless transceiver, and/or a sampling rate associated with data supplied from at least one sensor to the first wireless transceiver. The user can specify a transmission rate via a rendered user interface on an information device. In certain exemplary embodiments, the transmission rate can be selected via the rendered user via, for example, a pull down menu, radio button, and/or data entry cell, etc.
At activity 2400 , a data communication can be validated. For example, the first wireless transceiver can query and/or test transmissions from the second wireless receiver in order to find, correct, and/or report errors in at least one data transmission. In certain exemplary embodiments, a user can be provided with a status related to the data communication via a user interface based rendering.
At activity 2500 , data can be stored pursuant to receipt by an information device. The information device can store the data in a memory device. The data can be stored in a plurality of formats such as SQL, MySQL, Microsoft Access, Oracle, FileMaker, Excel, SYLK, ASCII, Sybase, XML, and/or DB2, etc.
At activity 2600 , data can be compared to a standard. The standard can be a predetermined value, limit, data point, and/or pattern of data related to the machine. Comparing data to a standard can, for example, determine a past, present, or impending mechanical failure; electrical failure; operator error; operator performance; and/or supervisor performance, etc.
At activity 2650 , a failure can be detected. The failure can be associated with a mechanical and/or electrical component of the machine. For example, the mechanical failure can relate to a bearing, wear pad, engine, gear, and/or valve, etc. The electrical failure can relate to a connecting wire, motor, motor controller, starter, motor controller, transformer, capacitor, diode, resistor, and/or integrated circuit, etc.
At activity 2700 , a user can be alerted. The user can be local to the machine and/or operating the machine. In certain exemplary embodiments, the user can be the wirelessly receiving user, the dispatch entity, a management entity, and/or a maintenance entity. The user can be automatically notified to schedule and/or perform a maintenance activity associated with the machine.
At activity 2800 , data can be queried. The data related to the machine can be parsed and or extracted from a memory device. The data can be compared to a predetermined threshold and/or pattern. The data can be summarized and/or reported subsequent to the query. Querying the data can allow the wirelessly receiving user to manipulate and/or analyze the data related to the machine. In certain exemplary embodiments the data can be queried using a Machine Search Language engine.
Certain exemplary embodiments can monitor the machine while the machine is operating. Machine analysis functions can evaluate events associated with the machine. Machine analysis functions can determine causes of events and/or conditions that precede one or more events, such as a failure. Received data can be analyzed to detect average, below average, and/or above average performance associated with the machine. The information associated with the machine can be correlated with the dispatch system. In certain exemplary embodiments, applications can be customized towards individualized needs of operational units associated with the machine, such as a mine.
Certain exemplary embodiments can be adapted to remotely visualize operations associated with the machine from a perspective approximating that of an operator of the machine. Continuous monitoring and logging can take away “right timing” constraints on making direct observations of the machine. That is, performance can be logged and reviewed at a later time.
At activity 2850 , a report can be rendered. The report can comprise a summary of the data and/or exceptions noted during an analysis of the data. The report can comprise information related to, for example, actual torques, speeds, operator control positions, dispatch data, production, energy use associated with the machine, machine position, machine motion, and/or cycle times associated with the machine, etc. The report can comprise information related to the operation of the machine. For example, wherein the machine is a mining shovel, the report can comprise information related to the mining shovel digging, operating but not digging, propelling, idling, offline, total tons produced in a predetermined time period, total haulage machines loaded in the predetermined time period, average cycle time, average tons mined, and/or average haulage machine loads transferred, etc. The report can provide operating and/or maintenance entities with information related to the machine; recommend a course of action related to the operation and/or maintenance of the machine; historical and/or predictive information; trends in data, machine production data; and/or at least one deviation from an expected condition as calculated based upon the data; etc.
In certain exemplary embodiments, the data can be rendered and/or updated via a user interface in real-time with respect to the sensing of the physical properties underlying the data, and/or the generation, collection, and/or transmission of the data from the machine. The user interface can be automatically updated responsive to updates and/or changes to the data as received from the machine. In certain exemplary embodiments data can be rendered via the user interface from a user selected subset of sensors of a plurality of sensors associated with the machine. In certain exemplary embodiments data can be rendered via the user interface from a user selected subset of data point, such as, for example, every 8 th data point, every data point having a value outside a predetermined limit, every data point corresponding to a predetermined event, etc. The user can select a time period over which historical data can be rendered via the user interface. In this manner the user can analyze historical events in order to determine trends and/or assist in improving machine operations and/or maintenance.
In certain exemplary embodiments data from the machine can be rendered via the user interface which can comprise a 2-dimensional, 3-dimensional, and/or 4-dimensional (e.g., animated, or otherwise time-coupled) schematic model of the machine. The schematic model of the machine can assist the user in visualizing certain variables and/or their effects related to the machine. The schematic model of the machine can reflect a position of the machine relative to a fixed location, geographical position, and/or relative to another machine, etc. The schematic model can comprise proportionally accurate graphics and/or quantitative and/or qualitative indicators of conditions associated with one or more machine components. For a mining shovel, for example, the plurality of machine components can comprise hoist rope length, stick extension, and/or swing angles, etc. The rendering can comprise graphical indicators of joystick positions and the status displays that an operating entity can sense while running the machine. In this way, the rendering can be adapted to show a mechanical response of the machine under a given set of conditions and/or how the operating entity judges the mechanical response. The rendering can comprise an electrical response of the machine and/or how the operating entity judges the electrical response. In certain exemplary embodiments, data rendered from the machine can comprise GPS based positioning information related to the machine. The data can comprise information related to a survey. For example, in a mining operation, mine survey information can be integrated with positioning information related to the machine.
The rendering can comprise production information related to the machine. In the case wherein the machine is an electric mining shovel, production information can comprise a bucket load, haulage machine load, last haulage machine load, shift total, and/or cycle timer value, etc. The rendering can comprise electrical information such as, for example, readings from line gauges, power gauges, line strip charts, power strip charts, and/or temperature sensors related to an electrical component such as a transformer, etc. The rendering can comprise mechanical information such as, for example, readings from temperature sensors related to a mechanical component such as a bearing, air pressure sensors, lubrication system pressure sensors, and/or vibration sensors, etc.
In certain exemplary embodiments data can be rendered via a user interface in one or more of a plurality of display formats. For example, data can be rendered on a motion strip chart, motion XY plot, and/or motion gauge, etc. Data can be rendered on a chart comprising a minimum and/or maximum pointer associated with the data. The minimum and/or maximum pointer can provide a comparison of a value of a process variable with a predetermined value thereby potentially suggesting that some form of intervention be undertaken. Certain exemplary embodiments can comprise a feature adapted to allow the minimum and/or maximum to be reset and/or changed. For example, the minimum and/or maximum can be changed as a result of experience and/or a change in design and/or operation of the machine. The minimum and/or maximum can be changed by, for example, an operating entity, management entity, and/or engineering entity, etc.
The rendering can comprise elements of graphic user interface, such as menu selections, buttons, command-keys, etc., adapted to save, print, change cursors, and/or zoom, etc. Certain exemplary embodiments can be adapted to allow the user to select a subset of sensors and/or data associated with the machine to be rendered. Certain exemplary embodiments can be adapted to allow the user to select a time range over which the data is rendered. Certain exemplary embodiments can be adapted to provide the user with an ability to load and play log files via the rendering. Rendering commands can include step forward, forward, fast forward, stop, step back, play back, and/or fast back, etc. Additional features can be provided for log positioning. Certain exemplary embodiments can comprise a drop down box adapted to accept a user selection of time intervals and/or a start time.
At activity 2900 , data can be exported. Data can be exported from a memory device. Data can be exported in a plurality of formats. For example, data formatted as a SQL database can be exported in a Microsoft Access database format, an ASCII format, and/or a Microsoft Excel spreadsheet format, etc.
FIG. 3 is a flow diagram of an exemplary embodiment of a machine data management method 3000 . At activity 3100 , data can be received at a server and/or an information device. The data can comprise a plurality of values for a plurality of machine system variables associated with one or more machine system components. The plurality of machine system variables can comprise operational variables, environmental variables, variables related to maintenance, variables related to mechanical performance of the machine, and/or variables related to electrical performance of the machine, etc. In certain exemplary embodiments, the machine can be an electric mining shovel. The plurality of machine system variables can comprise at least one operational variable. In certain exemplary embodiments, the at least one operational variable can be related to digging earthen material. In certain exemplary embodiments, the at least one operational variable can comprise non-binary values.
At activity 3200 , variables from the machine data can be correlated. For example, values for two of the plurality of machine system variables can be mathematically analyzed in order to determine a correlation between those variables. Determining a correlation between variables can, for example, provide insights into improving machine operations and/or reducing machine downtime.
At activity 3300 , a metric can be determined. The metric can be a statistical metric related to least one of the machine system variables. The metric can be, for example, a mean, average, mode, maximum, minimum, standard deviation, variance, control chart range, statistical analysis of variance parameter, statistical hypothesis testing value, and/or a deviation from a standard value, etc. Determining the metric can provide information adapted to improve machine operation, improve performance of a machine operating entity, improve performance of a machine dispatching entity, improve machine maintenance, and/or reduce machine downtime, etc.
At activity 3400 , the server and/or information device can determine a trend related to at least one of the machine system variables. The trend can be relative to time and/or another machine system variable. Determining the trend can provide information adapted to improve machine design, improve machine operation, improve performance of a machine operating entity, improve performance of a machine dispatching entity, improve machine maintenance, and/or reduce machine downtime, etc.
At activity 3500 , values for one or more variables can be compared. In certain exemplary embodiments, values for a variable can be compared to a predetermined standard. For example, a bearing vibration reading can be compared to a predetermined standard vibration amplitude, pattern, phase, velocity, acceleration, etc., the predetermined standard representing a value indicative of an impending failure. Predicting an impending bearing failure can allow proactive, predictive, and/or preventive maintenance rather than reactive maintenance. As another example, a production achieved via the machine can be compared with a predetermined minimum threshold. If the production achieved is less than the predetermined minimum, a management entity can be notified in order to initiate corrective actions. If the production achieved is above the predetermined minimum by a predetermined amount and/or percentage, the management entity can be notified to provide a reward and/or investigate the causes of the production achieved.
As yet another example, an operating temperature for an electric motor controller can be compared to a predetermined maximum. If the operating temperature exceeds the predetermined maximum, a maintenance entity can be notified that a cooling system has failed and/or is non-functional. Repairing the cooling system promptly can help prevent a failure of the electric motor controller due to overheating. As still another example, an electric mining shovel idle time while operating can be compared to a predetermined maximum threshold. If the electric mining shovel idle time exceeds the predetermined maximum threshold, a mine dispatch entity can be notified that at least one additional haulage machine should be assigned to the electric mining shovel in order to improve mine production.
As still another example, a lubrication system pressure and/or use can be compared to predetermined settings. If the lubrication system is down or not performing properly, an operational and/or maintenance entity can be notified. Tracking and/or comparing lubrication system characteristics can be useful in predicting and/or preventing failures associated with inadequate lubrication.
As a further example, machine productivity can be compared to a predetermined standard. For example, in a mining operation for predetermined production period, tons mined can be compared to a historical statistical metric associated with the machine. The machine productivity comparison can provide a management entity with information that can be adapted to improve performance related to a machine operator, a dispatch entity, a maintenance entity, and/or an operator associated with a related machine.
At activity 3600 , variables associated with the machine can be analyzed. In certain exemplary embodiments, two correlated variables associated with the machine can be analyzed. In embodiments wherein the machine is an electric mining shovel, the two correlated variables can be non-load-related and/or non-positional variables related to the electric mining shovel.
Analyzing variables associated with the machine can comprise utilizing a pattern classification and/or recognition algorithm such as a decision tree, Bayesian network, neural network, Gaussian process, independent component analysis, self-organized map, and/or support vector machine, etc. The algorithm can facilitate performing tasks such as pattern recognition, data mining, classification, and/or process modeling, etc. The algorithm can be adapted to improve performance and/or change its behavior responsive to past and/or present results encountered by the algorithm. The algorithm can be adaptively trained by presenting it examples of input and a corresponding desired output. For example, the input might be a plurality of sensor readings associated with a machine component and an experienced output a failure of a machine component. The algorithm can be trained using synthetic data and/or providing data related to the component prior to previously occurring failures. The algorithm can be applied to almost any problem that can be regarded as pattern recognition in some form. In certain exemplary embodiments, the algorithm can be implemented in software, firmware, and/or hardware, etc.
Certain exemplary embodiments can comprise analyzing a vibration related to the machine based on values from at least one vibration sensor. The values can relate, for example, to a time domain, frequency domain, phase domain, and/or relative location domain, etc. The values can be presented to the pattern recognition algorithm to find patterns associated with impending failures. The values can be normalized, for example, with respect to a frequency and/or phase of rotation associated with the machine. The values can be used to obtain dynamic information usable in detecting and/or classifying failures.
Failures associated with the machine can be preceded by a condition such as, for example, a changing tolerance, imbalance, and/or bearing wear, etc. The condition can result in a characteristic vibration signature associated with an impending failure. In certain exemplary embodiments, the characteristic vibration signature can be discernable from other random and/or definable patterns within and/or potentially within the values.
Certain exemplary embodiments can utilize frequency normalization of the values. For example, frequency variables associated with power spectral densities can be scaled to predetermined frequencies. Scaling frequency variables can provide clearer representations of certain spectral patterns.
Vibration sensor readings can be sampled and processed at constant and/or variable time intervals. Certain exemplary embodiments can demodulate the vibration sensor readings. In certain exemplary embodiments, a frequency spectrum can be computed via a Fourier transform technique. The pattern recognition algorithm can be adapted to recognize patterns in the frequency spectrum to predict an impending machine component failure.
The pattern recognition algorithm can comprise a plurality of heuristic rules, which can comprise, for example, descriptive characteristics of vibration patterns associated with a failure of the component of the machine. The heuristic rules can comprise links identifying likely causes, diagnostic procedures, and/or effects related to the failure. For example, the heuristic rules can be adapted to adjust maintenance, machine, and/or personnel schedules responsive to detecting an impending failure.
Activity 3600 can comprise, for example, predicting machine performance, predicting a failure related to the machine, predicting a failure related to a machine component, predicting a failure related to a mechanical machine component, and/or predicting a failure related to an electrical machine component.
At activity 3700 , a report can be generated. The report can comprise, for example, a machine performance variable; information related to performance of a dispatch entity, such as a mine dispatch entity; information related to performance of a machine mechanical component; information related to performance of an machine electrical component; information related to activities involving the machine, such as digging activities in the case of an electric mining shovel; information related to non-digging activities involving the machine, such as operator training; and/or information related to propelled motion of the machine; etc.
At activity 3800 , a management entity associated with the machine can be notified of information related to the machine. The management entity can be notified of certain comparisons associated with activity 3500 and/or results associated with activity 3600 . Notifying the management entity can allow for corrective action to be taken to avoid lower than desired performance. Notifying the management entity can provide the management entity with information usable to improve performance related to the machine.
At activity 3900 , a maintenance entity associated with the machine can be notified. Notifying the maintenance entity can provide for prompt repair and/or prompt scheduling of a repair associated with the machine. Information obtained via activity 3600 can provide information usable in improving preventative maintenance related to the machine.
FIG. 4 is a block diagram of an exemplary embodiment of an information device 4000 , which in certain operative embodiments can comprise, for example, information device 1160 , server 1400 , and information device 1500 of FIG. 1 . Information device 4000 can comprise any of numerous well-known components, such as for example, one or more network interfaces 4100 , one or more processors 4200 , one or more memories 4300 containing instructions 4400 , one or more input/output (I/O) devices 4500 , and/or one or more user interfaces 4600 coupled to I/O device 4500 , etc.
In certain exemplary embodiments, via one or more user interfaces 4600 , such as a graphical user interface, a user can view a rendering of information related to a machine.
FIGS. 5 a , 5 b , and 5 c are an exemplary embodiment of a partial log file layout for data associated with a mining shovel. Data comprised in the log file can be saved for analytical purposes.
FIG. 6 is an exemplary user interface showing a graphical trend chart of electrical data for a crowd motor of a mining shovel. The crowd motor is adaptable to provide motion to a bucket of the mining shovel toward, to “crowd”, material holdable by the bucket.
FIG. 7 is an exemplary user interface showing a graphical rendering of gauges displaying electrical data of a crowd motor of a mining shovel. Data used in generating the graphical rendering can be saved for analytical purposes. The graphical rendering be rendered approximately in real-time.
FIG. 8 is an exemplary user interface showing a relationship between speed and torque of a crowd motor of a mining shovel.
FIG. 9 is an exemplary user interface showing a graphical rendering of gauges displaying temperatures related to a mining shovel crowd. Data used in generating the graphical rendering can be saved for analytical purposes. The graphical rendering be rendered approximately in real-time.
FIG. 10 is an exemplary user interface showing information related to driver operation of a mining shovel. The graphical rendering be rendered approximately in real-time.
FIG. 11 is an exemplary user interface showing a graphical trend chart of electrical data for a hoist motor of a mining shovel.
FIG. 12 is an exemplary user interface showing a graphical rendering of gauges displaying electrical data for a hoist motor of a mining shovel. Data used in generating the graphical rendering can be saved for analytical purposes. The graphical rendering be rendered approximately in real-time.
FIG. 13 is an exemplary user interface showing a relationship between speed and torque of a hoist motor of a mining shovel.
FIG. 14 is an exemplary user interface showing a graphical rendering of gauges displaying temperatures related to a mining shovel hoist. Data used in generating the graphical rendering can be saved for analytical purposes. Maximum and/or minimum thresholds can be set for purposes of generating alarms and/or flagging data. The graphical rendering be rendered approximately in real-time.
FIG. 15 is an exemplary user interface showing a graphical trend chart of electrical data related to a mining shovel.
FIG. 16 is an exemplary user interface showing information related to mining shovel operations.
FIG. 17 is an exemplary user interface showing position information related to a mining shovel.
FIG. 18 is an exemplary user interface showing a graphical rendering of gauges displaying pressures of mining shovel components. Data used in generating the graphical rendering can be saved for analytical purposes. The graphical rendering be rendered approximately in real-time.
FIG. 19 is an exemplary user interface showing a graphical rendering of gauges displaying temperatures of mining shovel components.
FIG. 20 is an exemplary user interface showing a graphical rendering of gauges displaying electrical data of hoist, crowd, and swing motors of a mining shovel.
FIG. 21 is an exemplary user interface showing a graphical trend chart of motion data related to a mining shovel.
FIG. 22 is an exemplary user interface showing a graphical trend chart of production data related to a mining shovel.
FIG. 23 is an exemplary user interface showing a graphical rendering of gauges displaying production data of a mining shovel.
FIG. 24 is an exemplary user interface providing operating statuses of mining shovel components.
FIG. 25 is an exemplary user interface showing a graphical trend chart of electrical data for a swing motor of a mining shovel.
FIG. 26 is an exemplary user interface showing a graphical rendering of gauges displaying electrical data for a swing motor of a mining shovel.
FIG. 27 is an exemplary user interface showing a relationship between speed and torque of a swing motor of a mining shovel.
FIG. 28 is an exemplary user interface showing a graphical rendering of gauges displaying temperatures related to a mining shovel swing.
Still other embodiments will become readily apparent to those skilled in this art from reading the above-recited detailed description and drawings of certain exemplary embodiments. It should be understood that numerous variations, modifications, and additional embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the appended claims. For example, regardless of the content of any portion (e.g., title, field, background, summary, abstract, drawing figure, etc.) of this application, unless clearly specified to the contrary, there is no requirement for the inclusion in any claim of the application of any particular described or illustrated activity or element, any particular sequence of such activities, or any particular interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. Further, any activity or element can be excluded, the sequence of activities can vary, and/or the interrelationship of elements can vary. Accordingly, the descriptions and drawings are to be regarded as illustrative in nature, and not as restrictive. Moreover, when any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. When any range is described herein, unless clearly stated otherwise, that range includes all values therein and all subranges therein. Any information in any material (e.g., a United States patent, United States patent application, book, article, etc.) that has been incorporated by reference herein, is only incorporated by reference to the extent that no conflict exists between such information and the other statements and drawings set forth herein. In the event of such conflict, including a conflict that would render a claim invalid, then any such conflicting information in such incorporated by reference material is specifically not incorporated by reference herein.
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Certain exemplary embodiments can include obtaining and analyzing data from at least one discrete machine, automatically determining relationships related to the data, taking corrective action to improve machine operation and/or maintenance, automatically and heuristically predicting a failure associated with the machine and/or recommending preventative maintenance in advance of the failure, and/or automating and analyzing mining shovels, etc.
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RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Patent Application 61/660,879, which is incorporated herein by reference in its entirety.
COPYRIGHT NOTICE AND PERMISSION
[0002] A portion of this patent document contains material subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyrights whatsoever. The following notice applies to this document: Copyright © 2012, Alan B. Powell
TECHNICAL FIELD
[0003] Various embodiments of the present invention concern moisture detection and indication devices, particularly those suitable for use in buildings.
BACKGROUND
[0004] We have a love-hate relationship with water. We love it when it's where we need it to be, doing what we need it to do. And we hate it when it's not. The truth of this is readily known around the world by homeowners who have endured the expense, hassle, and sometimes life-threatening consequences of water intrusion into their homes, not only in the highly visible and unescapable form of seasonal flooding, but also in the elusive, often invisible form of moisture intrusion. Which can remain invisible for years until the serious damage of lost structural integrity or mold growth manifest.
[0005] For most stick-frame homes, the type most common in the United States and Canada, moisture intrusions typically occur in their wall cavities, the six-inch-thick insulation-filled space between a home's exterior siding and its interior sheetrock. The wood structure and insulation in this wall cavity can act like a large sponge, with outward signs of moisture buildup only becoming visible when the cavity is saturated and the problem is serious.
[0006] Moisture testing of all types of homes, especially stucco homes, is the best way to minimize the risk of water damage and to identify problems before they become serious. Typical testing methods require experts to measure the moisture content in the wall cavities of a home. Generally, this entails drilling holes in the home's exterior siding or interior sheetrock, inserting highly sensitive electronic moisture meters into its wall cavities. Readings from the moisture meters are then recorded and the holes refilled with caulk or spackle.
[0007] The present inventor has identified at least two problems with this form of testing. The first is that the testing is generally performed only when signs of damage are already being noticed or when a home is on the market, meaning not only that most detected intrusions could have been detected and treated much earlier, but also that homeowners could have saved thousands of dollars in repair expenses. The second problem is that regular testing requires repeated drillings, probings, and refillings. This level of professional effort using expensive measuring instruments puts testing at a price point that many homeowners view as too expensive to perform regularly.
[0008] Accordingly, the present inventor has identified a need for better ways of testing for moisture in buildings.
SUMMARY
[0009] To address this and/or other needs, the present inventor devised, among other things, a passive moisture detection probe that can be installed and left in place to continuously indicate whether the moisture-content in the wall-cavity of a building is below or above a desirable level. One exemplary moisture detection assembly includes a moisture-absorbent sensor element and an indicator. The sensor element, which can be placed in contact with the inner surface of a home's exterior sheathing, expands and contracts in response to the moisture content of the sheathing. The indicator, for example a rod, moves in responsive to the expansion and contraction of the sensor element, with its relative position corresponding to the moisture in the exterior sheathing and thus providing an on-going and observable sign of moisture intrusion.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a center cross-sectional view of an exemplary moisture detection assembly, which corresponds to one or more embodiments of the present invention.
[0011] FIG. 2 is an end view of the assembly in FIG. 1 , corresponding to one or more embodiments of the present invention.
[0012] FIG. 3 is a top plan view of an exemplary wingnut-style driver tool for use in installing and/or removing the FIG. 1 assembly, corresponding to one or more embodiments of the present invention.
[0013] FIG. 4 is a profile view of the exemplary wingnut-style driver tool in FIG. 3 , corresponding to one or more embodiments of the invention.
[0014] FIG. 5 is a profile view of the wingnut-style driver tool in FIGS. 3 and 5 , corresponding to one or more embodiments of the invention.
[0015] FIG. 6 is a center cross-sectional view of an exemplary drywall bore tool for use in creating the FIG. 1 assembly, corresponding to one or more embodiments of the invention.
[0016] FIG. 7 is a schematic diagram of an exemplary kit corresponding to one or more embodiments of the present invention.
[0017] FIG. 8 is a center cross-sectional view of another exemplary moisture detection assembly, which corresponds to one or more embodiments of the present invention.
[0018] FIG. 9 is an exploded isometric view of the FIG. 8 moisture detection assembly and thus corresponds to one or more embodiments of the present invention.
[0019] FIG. 10 is an alternative form of a guide tube portion of the FIG. 8 moisture detection assembly, which corresponds to one or more embodiments of the present invention.
[0020] FIG. 11 is a front perspective view of an alternative drywall bore tool, which may be used in place of the FIG. 6 bore tool, and which corresponds to one or more embodiments of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0021] This document, which incorporates the drawings and the appended claims, describes one or more specific embodiments of one or more inventions. These embodiments, offered not to limit but only to exemplify and teach the invention, are shown and described in sufficient detail to enable those skilled in the art to implement or practice the invention(s). Thus, where appropriate to avoid obscuring the invention(s), the description may omit certain information known to those of skill in the art.
[0022] FIG. 1 shows cross-sectional view of a passive mechanical moisture detection assembly. The assembly includes an exterior wood sheathing 101 and an interior drywall or sheetrock 102 , with sheathing 101 having an interior sheathing surface 101 A and drywall having a bore hole 102 A. (Although not shown for sake of clarity, the space between the sheathing and drywall is understood to include some form of insulation, such as a fiberglass insulation.) Inserted through bore hole 102 A is an exemplary moisture detection probe assembly 100 .
[0023] Probe assembly 100 includes a probe body 110 , an indicator rod 120 , a spring bias element 130 , a moisture sensor element 140 , and an end cap 150 .
[0024] Probe body 110 , which takes the exemplary form of a right circular cylindrical tube formed of machined, 3-D printed, injection-molded or cast-molded PVC or other durable plastic, includes a sheathing end portion 111 , a drywall end portion 112 , an exterior surface 113 , an interior axial passage or bore 114 . (Drywall and sheathing side modifiers are used as directional cues to facilitate reference to specific portions of other parts and components in this description, without necessarily using reference numbers for those specific portions. For example, indicator rod 120 has a drywall end portion, i.e. end closest to the drywall, and a sheathing end closest to the sheathing.) At the drywall end portion 112 , exterior surface 113 includes integrally formed screw threads 113 A which engage with drywall 102 , specifically the interior surface of bore hole 102 A. Axial bore 114 , which extends the entire length of the probe body from the drywall end portion to the sheathing end portion, includes a first diameter region 114 A and second diameter region 114 C that has a smaller diameter than region 114 A to define an annular ledge or step 114 C. The smaller diameter of region 114 C can be defined as integral dimensional change within bore 114 or by insertion of a separate right cylindrical tube within the probe body. Positioned within axial bore 114 is indicator rod 120 .
[0025] Indicator rod 120 , which is also form of a machined, 3-D printed, or injection-molded or cast-molded PVC or other durable plastic, includes an elongated body portion 121 and a plunger head portion 122 . Elongated body portion 121 and plunger head portion 122 both take the exemplary form of a right circular cylinder, with body portion 121 being substantially longer and having a smaller diameter than plunger head portion 122 . Plunger head portion 122 is larger in diameter than second diameter region 114 C, so that annular ledge 114 C limits axial travel or movement the indicator rod in a direction toward drywall end portion 112 . Plunger head portion 122 has a sheathing side and an opposing drywall side that is integral with the elongated body portion 121 extending through spring bias element 130 .
[0026] Spring bias element 130 , which in the exemplary embodiment takes the form of a helical spring, has respective first and second ends 131 and 132 . First end 131 is seated against annular ledge 114 C, and second end 132 is seated against a drywall side of plunger head portion 122 , thereby biasing the adjacent sensor element 140 into contact with interior sheathing surface 101 A.
[0027] Sensor element 140 , which for example takes the form a right cylindrical plug, includes a water-absorbent (more generally liquid-absorbing) material composition, which not only absorbs water but expands in size at least laterally or axially (along the lengthwise dimension of the indicator rod) during absorption. In the exemplary embodiment, the sensor element consists essentially of Hydrospan 100 material, a commercially available material composition from Industrial Polymers, Inc., 3250 South Sam Houston Parkway East, Houston, Tex. 77047. The Hydrospan 100 material generally expands uniformly in all three of its physical dimensions as it absorbs water, potentially expanding 60% by volume. The Hydrospan 100 material belongs to the Polyurethane chemical family, and has a formula maintained as a trade secret of Industrial Polymers, Inc. However, it is understood to be a reaction product of a Polyether with toluene diisocyanate (TDI).) Other embodiment may use or types of materials that also expand and/or contract, or more generally move, with changing moisture conditions. Some embodiment use composites that include the Hydrospan 100 material in combination with other absorbent or non-absorbent materials to control or restrict its expansion in certain dimensions for example dimensions perpendicular to the axial dimension of the probe body. Other potential materials include urethane resins used in diapers, and polymers used to hold and release water in soils for plant growing.
[0028] As sensor element 140 expands it pushes against plunger head portion 122 of indicator rod 120 , countering the bias of spring bias element 130 . With continued expansion due to persistent presence of moisture in sheathing 101 , the sensor element will expand enough in size along its axial dimension to overcome the spring bias and move the rear portion (drywall end portion) of indicator rod 120 out the rear of the probe body and end cap 150 away from drywall 102 , thereby providing a visual indication that a moisture condition has been detected.
[0029] End cap 150 , in the exemplary embodiment, takes a plastic flange-head form and includes a neck or stem portion 151 bored to engage in an interference fit with the drywall end portion of indicator rod 120 and a flat head portion 152 integrally formed with stem portion 151 . In place of end cap 150 , some embodiments connect the indicator rod to actuate a normally open or normally closed electrical switch. The switch can be electrically coupled in series with an RFID (radio frequency identification) coil to disable or enable an RFID circuit or to circuitry to trigger an audible or visual alarm or to activate a wireless transmitter. In the case of the RFID coil, the switch simply couples or decouples one node or terminal of the coil from the RFID chip. Thus, an attempt to read the RFID tag, for example, will indicate either presence or nonpresence of the tag at the time of the reading.
[0030] FIG. 2 shows an end view of probe body 110 , with endcap 150 removed for clarity. In this view, an opening 116 through which the elongated portion 121 of indicator rod 120 can pass is more clearly visible. Opening 116 include four prongs, of which prong 116 A is representative. The prong opening allows use of a driver tool, such as the exemplary wingnut-style driver tool 200 , shown in FIGS. 3 , 4 , and 5 , to install the probe assembly such that its end is generally flush with the interior most surface of drywall 102 .
[0031] FIG. 6 , a center cross-sectional view, shows an exemplary drywall bore tool 600 for use in manually boring holes through drywall or sheetrock, with the holes being suitable for installation of a moisture detection probe, such as probe assembly 100 , as well as for other purposes. Bore tool 600 includes a handle portion 610 and a cutting tube 620 . Handle portion 610 includes a stem portion 611 which is fixedly mounted, for example threadly engaged, adhered, or welded, to cutting tube 620 . Cutting tube 620 , which is made of a durable metal, such as copper, bronze, steel, or aluminum, or a suitable hard and durable polycarbonate or other plastic, includes a sharpened cutting end 621 . The end may be formed to include sawtooth teeth in some embodiments.
[0032] In use, one positions the cutting end of the tube on the location of a desired hole in sheetrock or drywall and uses the handle to push the tool into the drywall, while turning or reciprocating the handle back and forth, in clockwise and counterclockwise directions, until the cutting tube penetrates the drywall. The tool can then be worked with less effort to cut through insulation, thereby forming an effective bore hole or tunnel for installing probe assembly 100 , or other suitable purposes. In the exemplary embodiment, cutting tube 620 forms holes approximately 0.5 or 0.625 inches in diameter to cooperate with a slightly smaller probe body diameter.
[0033] FIG. 7 shows an exemplary moisture detection kit 700 . In the exemplary embodiment, kit 700 includes one or more moisture probe assemblies, such as probe assembly 100 (or 800 in FIG. 8 ), one or more bore tools, such as bore tool 600 or bore tool ( 1200 in FIG. 12 ), and one or more installation driver tools, such as wingnut-style driver tool 300 .
[0034] FIG. 8 shows an exemplary moisture probe assembly 800 , which is similar in structure and function to assembly 100 in FIG. 1 . The main difference between assembly 800 and assembly 100 is the inclusion of a guide tube 810 .
[0035] More specifically, guide tube 810 not only anchors probe body 110 ′ to drywall 102 , but also ensures that it is substantially perpendicularly to the surface of drywall 102 and sheathing 101 , thereby ensuring that the sheathing side of sensor element 140 fully contacts surface 101 A. It is believed that deviation from full endface contact of the sensor element with the monitored surface (surface 101 A) will result in less than optimal performance of the moisture detection probe assembly, since moisture will likely force the sensor element to expand beyond containment of the probe body and thereby reduce transfer of axial expansion force to indicator rod 120 . Guide tube 810 (probe guide tube), shown best in FIG. 9 , includes a face 811 , and two or more, for example 3 or 4, leaf-spring prongs 812 , and opening 813 . Leaf-spring prongs 812 , are formed as tapered U-channels with the taper increasing with distance away from face plate. Thus, when inserted into a drywall hole and probe body 110 ′ is passed through opening 813 , the probe body spreads the leaf-spring prongs into frictional engagement with the interior surface of the drywall hole, anchoring the guide tube in place. The probe body may then be pushed flush to sheathing surface ends of the
[0036] Other differences between assembly 800 and 100 include an endcap 150 ′ which receives the elongated body portion of indicator rod 120 , internal longitudinal ribs 820 (best seen in FIG. 9 ) within the axial passage of probe body 110 ′, substitution of flattened exterior threads 113 A′ on probe body 110 .
[0037] FIG. 10 shows an side and perspective views of an altenative guide plate 910 which may be used in place of guide tube 810 . In contrast to guide tube 810 which includes three leaf-spring prongs of substantially equally length, probe guide tube 910 includes two leaf-spring prongs 812 and two opposing thread prongs 814 A and 814 B, which are about half as long as the leaf-spring prongs and which include respective cleats or protusions 815 A and 815 B to better engage with the threads on probe body 110 ′ and thus better ensure the desired perpendicular alignment with the sheathing surface 101 A.
[0038] FIG. 11 shows a profile view of an alternative exemplary drywall bore tool 1100 , which is similar in basic function and structure of drywall bore tool 600 in FIG. 6 , with the exception of some added features and for ensure higher precision boring and efficiency. Bore tool 1100 includes a handle portion 1110 and a slotted cutting tube 1120 , a bore guide plate 1130 , and a bore guide ring 1140 . Handle portion 1110 includes a stem portion 1111 which is fixedly mounted, for example threadly engaged, adhered, or welded, to slotted cutting tube 1120 . Cutting tube 1120 , which is made of a durable metal, such as copper, bronze, steel, or aluminum, or a suitable hard and durable polycarbonate or other plastic, includes a sharpened cutting end 1121 and includes a longitudical slot 1123 . The longitudinal slot runs to the top end of the tude to allow full assembly of the tool, though this is not visible in the figure because of handle stem portion 1111 . Bore guide plate 1130 includes a bottom face 1131 with protusions 1132 to engage surface of the drywall being bored and ensure stable position of the tool during boring operations. Plate 1130 also includes a guide stem portion 1133 with an annular guide ridge 1134 . Bore guide ring 1140 includes a slot engagement member 1141 that engages with slot 1123 , enabling the bore guide ring to slide freely along the length of the cutting tube between the cutting end and the handle. Bore guide ring 1140 also includes an annular groove 1142 that slideably engages via snap fit with annular guide ridge 1134 , defining a lateral rotational plane for the guide ring that is substantially parallel to bottom face 1131 . In operation, a user manually places the guide plate over the desired bore location and pushes the cutting tube into the drywall surface (generally substrate surface) using the handle. The handle is then worked back and forth, as with tool 600 , with the guide plate and guide ring maintain perpendicular boring through the drywall and beyond.
CONCLUSION
[0039] The embodiments described above are intended only to illustrate and teach one or more ways of practicing or implementing the present invention, not to restrict its breadth or scope. Nothing presented herein is intended to be construed as critical, required, or essential to the invention as claimed. The actual scope of the invention, which embraces all ways of practicing or implementing the teachings of the invention, is defined only by the following claims including any amendments made during pending of the application and all equivalents of those claims as issued.
[0040] Moreover in this document, relational terms, such as second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has”, “having,” “includes”, “including,” “contains”, “containing” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises a”, “has . . . a”, “includes . . . a”, “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within 10%, in another embodiment within 5%, in another embodiment within 1% and in another embodiment within 0.5%. The term “coupled” as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way, but may also be configured in ways that are not listed.
[0041] The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter
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To address this and/or other needs, the present inventor devised, among other things, a passive moisture detection probe that can be installed and left in place to continuously indicate whether the moisture-content in the wall-cavity of a building is below or above a desirable level. One exemplary moisture detection assembly includes a moisture-absorbent sensor element and an indicator. The sensor element, which can be placed in contact with the inner surface of a home's exterior sheathing, expands and contracts in response to the moisture content of the sheathing. The indicator, for example a rod, moves in responsive to the expansion and contraction of the sensor element, with its relative position corresponding to the moisture in the exterior sheathing and thus providing an on-going and observable sign of moisture intrusion.
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TECHNICAL FIELD
[0001] The present invention relates to a method for producing microcapsules, wherein the method can control the particle size and produce microcapsules excellent in retentivity and releasability of a water-soluble core agent. The present invention also relates to a microcapsule excellent in retentivity and releasability of a water-soluble core agent.
BACKGROUND ART
[0002] Microcapsules containing a core agent covered with a shell are used in various fields. For example, in the case of an epoxy resin composition used as an adhesive, sealing agent, coating agent, or the like, a stable one-pack product containing an epoxy resin and a curing agent or a curing accelerator that accelerates curing of the epoxy resin is achieved by use of microcapsules containing a curing agent or a curing accelerator as a core agent covered with a shell to provide a latent effect. Microcapsules are also used in medicinal products. Such microcapsules containing a physiologically active substance or a drug as a core agent covered with a shell. These microcapsules are required to have both the retentivity of a core agent and the releasability (on an as-needed basis) of the core agent.
[0003] Although the core agent, such as a physiologically active substance, a drug, a curing agent, or a curing accelerator, is water-soluble in some cases, microcapsules containing a water-soluble core agent or a method for producing the same is unfortunately relatively underdeveloped, compared to the case where the core agent is hydrophobic.
[0004] As a microcapsule containing a water-soluble core agent or a method for producing the same, Patent Literature 1 discloses a microcapsule containing a polyvinyl alcohol copolymer, a surfactant, and a drug. As a method for producing microcapsules containing a water-soluble physiologically active substance, Patent Literature 2 discloses a production method including forming a w/o emulsion in which an aqueous solution containing a water-soluble physiologically active substance is the internal water phase and a homogeneous organic solvent solution containing a biodegradable polymer and an oil is the oil phase; and removing the organic solvent.
[0005] In the conventional methods disclosed in Patent Literatures 1 and 2, encapsulation is performed by a method such as a spray drying method or a drying-in-liquid method, for example. With the spray drying method, a water-in-oil (w/o) emulsion is sprayed in a dry chamber of a spray dryer and is instantly dried to obtain microcapsules. With the spray drying method, the resulting microcapsules are inhomogeneous in terms of average particle size, shell thickness, and the like, so that the retentivity or releasability of the core agent is unfortunately insufficient. In addition, the particle size is difficult to control.
[0006] With the drying-in-liquid method, a water-in-oil (w/o) emulsion is further added to the aqueous phase to forma w/o/w emulsion, and the solvent in the oil phase is dried to obtain microcapsules. The drying-in-liquid method also has a drawback, i.e., an increase in the average particle size of the resulting microcapsules due to use of a three-phase w/o/w emulsion.
CITATION LIST
Patent Literature
[0007] Patent Literature 1: WO 2006/106799
[0008] Patent Literature 2: JP-A H11-79976
SUMMARY OF INVENTION
Technical Problem
[0009] The present invention aims to provide a method for producing microcapsules, wherein the method can control the particle size and produce microcapsules excellent in retentivity and releasability of a water-soluble core agent.
[0010] The present invention also aims to provide a microcapsule excellent in retentivity and releasability of a water-soluble core agent.
Solution to Problem
[0011] The present invention relates to a method for producing microcapsules including the steps of: preparing an emulsion by dispersing an aqueous solution A obtained by dissolving at least an aqueous solvent-soluble polymer and a water-soluble core agent in an aqueous solvent in a non-polar solution B obtained by dissolving an emulsifier or a dispersant in a non-polar medium; and forming a core-shell structure in which the water-soluble core agent is covered with a shell containing the aqueous solvent-soluble polymer by heating the emulsion at a temperature of 20° C. to 100° C. and/or decompressing the emulsion at a pressure of 0.1 to 0.001 MPa to remove the aqueous solvent, the weight ratio of the aqueous solution A to the non-polar solution B being 1/10 to 1/1.
[0012] The present invention is described in detail below.
[0013] The present inventors investigated, as a method for forming a core-shell structure in which a water-soluble core agent is covered with a shell, a method for depositing the shell while phase-separating the shell and the water-soluble core agent by heating and/or decompressing a water-in-oil (w/o) emulsion so as to remove a solvent in droplets, in lieu of a conventional method such as the spray drying method or the drying-in-liquid method that uses a w/o/w emulsion.
[0014] Specifically, the present inventors found the following: when a method for producing microcapsules includes the step of preparing an emulsion by dispersing an aqueous solution A obtained by dissolving at least an aqueous solvent-soluble polymer and a water-soluble core agent in an aqueous solvent in a non-polar solution B obtained by dissolving an emulsifier or a dispersant in a non-polar medium; and forming a core-shell structure in which the water-soluble core agent is covered with a shell containing the aqueous solvent-soluble polymer by heating and/or decompressing the emulsion under predetermined conditions to remove the aqueous solvent, with the weight ratio of the aqueous solution A to the non-polar solution B in a predetermined range, then the method can produce microcapsules excellent in retentivity and releasability of the core agent even when the core agent is soluble in water. The present inventors also found that the above method for producing microcapsules can control the particle size of microcapsules by adjusting the size of droplets of the aqueous solution A in the emulsion, and the present inventors accomplished the present invention.
[0015] The method for producing microcapsules of the present invention first includes the step of preparing an emulsion by dispersing an aqueous solution A obtained by dissolving at least an aqueous solvent-soluble polymer and a water-soluble core agent in an aqueous solvent in a non-polar solution B obtained by dissolving an emulsifier or a dispersant in a non-polar medium.
[0016] In this step, the size of droplets of the aqueous solution A in the emulsion is adjusted by adjusting an emulsification method or the like, which in turn enables to control the particle size of microcapsules.
[0017] The aqueous solution A is obtained by dissolving at least an aqueous solvent-soluble polymer and a water-soluble core agent in an aqueous solvent.
[0018] The aqueous solvent is not particularly limited as long as it can dissolve an aqueous solvent-soluble polymer and a water-soluble core agent at a temperature of about 0° C. to 80° C., and is suitably selected in accordance with the aqueous solvent-soluble polymer and the water-soluble core agent. Examples thereof include water, methanol, and a mixed solvent of water and methanol.
[0019] The aqueous solvent-soluble polymer is not particularly limited as long as it can be dissolved in an aqueous solvent, and is suitably selected in accordance with the aqueous solvent. The lower limit of the solubility of the aqueous solvent-soluble polymer in an aqueous solvent at 20° C. is preferably 0.5% by weight, and the upper limit thereof is preferably 80% by weight, in terms of yield of microcapsules and also in terms of suppressing aggregation of microcapsules caused by the shell softened by the aqueous solvent remaining as residue when the aqueous solvent is removed in the step of forming a core-shell structure. The upper limit of the solubility is more preferably 50% by weight.
[0020] Herein, the “solubility of the aqueous solvent-soluble polymer in an aqueous solvent at 20° C.” means the maximum amount of the aqueous solvent-soluble polymer at which the solution remains homogeneous when the aqueous solvent-soluble polymer is added to the aqueous solvent at 20° C.
[0021] Specific examples of the aqueous solvent-soluble polymer include polyvinyl alcohol, polyvinylphenol, polyvinylpyrrolidone, polyacrylamide, polyacrylic acid, polymethacrylic acid, polyethylene glycol, methylcellulose, hydroxypropyl cellulose, agar, gelatin, poly(acrylic acid-co-acrylamide), and poly(acrylic acid-co-methacrylic acid). These may be used alone or in combination of two or more thereof. Among these, polyvinyl alcohol and methylcellulose are preferred because the properties such as polarity and molecular weight of these polymers can be adjusted. In addition, polyacrylic acid, gelatin, and polyvinylpyrrolidone are also suitably used because the viscosity of these polymers increases only slightly when dissolved in an aqueous solvent and it is thus possible to increase the solids content in the aqueous solution A.
[0022] The water-soluble core agent is not particularly limited as long as it can be dissolved in an aqueous solvent. The lower limit of the solubility in an aqueous solvent at 20° C. is preferably 0.1% by weight, and the upper limit thereof is preferably 0.5% by weight.
[0023] Herein, the “solubility of the water-soluble core agent in an aqueous solvent at 20° C.” means the maximum amount of the water-soluble core agent at which the solution remains homogeneous when the water-soluble core agent is added to the aqueous solvent at 20° C.
[0024] Examples of the water-soluble core agent include curing agents and/or curing accelerators, foaming agents, adhesives, inks, cosmetic materials, and flavoring agents. For example, in the case where the water-soluble core agent contains a curing agent and/or a curing accelerator, such microcapsules may be suitably used as a latent curing agent and/or a latent curing accelerator. Examples of the curing agent and/or curing accelerator include, but not limited to, hydrazide compounds, amine compounds such as aliphatic polyamine compounds, primary amine compounds, tertiary amine compounds, and imidazole compounds, or phosphorus catalysts. In particular, malonic dihydrazide, dicyandiamide, and 1-benzyl-2-methylimidazole are preferred for their high solubility in an aqueous solvent.
[0025] In the case where the water-soluble core agent contains a foaming agent, the resulting microcapsules may be suitably used as microcapsule-type foaming agents that expand by light or heat. Examples of the foaming agent include, but not limited to, tetrazole compounds. Any tetrazole compound may be used, but 3-(1H-tetrazol-5-yl)aniline is preferred.
[0026] In the case where the water-soluble core agent contains a cosmetic material, the resulting microcapsules may be suitably used as microcapsule-type cosmetic agents that release the core agent by heat or pressure. Any cosmetic material may be used, but glycerin, hyaluronic acid, and arginine are preferred.
[0027] According to the method for producing microcapsules of the present invention, it is possible to produce microcapsules excellent in retentivity and releasability of the core agent, even if the core agent is a water-soluble core agent having high solubility in an aqueous solvent and high polarity (for example, a water-soluble core agent having an SP value of 10 or more).
[0028] The “SP value” herein refers to a solubility parameter δ calculated from formula (A) shown below, using Okitsu's ΔF and Δv values for various atomic groups (Toshinao Okitsu, Setchaku, Kobunshi Kankokai, 1996, Vol. 40, No. 8, pp. 342-350). In the case of mixtures and copolymers, the SP value refers to a solubility parameter δ mix calculated from formula (B) shown below.
[0000] δ=ΣΔ F/ΣΔv (A)
[0000] δ mix =φ 1 δ 1 +φ 2 δ 2 + . . . φ n δ n (B)
[0029] In these formulae, ΔF represents Okitsu's ΔF for various atomic groups and Δv represents the molar volume Δv. The symbol φ represents the volume fraction or molar fraction, with φ 1 +φ 2 + . . . φ n =1.
[0030] The amount of the water-soluble core agent is not particularly limited. Yet, the lower limit of the amount relative to 100 parts by weight of a raw material constituting the shell is preferably 20 parts by weight, and the upper limit thereof is preferably 150 parts by weight, in terms of weight ratio of the enclosure in the microcapsule as well as in terms of releasability and retentivity of the water-soluble core agent. The lower limit of the amount is more preferably 40 parts by weight, and the upper limit thereof is more preferably 100 parts by weight.
[0031] The “raw material constituting the shell” refers to one obtained by adding a crosslinking agent or the like as needed to the aqueous solvent-soluble polymer.
[0032] The relationship between the aqueous solvent-soluble polymer and the water-soluble core agent is preferably such that the ratio of the solubility of the water-soluble core agent in an aqueous solvent at 20° C. to the solubility of the aqueous solvent-soluble polymer in an aqueous solvent at 20° C. (solubility of the water-soluble core agent/solubility of the aqueous solvent-soluble polymer) is more than 1.0. If the solubility ratio is more than 1.0, the aqueous solvent-soluble polymer will be deposited before the water-soluble core agent, so that leakage of the water-soluble core agent into the non-polar solvent b can be suppressed. The solubility ratio is more preferably more than 1.2.
[0033] As long as the aqueous solution A is one obtained by dissolving at least an aqueous solvent-soluble polymer and a water-soluble core agent in an aqueous solvent, the aqueous solution A may further contain a crosslinking agent that crosslinks the aqueous solvent-soluble polymer.
[0034] In the case of using polyvinyl alcohol as the aqueous solvent-soluble polymer, examples of the crosslinking agent to be added to the aqueous solution A include titanium alkoxide, titanium chelate, and a water-soluble silane coupling agent. In the case of using gelatin as the aqueous solvent-soluble polymer, examples of the crosslinking agent to be added to the aqueous solution A include formaldehyde, glutaraldehyde, titanium chelate, and water-soluble silane coupling agent.
[0035] The upper limit of the viscosity of the aqueous solution A is preferably 50 mPa·s, in terms of size of droplets of the aqueous solution A in the emulsion and particle size of microcapsules, as well as in terms of selectively preparing a water-in-oil (w/o) emulsion.
[0036] The non-polar solution B is obtained by dissolving an emulsifier or a dispersant in a non-polar medium.
[0037] The non-polar medium is not particularly limited, and is suitably selected in accordance with an aqueous solvent.
[0038] The relationship between the aqueous solvent and the non-polar medium is preferably such that the non-polar medium has a higher boiling point than the aqueous solvent, and the solubility of the aqueous solvent in the non-polar medium at 20° C. is 5% by weight or less. Use of such an aqueous solvent and a non-polar medium enables preparation of a stable emulsion and suppression of coalescence of droplets or the like in the step of forming a core-shell structure, thus enabling to control the particle size of the microcapsules.
[0039] The “solubility of the aqueous solvent in a non-polar medium at 20° C.” refers to the amount of the aqueous solvent in the non-polar medium when the non-polar medium is analyzed by gas chromatography at 20° C. after mixing the non-polar medium and the aqueous solvent and stirring the mixture for one day.
[0040] In the case where the aqueous solvent is water (boiling point: 100° C.), examples of the non-polar medium include normal paraffinic solvents such as Norpar 13 and Norpar 15 (both available from Exxon Mobil Corporation), naphthenic solvents such as Exxsol D30 and Exxsol D40 (both available from Exxon Mobil Corporation), isoparaffinic solvents such as Isopar G, Isopar H, Isopar L, and Isopar M (all available from Exxon Mobil Corporation), octane, nonane, and decane. These may be used alone or in combination of two or more thereof. Among these, Isopar H and Isopar M are preferred because of their low solubility in water.
[0041] The emulsifier is not particularly limited as long as it can be dissolved in a non-polar medium. Yet, the emulsifier preferably has an HLB of 10 or less. An emulsifier having an HLB of 10 or less can stably prepare a water-in-oil (w/o) emulsion, and can suppress formation of an oil-in-water emulsion (o/w) or a multi-layer emulsion (w/o/w).
[0042] Specific examples of the emulsifier include sorbitan monolaurate (HLB 8.6), sorbitan monopalmitate (HLB 6.7), sorbitan monostearate (HLB 4.7), sorbitan distearate (HLB 4.4), sorbitan monooleate (HLB 4.3), sorbitan sesquioleate (HLB 3.7), sorbitan tristearate (HLB 2.1), and sorbitan trioleate (HLB 1.8).
[0043] The lower limit of the amount of the emulsifier added relative to 100 parts by weight of the non-polar medium is preferably 0.05 parts by weight, and the upper limit thereof is preferably 5 parts by weight. If the amount of the emulsifier added is 0.05 parts by weight or more, a water-in-oil (w/o) emulsion can be stably prepared. If the amount of the emulsifier added is 5 parts by weight or less, the size of droplets of the aqueous solution A in the emulsion will be adequate, resulting in microcapsules having an adequate particle size.
[0044] The dispersant is not particularly limited as long as it can be dissolved in a non-polar medium. Yet, the dispersant preferably has a molecular weight of 1000 or more. A dispersant having a molecular weight of 1000 or more can further stabilize droplets of the aqueous solution A in the emulsion by steric repulsion.
[0045] Specific examples of the dispersant include polydimethylsiloxane, Solsperse 8000, Solsperse 13650, Solsperse 13300, Solsperse 17000, and Solsperse 21000 (all available from the Lubrizol Corporation).
[0046] The lower limit of the amount of the dispersant added relative to 100 parts by weight of the non-polar medium is preferably 0.1 parts by weight, and the upper limit thereof is preferably 10 parts by weight. If the amount of the dispersant added is 0.1 parts by weight or more, the dispersant can further stabilize droplets of the aqueous solution A in the emulsion by steric repulsion.
[0047] The non-polar solution B may further contain a crosslinking agent that crosslinks the aqueous solvent-soluble polymer.
[0048] Examples of the crosslinking agent to be added to the non-polar solution B include, but not limited to, hexamethylene diisocyanate, oil-soluble silane coupling agents, titanium alkoxide, isocyanate-containing polymers, isocyanate-containing oligomers, and silicone alkoxy oligomers.
[0049] In preparation of an emulsion by dispersing the aqueous solution A in the non-polar solution B, the non-polar solution B may be added to the aqueous solution A, or the aqueous solution A may be added to the non-polar solution B. Examples of the emulsification method include a method in which a homogenizer is used for stirring, a method in which ultrasonic irradiation is used for emulsification, a method in which an emulsion is formed through microchannels or SPG membranes, a method in which a spray is used for spraying, and a phase-transfer emulsification method.
[0050] At this point, the weight ratio of the aqueous solution A to the non-polar solution B is 1/10 to 1/1. If the weight ratio is less than 1/10, the solids content in the emulsion will be low, resulting in a low yield of microcapsules. If the weight ratio is more than 1/1, the volume percent of the aqueous solution A relative to the non-polar solution B will be too high, so that a water-in-oil (w/o) emulsion cannot be selectively prepared, thus unfortunately resulting in a multi-layer emulsion (for example, an o/w/o emulsion). As a result, coalescence of droplets of the aqueous solution A or agglomeration of microcapsules may occur, or the particle size of microcapsules may increase. The lower limit of the weight ratio is preferably 1/4, and the upper limit thereof is preferably 2/3.
[0051] The method for producing microcapsules of the present invention subsequently includes the step of forming a core-shell structure in which the water-soluble core agent is covered with a shell containing the aqueous solvent-soluble polymer by heating the emulsion at a temperature of 20° C. to 100° C. and/or decompressing the emulsion at a pressure of 0.1 to 0.001 MPa to remove the aqueous solvent. Removal of the aqueous solvent enables deposition of the aqueous solvent-soluble polymer while phase-separating the aqueous solvent-soluble polymer and the water-soluble core agent so as to form a core-shell structure.
[0052] If the temperature is lower than 20° C. or if the pressure is more than 0.1 MPa, removal of the aqueous solvent will take time, thus causing leakage of the water-soluble core agent into the non-polar solution B. If the temperature is higher than 100° C. or if the pressure is less than 0.001 MPa, it will cause bumping of the aqueous solvent. Thus, the core-shell structure cannot be formed.
[0053] In the step of forming a core-shell structure, it is possible to form pores in the shell of each microcapsule by adjusting temperature and pressure conditions. Thereby, the retentivity and the releasability of the water-soluble core agent can be controlled. The average pore size of such pores tends to increase as the temperature in the step of forming a core-shell structure increases.
[0054] For example, in the case where the aqueous solvent is removed at a temperature of 75° C. and a pressure of 0.1 MPa, for example, it results in microcapsules having an average particle size of 5 μm in which pores having an average pore size of about 2.5 μm are formed on the surface (see FIG. 1 ). In contrast, in the case where the aqueous solvent is removed at a temperature of 45° C. and a pressure of 0.1 MPa, for example, it results in microcapsules having an average particle size of 5 μm with no pores on the surface (see FIG. 2 ).
[0055] It should be noted that preferably no pores are present in the shell of the microcapsule in order to improve the retentivity of the water-soluble core agent at room temperature. While the temperature and pressure conditions must be moderated in order to ensure that no pores are present, the evaporation rate of the aqueous solvent is preferably increased in terms of productivity.
[0056] Conditions that satisfy the above requirements are as follows: for example, in the case where the aqueous solvent contains water, it is preferred to remove the aqueous solvent at a temperature of 35° C. to 70° C. and a pressure of 0.1 to 0.01 MPa, and it is more preferred to remove the aqueous solvent under temperature and pressure conditions above the vapor pressure curve of water. In addition, for example, in the case where the aqueous solvent is methanol only, it is preferred to remove the aqueous solvent at temperature of 20° C. to 55° C. and a pressure of 0.1 to 0.04 MPa, and it is more preferred to remove the aqueous solvent under temperature and pressure conditions above the vapor pressure curve of methanol.
[0057] In addition, as for the relationship between the temperature in the step of forming a core-shell structure and the melting point of the aqueous solvent-soluble polymer, the difference between the melting point of the aqueous solvent-soluble polymer and the temperature in step of forming a core-shell structure (i.e., (the melting point of the aqueous solvent-soluble polymer)−(the temperature in the step of forming a core-shell structure)) is preferably higher than 1° C., in terms of suppressing agglomeration of microcapsules. Such agglomeration of microcapsules can also be suppressed by adding a crosslinking agent that crosslinks the aqueous solvent-soluble polymer to the aqueous solution A.
[0058] The melting point of the aqueous solvent-soluble polymer can be measured by heating 5 mg of samples from room temperature to 200° C. at 5° C./min in nitrogen atmosphere, using a DSC (for example, EXSTAR DSC6200 available from Hitachi High-Tech Science Corporation).
[0059] The resulting microcapsules may be further coated, as needed. Examples of the method for further coating the microcapsules include, but not limited to, the drying-in-liquid method in which polystyrene or the like is used, interfacial polycondensation of hexamethylene diisocyanate or the like, polycondensation reaction of a silane coupling agent or titanium alkoxide.
[0060] The resulting microcapsules may be repeatedly washed with purified water, and then dried by, for example, vacuum drying.
[0061] The method for producing microcapsules of the present invention can produce microcapsules excellent in retentivity and releasability of a water-soluble core agent. In addition, the particle size of the microcapsules can be controlled by adjusting the size of droplets of the aqueous solution A in the emulsion. Further, the retentivity and the releasability of the water-soluble core agent can be controlled by adjusting the temperature and pressure conditions in the step of forming a core-shell structure.
[0062] Another aspect of the present invention is a microcapsule obtained by the method for producing microcapsules of the present invention.
[0063] As for the shell thickness of the microcapsule of the present invention, the lower limit is preferably 0.05 μm and the upper limit is preferably 0.8 μm, in terms of retentivity and releasability of the water-soluble core agent. The lower limit of the shell thickness is more preferably 0.08 μm, and the upper limit thereof is more preferably 0.5 μm.
[0064] The shell thickness is a value calculated using formulae (1) and (2) shown below. In other words, it is a value determined by subtracting the diameter of the water-soluble core agent calculated from the volume of the microcapsule and the proportion of the enclosure volume from the average particle size of the microcapsules.
[0000] Shell thickness={(average particle size of microcapsules)−(diameter of water-soluble core agent)}/2 (1)
[0000] Diameter of water-soluble core agent=2×{(3×volume of microcapsule×proportion of enclosure volume)/(4×π)} (1/3) (2)
[0065] As for the proportion of the enclosure volume in the microcapsule of the present invention, the lower limit is preferably 15 volume % and the upper limit is preferably 70 volume %, in terms of retentivity and releasability of the water-soluble core agent. The lower limit of the proportion of the enclosure volume is more preferably 25 volume %, and the upper limit thereof is more preferably 50 volume %.
[0066] The “proportion of the enclosure volume” herein means a value calculated from formula (3) shown below, using the volume of the microcapsule calculated from the average particle size and the amount of the core agent determined by gas chromatography.
[0000] Proportion of enclosure volume (%)=(amount of water-soluble core agent (% by weight)/specific gravity of water-soluble core agent (g/cm 3 ))/volume of microcapsule (cm 3 ) (3)
[0067] As for the average particle size of the microcapsules of the present invention, the lower limit is preferably 0.1 μm and the upper limit is preferably 50.0 μm, in terms of retentivity of the water-soluble core agent as well as in terms of suppressing leakage of the water-soluble core agent into the non-polar solution B during removal of the aqueous solvent in the step of forming a core-shell structure. The upper limit of the average particle size is more preferably 10.0 μm.
[0068] The “average particle size” herein means the average value of maximum diameters, measured with a caliper, of 50 microcapsules randomly selected from microcapsules observed with a scanning electron microscope at a magnification that enables observation of about 100 microcapsules in one field of view.
[0069] The microcapsule of the present invention may or may not have pores on the surface. Although the average pore size of such pores is not particularly limited, the upper limit is preferably 3.0 μm in terms of retentivity of the water-soluble core agent. The upper limit of the average pore size is more preferably 2.5 μm.
[0070] The “average pore size” means the average value of pore sizes, measured with a caliper, of 25 microcapsules randomly selected from images of 10 fields of view of microcapsules observed with a scanning electron microscope at a magnification that enables observation of about 10 microcapsules in one field of view.
Advantageous Effects of Invention
[0071] The present invention can provide a method for producing microcapsules, wherein the method can control the particle size and produce microcapsules excellent in retentivity and releasability of a water-soluble core agent. The present invention can also provide a microcapsule excellent in retentivity and releasability of a water-soluble core agent.
BRIEF DESCRIPTION OF DRAWINGS
[0072] FIG. 1 is an electron micrograph of microcapsules obtained by removing an aqueous solvent at a temperature of 75° C. and a pressure of 0.1 MPa according to the method for producing microcapsules of the present invention.
[0073] FIG. 2 is an electron micrograph of microcapsules obtained by removing an aqueous solvent at a temperature of 45° C. and a pressure of 0.1 MPa according to the method for producing microcapsules of the present invention.
DESCRIPTION OF EMBODIMENTS
[0074] The present invention is described in further detail below with reference to examples, but the present invention is not limited to these examples.
Example 1
[0075] Polyvinyl alcohol (W-24N available from DENKI KAGAKU KOGYO KABUSHIKI KAISHA, solubility in water at 20° C. of 16% by weight, melting point of 180° C., amount of 3 parts by weight) as an aqueous solvent-soluble polymer and malonic dihydrazide (SP value of 18.6, solubility in water at 20° C. of 45% by weight, amount of 1 part by weight) as a water-soluble core agent were dissolved in water (boiling point of 100° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.1% by weight or less, amount of 75 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 29 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=2.8).
[0076] Separately, a non-polar solution B containing sorbitan sesquioleate (1% by weight) as an emulsifier in an isoparaffinic solvent (Isopar H available from Exxon Mobil Corporation, boiling point of 179° C.) as a non-polar medium was prepared.
[0077] Then, the aqueous solution A (79 parts by weight) was added to the non-polar solution B (375 parts by weight), and the mixture was emulsified and dispersed by stirring at 5000 rpm with a homogenizer. Subsequently, the resulting emulsion was heated at 70° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the water, whereby a dispersion of microcapsules having a core-shell structure was obtained. Microcapsules in the microcapsule dispersion obtained were repeatedly washed with cyclohexane, and then vacuum-dried.
Example 2
[0078] Microcapsules were obtained in the same manner as in Example 1 except that the emulsion was heated at 55° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the water.
Example 3
[0079] Microcapsules were obtained in the same manner as in Example 1 except that the emulsion was heated at 45° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the water.
Example 4
[0080] Gelatin (available from Wako Pure Chemical Industries, Ltd., solubility in water at 20° C. of 20% by weight, melting point of 40° C. (crosslinking with glutaraldehyde results in disappearance of the melting point), amount of 3 parts by weight) as an aqueous solvent-soluble polymer, a 25% aqueous solution of glutaraldehyde (available from Wako Pure Chemical Industries, Ltd., amount of 1 part by weight), and malonic dihydrazide (SP value of 18.6, solubility in water at 20° C. of 45% by weight, amount of 1 part by weight) as a water-soluble core agent were dissolved in water (boiling point of 100° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.1% by weight or less, amount of 75 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 13 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=2.3).
[0081] Then, microcapsules were obtained in the same manner as in Example 1 except that the above aqueous solution A was used in an amount of 80 parts by weight and the emulsion was heated at 45° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the water.
Example 5
[0082] The microcapsules (20 parts by weight) obtained in Example 4 were dispersed in Isopar H (200 parts by weight), and hexamethylene diisocyanate (1 part by weight) was added to the dispersion, followed by stirring at 60° C. for 24 hours. Microcapsules in the microcapsule dispersion obtained were repeatedly washed with cyclohexane, and then vacuum-dried.
Example 6
[0083] Gelatin (available from Wako Pure Chemical Industries, Ltd., solubility in water at 20° C. of 20% by weight, melting point of 40° C. (crosslinking with glutaraldehyde results in disappearance of the melting point), amount of 1.5 parts by weight) as an aqueous solvent-soluble polymer, a 25% aqueous solution of glutaraldehyde (available from Wako Pure Chemical Industries, Ltd., amount of 0.5 parts by weight), and malonic dihydrazide (SP value of 18.6, solubility in water at 20° C. of 45% by weight, amount of 0.5 parts by weight) as a water-soluble core agent were dissolved in water (boiling point of 100° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.1% by weight or less, amount of 35 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 13 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=2.3).
[0084] Microcapsules were obtained in the same manner as in Example 4 except that the above aqueous solution A was used in an amount of 37.5 parts by weight.
Example 7
[0085] Gelatin (available from Wako Pure Chemical Industries, Ltd., solubility in water at 20° C. of 20% by weight, melting point of 40° C. (crosslinking with glutaraldehyde results in disappearance of the melting point), amount of 10 parts by weight) as an aqueous solvent-soluble polymer, a 25% aqueous solution of glutaraldehyde (available from Wako Pure Chemical Industries, Ltd., amount of 3.3 parts by weight), and malonic dihydrazide (SP value of 18.6, solubility in water at 20° C. of 45% by weight, amount of 3.3 parts by weight) as a water-soluble core agent were dissolved in water (boiling point of 100° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.1% by weight or less, amount of 233.4 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 13 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=2.3).
[0086] Microcapsules were obtained in the same manner as in Example 4 except that the above aqueous solution A was used in an amount of 250 parts by weight.
Example 8
[0087] Microcapsules were obtained in the same manner as in Example 4 except that the emulsion was heated at 90° C. and decompressed under vacuum of 0.075 MPa in a reactor equipped with a decompressor to remove the water.
Example 9
[0088] Microcapsules were obtained in the same manner as in Example 4 except that the emulsion was heated at 70° C. and decompressed under vacuum of 0.04 MPa in a reactor equipped with a decompressor to remove the water.
Example 10
[0089] Microcapsules were obtained in the same manner as in Example 4 except that the emulsion was heated at 40° C. and decompressed under vacuum of 0.015 MPa in a reactor equipped with a decompressor to remove the water.
Example 11
[0090] Polyacrylic acid (available from Wako Pure Chemical Industries, Ltd., solubility in water at 20° C. of 25% by weight, melting point of 200° C. or higher, amount of 3 parts by weight) as an aqueous solvent-soluble polymer and 2-methylimidazole (SP value of 10.8, solubility in water at 20° C. of 80% by weight, amount of 1 part by weight) as a water-soluble core agent were dissolved in water (boiling point of 100° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.1% by weight or less, amount of 75 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 11 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=3.2).
[0091] Then, microcapsules were obtained in the same manner as in Example 1 except that the above aqueous solution A was used and the emulsion was heated at 70° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the water.
Example 12
[0092] Polyacrylic acid (available from Wako Pure Chemical Industries, Ltd., solubility in water at 20° C. of 25% by weight, melting point of 200° C. or higher, amount of 3 parts by weight) as an aqueous solvent-soluble polymer and hexamethylenediamine (SP value of 10.1, solubility in water at 20° C. of 30% by weight, amount of 1 part by weight) as a water-soluble core agent were dissolved in water (boiling point of 100° C., solubility in isoparaffinic solvent Isopar Hat 20° C. of 0.1% by weight or less, amount of 75 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 10 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=1.2).
[0093] Microcapsules were obtained in the same manner as in Example 1 except that the above aqueous solution A was used and the emulsion was heated at 70° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the water.
Example 13
[0094] Polyvinylpyrrolidone (K-30 available from Dai-ichi Kogyo Seiyaku Co., Ltd., solubility in methanol at 20° C. of 40% by weight, melting point of 160° C., amount of 3 parts by weight) as an aqueous solvent-soluble polymer and 3-(1H-tetrazol-5-yl)aniline (SP value of 14.9, solubility in methanol at 20° C. of 60% by weight, amount of 1 part by weight) as a water-soluble core agent were dissolved in methanol (boiling point of 65° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.6% by weight, amount of 75 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 9 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=1.5).
[0095] Then, microcapsules were obtained in the same manner as in Example 1 except that the above aqueous solution A was used and the emulsion was heated at 30° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the methanol.
Example 14
[0096] Polyvinylpyrrolidone (K-30 available from Dai-ichi Kogyo Seiyaku Co., Ltd., solubility in methanol at 20° C. of 40% by weight, melting point of 160° C., amount of 3 parts by weight) as an aqueous solvent-soluble polymer and 1-benzyl-2-methylimidazole (SP value of 10.6, solubility in methanol at 20° C. of 50% by weight, amount of 1 part by weight) as a water-soluble core agent were dissolved in methanol (boiling point of 65° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.6% by weight, amount of 75 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 9 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=1.3).
[0097] Then, microcapsules were obtained in the same manner as in Example 1 except that the above aqueous solution A was used and the emulsion was heated at 30° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the methanol.
Example 15
[0098] Gelatin (available from Wako Pure Chemical Industries, Ltd., solubility in water/methanol (50/50) at 20° C. of 8% by weight, melting point of 40° C. (crosslinking with glutaraldehyde results in disappearance of the melting point), amount of 3 parts by weight) as an aqueous solvent-soluble polymer, a 25% aqueous solution of glutaraldehyde (available from Wako Pure Chemical Industries, Ltd., amount of 1 part by weight), and 3-(1H-tetrazol-5-yl)aniline (SP value of 14.9, solubility in water/methanol (50/50) at 20° C. of 20% by weight, amount of 1 part by weight) as a water-soluble core agent were dissolved in a mixed solvent of water (boiling point of 100° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.1% by weight or less, amount of 35.25 parts by weight) and methanol (boiling point of 65° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.6% by weight, amount of 35.25 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 15 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=2.5).
[0099] Then, microcapsules were obtained in the same manner as in Example 1 except that the above aqueous solution A was used in an amount of 80 parts by weight and the emulsion was heated at 70° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the methanol.
Comparative Example 1
[0100] Preparation was performed in the same manner as in Example 1 except that the emulsion was heated at 120° C. and decompressed under vacuum of 0.1 MPa in a reactor equipped with a decompressor to remove the water. However, no core-shell structures were formed (no capsules were formed).
Comparative Example 2
[0101] Gelatin (available from Wako Pure Chemical Industries, Ltd., solubility in water at 20° C. of 20% by weight, amount of 16 parts by weight) as an aqueous solvent-soluble polymer, a 25% aqueous solution of glutaraldehyde (available from Wako Pure Chemical Industries, Ltd., amount of 5.3 parts by weight), and malonic dihydrazide (SP value of 18.6, solubility in water at 20° C. of 45% by weight, amount of 5.3 parts by weight) as a water-soluble core agent were dissolved in water (boiling point of 100° C., solubility in isoparaffinic solvent Isopar H at 20° C. of 0.1% by weight or less, amount of 373.4 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 11 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=2.3).
[0102] The aqueous solution A (400 parts by weight) was added to the non-polar solution B (375 parts by weight), and the mixture was emulsified and dispersed by stirring at 5000 rpm with a homogenizer. As a result, a multi-layer emulsion was formed, resulting in a viscous emulsion. The water was removed in the same manner as in Example 4, but no core-shell structured microcapsules were obtained (no capsules were formed).
Comparative Example 3
[0103] Gelatin (available from Wako Pure Chemical Industries, Ltd., solubility in water at 20° C. of 20% by weight, amount of 1.2 parts by weight) as an aqueous solvent-soluble polymer, a 25% aqueous solution of glutaraldehyde (available from Wako Pure Chemical Industries, Ltd., amount of 0.4 parts by weight), and malonic dihydrazide (SP value of 18.6, solubility in water at 20° C. of 45% by weight, amount of 0.4 parts by weight) as a water-soluble core agent were dissolved in water (boiling point of 100°, solubility in isoparaffinic solvent Isopar H at 20° C. of 0.1% by weight or less, amount of 28 parts by weight) to obtain an aqueous solution A (viscosity of the aqueous solution: 11 mPa·s; ratio of the solubility of the water-soluble core agent to the solubility of the aqueous solvent-soluble polymer=2.3).
[0104] The aqueous solution A (30 parts by weight) was added to the non-polar solution B (375 parts by weight), and the mixture was emulsified and dispersed by stirring at 5000 rpm with a homogenizer. Subsequently, the water was removed in the same manner as in Example 4, and core-shell structured microcapsules were obtained. However, the yield of the resulting microcapsules was very low.
Comparative Example 4
[0105] Polyvinyl alcohol (KH-20 available from the Nippon Synthetic Chemical Industry Co., Ltd., solubility in water at 20° C. of 16% by weight, amount of 3 parts by weight) as an aqueous solvent-soluble polymer and malonic dihydrazide (SP value of 18.6, solubility in water at 20° C. of 45% by weight, amount of 1 part by weight) as a water-soluble core agent were dissolved in water (boiling point of 100° C., amount of 75 parts by weight) to obtain an aqueous solution. This solution was spray-dried at 115° C. and 0.1 MPa with a spray dryer, whereby core-shell structured microcapsules were obtained.
Comparative Example 5
[0106] Sodium alginate (available from Wako Pure Chemical Industries, Ltd., amount of 3 parts by weight) and malonic dihydrazide (SP value of 18.6, solubility in water at 20° C. of 45% by weight, amount of 1 part by weight) as a water-soluble core agent were dissolved in water (75 parts by weight) to obtain an aqueous solution. This aqueous solution was added dropwise to water (150 parts by weight) containing calcium chloride (3 parts by weight) dissolved therein to obtain a dispersion of microcapsules (the shell contains calcium alginate).
[0000] Microcapsules in the microcapsule dispersion obtained were repeatedly washed with cyclohexane, and then vacuum-dried.
<Evaluation>
[0107] The microcapsules obtained in the examples and the comparative examples were evaluated as follows. Table 1 shows the results.
(1) Measurement of Average Particle Size
[0108] Microcapsules were observed with a scanning electron microscope at a magnification that enables observation of about 100 microcapsules in one field of view. Then, the maximum diameters of 50 randomly selected microcapsules were measured with a caliper, and the average value was determined as the average particle size.
(2) Measurement of Average Pore Size
[0109] Microcapsules were observed with a scanning electron microscope at a magnification that enables observation of about 10 microcapsules in one field of view, and images of 10 fields of view were provided. Then, the pore sizes of 25 randomly selected microcapsules were measured with a caliper, and the average value was determined as the average pore size. The pores were observed on the surface of the microcapsules obtained only in Examples 1 and 2.
(3) Shell Thickness
[0110] Using the proportion of the enclosure volume calculated from formula (3) shown below, the diameter of the water-soluble core agent was calculated from formula (2) shown below. Further, using the diameter of the water-soluble core agent calculated, the shell thickness was calculated from formula (1) shown below.
[0000] Shell thickness={(average particle size of microcapsules)−(diameter of water-soluble core agent)}/2 (1)
[0000] Diameter of water-soluble core agent=2×{(3×volume of microcapsule×proportion of enclosure volume)/(4×π)} (1/3) (2)
[0000] Proportion of enclosure volume (%)=(amount of water-soluble core agent (% by weight)/specific gravity of water-soluble core agent (g/cm 3 ))/volume of microcapsule (cm 3 ) (3)
[0111] The volume of the microcapsule was calculated using the average particle size, and the amount of the water-soluble core agent was determined by gas chromatography.
(4) Retention Ratio of Water-Soluble Core Agent
[0112] The microcapsules (1.0 g) were dispersed in methyl ethyl ketone (100 mL) and the obtained dispersion was stirred at room temperature for 10 days. Subsequently, the microcapsules were removed by filtering. The methyl ethyl ketone in the obtained filtrate was removed by vacuum evaporation. Thereby the amount of the water-soluble core agent dissolved into the methyl ethyl ketone was measured, and the retention ratio of the water-soluble core agent was calculated from formula (4) shown below.
[0000] Retention ratio of water-soluble core agent=100−((amount of water-soluble core agent dissolved into methyl ethyl ketone)/(amount of water-soluble core agent encapsulated in capsules)×100)(% by weight) (4)
(5) Release Ratio of Water-Soluble Core Agent
[0113] The microcapsules (1.0 g) were dispersed in ethanol (100 mL) and the obtained dispersion was stirred at 40° C. for 10 days. Subsequently, the microcapsules were removed by filtering. The ethanol in the obtained filtrate was removed by vacuum evaporation. Thereby the amount of dissolved matter in the ethanol was measured, and the release ratio of the water-soluble core agent was calculated from formula (5) shown below.
[0000] Release ratio of water-soluble core agent=(amount of dissolved matter in ethanol)/(amount of water-soluble core agent encapsulated in microcapsules)×100(% by weight) (5)
[0000]
TABLE 1
Step of preparing an emulsion
Aver-
Re-
Aqueous
Step of
age
Aver-
ten-
solution
forming a core-
par-
age
Shell
tion
Aqueous solution A
A/
shell structure
ticle
pore
thick-
ratio
Release
Raw material
non-polar
Temp.
Pressure
Additional
size
size
ness
(wt
ratio
constituting the shell
Water-soluble core agent
solution B
(° C.)
(MPa)
coating layer
(μm)
(μm)
(μm)
%)
(wt %)
Example 1
Polyvinyl alcohol
Malonic dihydrazide
79/375
70
0.1
—
1.6
2.5
0.30
88
64
Example 2
55
0.1
—
2.1
0.1
0.38
95
45
Example 3
45
0.1
—
1.9
—
0.35
98
32
Example 4
Gelatin/glutaraldehyde
Malonic dihydrazide
80/375
45
0.1
—
1.2
—
0.23
90
78
Example 5
80/375
Hexamethylene
1.6
—
—
99
14
diisocyanate
Example 6
37.5/375
—
1.1
—
0.21
80
49
Example 7
250/375
—
2.2
—
0.42
84
35
Example 8
Gelatin/glutaraldehyde
Malonic dihydrazide
80/375
90
0.075
—
3.1
—
0.49
83
33
Example 9
70
0.04
—
2.6
—
0.39
80
32
Example 10
40
0.015
—
2.5
—
0.37
84
32
Example 11
Polyacrylic acid
2-Methylimidazole
79/375
70
0.1
—
1.4
—
0.22
96
186
Example 12
Hexamethylenediamine
—
2.3
—
0.39
94
137
Example 13
Polyvinylpyrrolidone
3-(1H-tetrazol-
79/375
30
0.1
—
4.6
—
0.50
89
283
5-yl)aniline
Example 14
1-Benzyl-2-
—
8.2
—
0.79
79
317
methylimidazole
Example 15
Gelatin/glutaraldehyde
3-(1H-tetrazol-5-
80/375
70
0.1
—
3.0
—
0.44
81
38
yl)aniline
Comparative
Polyvinyl alcohol
Malonic dihydrazide
79/375
120
0.1
—
No capsules were formed
Example 1
Comparative
Gelatin/glutaraldehyde
Malonic dihydrazide
400/375
45
0.1
—
No capsules were formed
Example 2
Comparative
30/375
—
0.9
—
0.19
69
45
Example 3
Comparative
Polyvinyl alcohol
Malonic dihydrazide
—
—
—
—
6.8
—
—
98
1
Example 4
Comparative
Calcium alginate
Malonic dihydrazide
—
—
—
—
1000
—
—
99
1
Example 5
or
more
The shell also dissolves in ethanol.
INDUSTRIAL APPLICABILITY
[0114] The present invention can provide a method for producing microcapsules, wherein the method can control the particle size and produce microcapsules excellent in retentivity and releasability of a water-soluble core agent. The present invention can also provide a microcapsule excellent in retentivity and releasability of a water-soluble core agent.
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The present invention aims to provide a method for producing microcapsules, wherein the method can control the particle size and produce microcapsules excellent in retentivity and releasability of a water-soluble core agent. The present invention also aims to provide a microcapsule excellent in retentivity and releasability of a water-soluble core agent. The present invention provides a method for producing microcapsules comprising the steps of: preparing an emulsion by dispersing an aqueous solution A obtained by dissolving at least an aqueous solvent-soluble polymer and a water-soluble core agent in an aqueous solvent in a non-polar solution B obtained by dissolving an emulsifier or a dispersant in a non-polar medium; and forming a core-shell structure in which the water-soluble core agent is covered with a shell containing the aqueous solvent-soluble polymer by heating the emulsion at a temperature of 20° C. to 100° C. and/or decompressing the emulsion at a pressure of 0.1 to 0.001 MPa to remove the aqueous solvent, the weight ratio of the aqueous solution A to the non-polar solution B being 1/10 to 1/1.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a Continuation-in-Part of application Ser. No. 08/550,457, filed Oct. 30, 1995, now U.S. Pat. No. 5,626,022, which is a Continuation-in-Part of application Ser. No. 08/250,537, filed May 31, 1994, now U.S. Pat. No. 5,461,867.
BACKGROUND OF THE INVENTION
The present invention relates generally to containers for heating or cooling materials such as food, beverages, medicines, and the like and, more specifically, to a container that includes an internal module that adds heat to or removes heat from the materials in the surrounding container.
Containers may have integral modules for warming materials in the container, such as Japanese sake, coffee, or soup. Examples of such self-heating containers are disclosed in U.S. Pat. No. 4,640,264, issued to Yamaguchi et al., and U.S. Pat. No. 4,784,113, issued to Nagai et al. Such containers typically include an outer can or body, in which the food or beverage is sealed, and an inner can or module that contains two chemical reactants. The reactants are stable when separated from one another but, when mixed, produce an exothermic reaction. It is known that combinations of other reactants will produce endothermic reactions to cool the container contents.
The inner can is typically disposed adjacent one end of the container body. The inner can has two chambers, each of which contains one of the chemical reactants, separated by a breakable barrier such as metal foil or a thin plastic film. Typically, one of the reactants is in solution, and the other is in a solid powdered or granular form. A rod extends into the outer can at the end adjacent the inner can. One end of the rod is adjacent to the barrier, and the other end terminates in a button outside the outer can. To initiate the reaction that warms or cools the contents of the outer can, the can is disposed with that end upright. Depressing the button forces the rod downward, breaking the barrier and allowing the liquid reactant to drop into the solid reactant. The end of the rod may have a flared head to facilitate complete puncturing of the barrier. The heat produced by the resulting exothermic reaction or used by the resulting endothermic reaction is transferred between the inner can and the contents of the outer can by conduction. Exothermic reactions also typically generate a gas, which is allowed to escape through vents in the end of the container. When the reaction has stopped, the container is inverted. The second end of the outer can has a seal, such as pull-tab, that may be opened and through which the user may consume the heated contents.
Self-heating and self-cooling containers known in the art are uneconomical to manufacture because the mechanism for puncturing the foil barrier commonly has multiple components. The inner can contains the solid reactant and has a short, tubular cap sealing one end. The cap contains the liquid reactant. One end of the cap is sealed with the foil barrier, and the rod extends through an opening in the other end of the cap. Depressing the button forces the rod to slide in the opening until it punctures the foil barrier. Practitioners in the art have found that forcing a rod through the foil opens a large passage through which the liquid reactant can flow, thereby minimizing the time required for the liquid to drain from the cap into the remainder of the inner can. However, fabricating and assembling the multiple components increases the cost of the container. Furthermore, liquid can leak between the rod and the opening in the cap through which the rod moves. Practitioners in the art have therefore disposed a ring of wax around the rod where it exits the inner can to improve sealing. The step of adding the wax, however, increases the manufacturing complexity and, ultimately, cost of the container. Self-heating and self-cooling containers known in the art may also leak the powdery material that is the product of the completed reaction through the vents when the container is inverted.
The inner can may be unitarily formed with the outer can, as illustrated, for example, in U.S. Pat. No. 3,970,068, issued to Sato, and U.S. Pat. No. 5,088,870, issued to Fukuhara et al. The unitary container body is formed by providing a metal cylinder that is open at one end and closed at the other, and punching or deep-drawing a cavity in the closed end. A cap containing the liquid reactant is attached to the open end of the cavity.
After a self-heating container has been activated and the contents heated or cooled, heat transfer through the container wall rapidly equalizes the temperature of the contents with the environmental temperature. Thus, a heated beverage, for example, may cool undesirably before the user consumes it.
It would desirable for a user to know the length of time after activation the contents of a self-heating container will have reached a certain temperature. For example, it may be desirable to assure a user that a container having coffer will have reached 150 degrees Fahrenheit three minutes after activating the container. Nevertheless, the time between activation of a self-heating or self-cooling container and the onset of the chemical reaction is typically inconsistent, varying from container to container by seconds or even minutes due to variations in the composition of the reactants and the conditions under which they were manufactured. For example, it is known that the characteristics of quicklime (calcium oxide) may vary from manufacturer to manufacturer and even from batch to batch depending on moisture and temperature of the environment in which the quicklime is manufactured. Most commercially available quicklime is manufactured for use in cement for the construction trade. Because building contractors and masons do not need to precisely time of the onset of cement curing, manufacturers of calcium oxide typically do not exercise precise control over manufacturing variables such as environmental moisture and temperature.
It would be desirable to provide a self-heating or self-cooling container that has a minimal number of separate parts and can be economically manufactured. It would also be desirable to provide such a container with improved vent sealing to prevent leakage of powdery reaction products. It would further be desirable to provide such a container that begins the reaction at a consistent time after activation and that maintains its contents at the desired temperature for an extended period of time after the reaction is completed. These problems and deficiencies are clearly felt in the art and are solved by the present invention in the manner described below.
SUMMARY OF THE INVENTION
The present invention relates to a container having a container body, a thermic module at one end of the body, and a closure at the other end of the body. The body may have any suitable generally tubular shape, such as cylindrical or bottle-shaped. The food, beverage, medicine or other material to be heated or cooled is contained in a material cavity in the container body. A first reactant is contained in a portion of the thermic module. A second reactant is contained in another portion of the thermic module that extends into the material cavity of the container body. A breakable barrier inside the thermic module separates the two reactants. Although these reactants may be included in any compounds or mixtures known in the art, the first reactant is preferably a solid and the second reactant is preferably a liquid that produce an exothermic or endothermic reaction upon mixing. Mixing of the reactants, which may comprise any suitable chemical compounds or mixtures, produces an exothermic or endothermic chemical reaction, depending upon the reactants selected. To create an exothermic reaction, one reactant may be calcium oxide, and the other reactant may be water. The calcium oxide may be in granular or powdered form.
In certain embodiments, the thermic module may comprise two separate elements: a module cap and a module body. The module cap seals an open end of the module body and retains the first reactant in the module body. In certain embodiments, the breakable barrier may seal an open end of the module cap and retain the second reactant in the module cap. Nevertheless, the breakable barrier may be disposed in any suitable location in the thermic module.
In other embodiments, a portion of the thermic module may be unitarily formed with the container body to define a two-cavity unitarily formed container body. For example, the container body may include the material cavity and a unitarily formed reactant cavity. The first reactant may be retained in the reactant cavity. The thermic module may include a module cap. The second reactant may be retained in the module cap, which has an end sealed by the breakable barrier. Thus, a portion of such a thermic module is defined by the reactant cavity, and another portion is defined by the module cap.
The module cap includes an actuator that a user depresses to activate the container. An elongated member having one or more prongs extends toward the barrier from the module cap. Prior to actuation, the elongated member is in a retracted position. In response to the force applied to the actuator by the user, the prong or prongs move in an axial direction, i.e., toward the barrier, thereby puncturing it and allowing the first and second materials to mix. After removing finger pressure from the flexible member, it may snap or lock into the depressed or extended position with the prongs extended or it may resiliently resume the retracted position.
The actuator may have any suitable shape. For example, it may include a flexible member such as a circular disc. The flexible member may be made of a semi-rigid material such as plastic or an elastomeric material such as rubber. In embodiments in which the flexible member is made of a semi-rigid material, the flexible member may have a living hinge unitarily formed in its periphery to facilitate flexure.
The cap may have one or more vent channels between surfaces of the module cap and the module body that contact one another when the module cap is connected to the module body. The channels allow gaseous products of a reaction to escape but inhibit leakage of solids.
After the reaction in the self-heating or self-cooling container is started, the user may invert the container. The gaseous reaction products escape through the vent channels. After the reaction is completed, the user may remove a closure, such as a pull tab, to access the contents for consumption. Despite the then-inverted orientation of the container, the channels minimize leakage of solid reaction products. (The liquid reactant does not leak because it is used up in the reaction or absorbed by the solids.)
To further minimize leakage of solids, the container may include a filter ring between the module body and the module cap. The filter ring thus blocks a portion of each vent channel. The filter ring is made of a suitable material that allows gaseous products to escape but blocks solid particles.
In certain embodiments, the solid reactant may be contained in a porous bag to minimize leakage of particles.
In accordance with still another feature of the invention, the container body may have double-walled construction, with a vacuum space between the inner and outer walls. After the container is activated, the vacuum insulates the container and prevents heat transfer between the external environment and the materials in the container that have been heated or cooled. Thus, heated materials remain hot, and cooled materials remain cooled. The container may be reused by replacing the thermic module. The thermic module may be removable from the container to facilitate replacement by a threaded screw connection or other suitable connection.
To facilitate use of the container, the container body may include instructions that can be read by a user when the container is oriented with the end having the thermic module vertically above the end having the closure. In other words, the instructions are inverted with respect to the orientation of the container in which a user would consume the contents through the closure.
The foregoing, together with other features and advantages of the present invention, will become more apparent when referring to the following specification, claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following detailed description of the embodiments illustrated in the accompanying drawings, wherein:
FIG. 1 is a side elevational view of the container, partially cut-away;
FIG. 2 is a plan view of the container;
FIG. 3 is a sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 1;
FIG. 5 is an enlarged view similar to FIG. 1, showing actuation of the container;
FIG. 6 is a partial perspective view of the container of FIGS. 1-5;
FIG. 7 is an enlarged view similar to FIG. 5, showing an alternative construction of the module cap;
FIG. 8 is a view similar to FIG. 1, showing an alternative container;
FIG. 9 is a sectional view of the container body by itself;
FIG. 10 is a top plan view of the cap;
FIG. 11 is a sectional view taken on line 11--11 of FIG. 10;
FIG. 12 is a perspective view of the lower end of the container, with the seal opened to expose the actuator disc;
FIG. 13 is a side elevational view of another alternative container, partially cut-away;
FIG. 14 is an enlarged view of a portion of FIG. 13;
FIG. 15 is a side elevational view of the exterior of the container, showing the inverted instructions printed thereon;
FIG. 16 is a perspective view of still another alternative container; and
FIG. 17 is a sectional view taken on line 17--17 of FIG. 16.
DESCRIPTION OF PREFERRED EMBODIMENTS
As illustrated in FIGS. 1-4, a container comprises a cylindrical container body 10, which may contain a beverage 12, and a thermic module 14 for heating beverage 12. Thermic module 14 seals one end of container body 10, and an endcap 15 with a pull-tab closure 16 of the type commonly used to seal beverage cans seals the other end. An exterior view of the end of the container at which thermic module 14 is disposed is shown in FIG. 6. When the container is actuated, as described below, thermic module 14 generates heat, which is transferred by conduction to beverage 12. The container may then be inverted and pull-tab closure 16 opened to allow beverage 12 to be consumed.
Thermic module 14 comprises a cylindrical module body 18 and a cylindrical module cap 20. Module cap 20 is of unitary construction and is made of a semi-rigid plastic, such as high density polyethylene. Module cap 20 has an actuator disc 22 and four prongs 24. A breakable barrier 34 made of metal foil is adhesively attached to module cap 20. Barrier 34 seals water 36 inside module cap 20. Module body 18 contains a solid chemical 38 such as calcium oxide, commonly known as quicklime. An annular cap channel 40 receives the lip 42 of module body 18, thereby sealing solid chemical 38 inside. Cap channel 40 may have crushable dimples 44 that improve sealing. Module body 18 is preferably made of a metal, such as aluminum.
As mentioned above, the container is sealed at both ends. Sealing ring 46 secures thermic module 14 in container body 10. Sealing ring 46 has a ring channel 48 that receives the hook-like lip 50 of container body 10. Sealing ring 46 is crimped over lip 50 to form a tight seal. At the opposite end of the container, endcap 15 has a similar endcap channel 51 that receives the opposite lip 53 of container body 10. Endcap 15 is crimped over the opposite lip 53 of container body 10 in a similar manner. A sealing compound (not shown) of the type commonly used in the can industry may be disposed in ring channel 48 to further improve sealing. Thermic module 14 is press-fit in the opening of sealing ring 46. The portion of thermic module 14 that contacts sealing ring 46 may have crushable dimples 52 to further improve sealing.
To actuate the container, a safety seal 54, which is adhesively attached to thermic module 14, must be removed or broken. Safety seal 54 minimizes the possibility of tampering or inadvertent actuation of the container. Although safety seal 54 may be plastic, foil, paper or other suitable films, it is preferably transparent to allow viewing of actuator disc 22. The container may also have an outer lid 55 made of plastic that snaps over the end of container body 10. Outer lid 55 not only further reduces the likelihood of inadvertent actuation, but can also be used to retain condiments such as a packet of sugar (not shown) or a promotional item such as a coupon (not shown) between it and safety seal 54. Lid 55 may be transparent.
As illustrated in FIG. 5, when an axially directed force is applied at or near the center of actuator disc 22, it flexes toward barrier 34. The distal ends of prongs 24 both move axially and spread apart radially to facilitate complete puncturing of barrier 34. Water 36 flows through the punctured barrier 34 and mixes with solid chemical 38. The resulting exothermic reaction produces heat, which is transferred to beverage 12 by conduction through module body 18, and carbon dioxide, which escapes through four vents 56 that are distributed around an annular lip 58 between module body 18 and module cap 20.
As best illustrated in FIGS. 3 and 4, vents 56 may comprise four flexible triangular flaps 60, which are in contact with one another when the pressures inside and outside module 14 are equal, but which spread apart to release the gas produced by the reaction. Alternatively, as illustrated in the embodiment shown in FIG. 7, a vent may be formed by a single flap 160.
In the retracted position of actuator disc 22, i.e., before the container is actuated, actuator disc 22 may appear convex or dome-shaped when viewed from the outside of the container, as shown in FIGS. 1 and 6. In its extended position, i.e., after the container has been actuated, actuator disc 22 may appear concave or dished, as shown in FIG. 5. Actuator disc 22 is preferably stable in both the extended and retracted positions, and "snaps" into the extended position when the container is actuated. The snapping action provides a positive visual and tactile indication to the user that the container has been actuated. At least a portion of actuator disc 22 must flex during the transition between the retracted and extended positions. In the illustrative embodiments, four radial folds 62 facilitate this transition by reducing the amount of force required to flex actuator disc 22. However, in other embodiments, actuator disc 22 may have more, fewer, or no radial folds 62.
Prongs 24 are distributed around the center of actuator disc 22 at the same radial distance. Prongs 24 may be formed by cutting lengthwise a tubular cylinder that is integrally molded in module cap 20. The resulting prongs 24 have sector-shaped cross-sections. Although in the illustrated embodiments, module cap 20 has prongs 24 distributed about the center of actuator disc 22, in other embodiments module cap 20 may have only a single central prong.
Furthermore, the portions of actuator disc 22 that flex when the container is actuated may be at any radial distance from the central axis and may have any suitable shape. They may be concentrated at one or more substantially discrete radial distances or may be continuous over all radial distances. In the embodiment illustrated in FIGS. 1-6, portions of actuator disc 22 that are between prongs 24 are flexible, thereby causing prongs 24 to spread apart radially when the container is actuated. In the alternative embodiment illustrated in FIG. 7, however, the portions of the alternative actuator disc 122 that flex are at greater radial distances than the prongs 124. The flat central portion of actuator disc 122 where prongs 124 are disposed does not flex. Therefore, prongs 124 do not spread apart radially when the container is actuated. Although prongs 124 preferably have a slight radial cant with respect to the central axis of the container, prongs 124 remain in that orientation regardless of whether actuator disc 122 is in the extended or retracted position. Such an embodiment facilitates injection molding because the areas of flexure are not adjacent to prongs 124.
Container body 10 may be made of any suitable material, such as cardboard, metal or plastic. A cardboard body 10 resists heat conduction and will thus not be uncomfortable for a user to hold after actuating the container. However, it is known in the art that solid chemical 38 and water 36 can be replaced with suitable combinations of chemicals for producing an endothermic reaction, which would cool beverage 12. In embodiments that cool a carbonated beverage, container body 10 should be made of metal or plastic because such materials would facilitate the formation of gas-tight seals.
As illustrated in FIGS. 8-12, an alternative embodiment of the container comprises a container body 210 and a cap 212. Rather than assembling a thermic module in container body 210, as in the embodiment described above, in the present embodiment a portion of container body 210 and a portion of cap 212 in combination perform the heating or cooling function. The resulting container can be manufactured more economically because fewer separate parts, seals and assembly steps are necessary, and because plastic is used extensively in the construction.
Container body 210 is preferably made of injection-molded food-grade plastic and includes a material cavity 214 unitarily formed with a reactant cavity 216. Nevertheless, in other embodiments, two or more plastic pieces may be sonically welded, adhesively joined, or joined by other suitable, sanitary methods to form a container body. Cap 212 is fit in the open end 217 of reactant cavity 216 and is preferably retained by a ring 218 that is crimped over the lip 220 at one end of container body 210. Nevertheless, as noted below, cap 212 may alternatively be sonically welded or adhesively joined to container body 210 because both elements are made of plastic. An endcap 222 with a pull-tab closure 224 of the type commonly used in beverage cans is crimped over the lip 220 at the other end of container body 210.
Cap 212 is of unitary construction and is made of a semi-rigid plastic, such as high density polyethylene. Cap 212 has an actuator disc 228 and a cylindrical prong 230 with an elongated notch 232. A breakable barrier 234 made of metal foil is adhesively attached to the open end of cap 212 to seal water 236 inside.
Cap 212 has multiple vent channels 238 distributed around its outside surface. When cap 212 is fit in the open end of reactant cavity 216, each of vent channels 238 preferably provides a cross-sectional area through which gas can escape of no more than between about 0.0002 and 0.001 square inches. Because vent channels 238 are not shown to scale in FIGS. 10 and 11 for purposes of clarity, it should be noted that this cross-sectional area is quite small, comparable to the inside diameter of a capillary tube. Because this cross-sectional area is thus relatively small in comparison to the predominant granule size of the solid reactant and reaction product tends to aggregate into, a large amount of these solids is unlikely to enter vent channels 238. Nevertheless, some portion of these solids may disintegrate into finer particles and even fine powder. It is in part for this reason that cap 212 has at least about eight vent channels 238. The relatively small cross-sectional area of each vent channel 238 minimizes the probability that the larger solid particles will enter, while the relatively large number of channels 238 minimizes the probability that any significant number of channels 238 will become plugged with the finer, powdery particles. If any vent channels 238 become plugged, gas will be released through the remaining vent channels 238. Vent channels 238 extend longitudinally along the outside surface of the cap body 240, change direction to extend radially along the lower surface of the flange 242 of cap 212, change direction again to extend longitudinally along the outside cylindrical surface of flange 242, and change direction again to extend radially along the upper surface of flange 242. It should be noted that the lower surface of flange 242 is not oriented perpendicularly with respect to the outside surface of cap body 240, but rather at an acute angle of about 45-55 degrees, resulting in a portion of vent channel 238 that is zig-zag or "Z"-shaped. This zig-zag shape of channels 238 functions as a baffle to inhibit the escape of very fine or powdery solid particles that may be small enough to enter channels 238 but too large to become lodged in them and plug them.
Although in the illustrated embodiment ring 218 retains cap 212 in container body 210, because cap 212 and container body 210 are both made of plastic, they may alternatively be sonically welded or adhesively joined. It should be noted that the plastic construction of cap 212 and container body 210 is an important feature of the invention; metal, cardboard and other materials conventionally used in self-heating and self-cooling containers would not be as suitable as plastic. Plastic facilitates construction of a sanitary container, without the need for special seals or coatings of the type used in conventional metal containers. Sonically welding or adhesively joining plastic elements creates joints that are gas-tight and sanitary. Maintaining a gas-tight seal is important in containers that are used to cool carbonated beverages. Moreover, the complex, dual-cavity shape of container body 210 defined by material cavity 214 and reactant cavity 216 is more economical to form in plastic than in metal.
The inner portion of container body 210 defining reactant cavity 216 has a corrugated or pleated wall 244 to increase surface area and, as a result, heat transfer. Cap 212 seals a solid reactant 246, such as calcium oxide, inside reactant cavity 216.
Material cavity 214 may be used to contain a beverage 247, food, medicine, or other material. As described above with respect to other embodiments, beverage 247 is heated or cooled (depending on the reactants used) when the user actuates the container. As noted above, although this embodiment may be used to either heat or cool the material, it is particularly advantageous for cooling due to its plastic construction. It is also particularly advantageous for cooling carbonated beverages because the carbon dioxide dissolved in beverage 247 cannot escape from open end 217 of container 210.
To actuate the container, the user must peel off a safety seal 248, as illustrated in FIG. 12. Safety seal 248 preferably comprises a peelable metal foil with a tab that a user can grip. The periphery of safety seal 248 is crimped under ring 218. A score line separates the central portion of safety seal 248 and allows a user to separate it from the peripheral area. As illustrated in FIG. 12, when a longitudinally or axially directed force is applied at or near the center 229 of actuator disc 228 it flexes toward barrier 234. The distal end of prong 230 punctures barrier 234. Water 236 flows through the punctured barrier 234 and mixes with solid reactant 246. Notch 232 in prong 230 facilitates the flow of water 236 into reactant cavity 216, because water 236 can flow into the hollow interior of prong 230 on one side of barrier 234 and out of prong 230 on the other side of barrier 234. The resulting exothermic reaction produces heat, which is transferred to beverage 247 by conduction through pleated wall 244. Gas produced in the reaction escapes through vent channels 238.
When the reaction is complete, the container may be inverted and pull-tab closure 224 opened to allow beverage 247 to be consumed. In self-heating containers known in the art, when the container is inverted the solid reaction product that remains in reactant cavity 216 tends to escape through the slot-like vents that are used in such conventional containers. While the solid reaction product is not harmful, the sight of it escaping from the container is discomforting to a user and detracts from the marketability of such containers. In the present invention, however, inverting the container does not allow solid reaction product to escape because, even if a small amount enters vent channels 238, the zig-zag shape of vent channels 238 impedes its progress.
To facilitate use, the container preferably includes instructions printed or otherwise suitably displayed on the outside of container body 210. As illustrated in FIG. 15, container body 210 includes a label 250 having first and second portions 252 and 254, respectively, on which are printed textual instructions. When container body 210 is oriented vertically with pull-tab closure 224 uppermost, the instructions on first portion 252 is oriented in the position in which a person would normally read text. In this position, the instructions on second portion 254 appear inverted to the user. When container body 210 is inverted and cap 212 uppermost, the instructions on second portion 254 is oriented in the position in which a person would normally read text. In this position, the instructions on first portion 252 appear inverted to the user. The instructions printed on first portion 252 direct the user to invert the can and follow instructions printed on second portion 254. The instructions printed on second portion 254 direct the user to actuate the container as described above, and may also direct the user to wait a specified time interval before consuming the contents. Although the instructions are preferably textual, symbolic instructions or any other type of indicia having an orientation in which they are normally viewed by a user and another orientation in which they appear inverted to a user would also be suitable.
As illustrated in FIGS. 13 and 14, another alternative embodiment of the container comprises a container body 310 having a material cavity 312, which for illustrative purposes is shown containing a beverage 314, and a thermic module 316 for heating beverage 314. Container body 310 has inner and outer walls 318 and 320, respectively, the space 322 between which is essentially evacuated of air. The vacuum insulates beverage 314 against heat conduction with the outside environment in the manner that conventional vacuum bottles, such as those sold under the THERMOS brand, insulate the materials stored within them.
Thermic module 316 is removable. Thus, after thermic module 316 has been activated and beverage 314 consumed, it can be removed and replaced. Thus, the container can be reused by replacing thermic module 316. To facilitate removal, thermic module 316 includes a module body 324 with a threaded module body portion 326. Container body 310 has a threaded container body portion 328 that is mateable with threaded module body portion 326. An annular gasket 329 between thermic module 316 and container body 310 inhibits leakage of beverage 314.
Thermic module 316 also includes a module cap 330. Module cap 330 is of unitary construction and is made of a semi-rigid plastic, such as high density polyethylene. Module cap 330 includes a cylindrical portion 332 and a flange 334. Module cap 330 also include an actuator disc 336 and a cylindrical prong 338 with an elongated notch 340, as in the embodiment described above with respect to FIGS. 8-12. A breakable barrier 342 made of metal foil is adhesively attached to the open end of module cap 330 to seal water 344 inside.
As in the embodiment described above with respect to FIGS. 8-12, module cap 330 has multiple vent channels 346 distributed around its outside surface. Each of vent channels 346 functions as an escape conduit for gas produced by the reaction, because the gas is channeled between the outside surface of module cap 330 and the inside surface of module body 324 when they are connected. As in the above-described embodiment, each of vent channels 346 preferably provides a cross-sectional area through which gas can escape of no more than between about 0.0002 and 0.001 square inches. Vent channels 346 extend longitudinally along the outside surface of cylindrical portion 332 of module cap 330, change direction to extend radially along the lower surface of flange 334, and change direction again to extend longitudinally along the outside cylindrical surface of flange 334, and change direction again to extend radially along the upper surface of flange 334.
A ring 348 is crimped onto the rim of module body 324 to retain module cap 330 in its open end. A safety seal 350 is adhered to ring 348. Safety seal 350 preferably comprises a peelable metal foil with a tab that a user can grip.
Module body 324 defines a reactant cavity for containing a solid reactant 352 such as calcium oxide. Solid reactant 352 is contained in a packet or bag 354 made of a suitable porous or fibrous material such as paper or cloth or a fine synthetic mesh. Bag 354 further prevents particles of solid reactant 352 from escaping through vent channels 346. Module cap 330 seals the reactant cavity when it is retained in the open end of module body 324 as described above. As in the embodiment described above with respect to FIGS. 8-12, module body 324 has a corrugated or pleated wall 356 to increase surface area and, as a result, heat transfer.
A filter ring 358 is disposed between the lower surface of flange 334 of module cap 330 and the upper surface of a corresponding step in the open end of module body 324. Filter ring 358 further prevents solid particles from escaping through vent channels 346 while allowing gases to vent unimpeded. Filter ring 358 may be made of any suitable filter material such as synthetic sponge, open-cell foamed rubber, or any woven or fibrous materials such as paper and cloth. Although in the illustrated embodiment filter ring 358 is disposed beneath flange 334 of module cap 330, in other embodiments it may be disposed in contact with any suitable portion of vent channels 346 between module body 324 and module cap 330 that suitably interferes with the communication of such particles through vent channels 346.
The lower surface of flange 334 has standoff prongs 360 that extend into filter ring 358. The length of standoff prongs 360 is determinitive of the extent to which filter ring 358 is compressed or squeezed when a user presses actuator disk 336. Compressing filter ring 358, like compressing any filter element, reduces the size of its interstices, thereby impeding flow. Standoff prongs 360 promote filtration consistency by substantially preventing deformation of filter ring 358. Standoff prongs 360 are preferably at least three or four in number and are evenly distributed around the circumference of flange 334.
To actuate the container, the user peels off safety seal 350, as described above with respect to other embodiments (see FIG. 12), exposing actuator disk 336. As described above with respect to other embodiments, when a longitudinally or axially directed force is applied at or near the center 362 of actuator disc 336 it flexes toward breakable barrier 342. (See FIG. 7.) Actuator disc 336 has a feature known in the art as a "living hinge" 364 unitarily formed around its circumference. As illustrated more clearly in FIG. 14, living hinge 364 is defined by a V-shaped groove molded into the plastic of actuator disc 336. The shape of the groove and the reduced thickness of the plastic that defines the groove facilitate flexure in a hinge-like manner. The function of living hinge 364 is thus similar to that of radial folds 62 described above with respect to the embodiment illustrated in FIGS. 1-7.
In response to the inward flexure of actuator disc 336, the distal end of prong 340 punctures barrier 342. Water 344 flows through the punctured barrier 342, penetrates bag 354, and mixes with solid reactant 352. As in the embodiment described above with respect to FIGS. 8-12, notch 340 in prong 338 facilitates the flow of water 344 into the reactant cavity. The resulting exothermic reaction produces heat, which is transferred to beverage 312 by conduction through pleated wall 356. Gas produced in the reaction escapes through vent channels 346, but any solid particles are filtered out by filter ring 358.
A suitable material may be added to the reactants to retard the reaction. The duration of a reaction between calcium oxide (quicklime) and water and the amount of heat it produces depends upon the amounts and proportions of calcium oxide and water. Nevertheless, the interval between the time at which the calcium oxide mixes with the water and the time at which heat is produced may vary depending upon the conditions under which the calcium oxide was manufactured. It is believed that moisture in the manufacturing environment can affect this time interval. The retardant can be added to the calcium oxide, water or both in an empirically determined amount necessary to ensure that the reaction begins a predetermined time interval after the container is activated. By ensuring that containers consistently begin the reaction at such a time, and ensuring that the amounts and proportions of quicklime and water are consistent among containers, it can be ensured that the containers consistently heat their contents to a predetermined temperature in a predetermined time interval. Any commercially available retardant of the type known to be usable in the curing of cement and plaster, both of which are principally composed of calcium oxide, would be suitable. Other materials, such as vinegar, are also known retardants and may be suitable. Nevertheless, certain commercially available retardants for the curing of cement and plaster may not be safe for incidental contact with food and thus would be undesirable to use in a container for heating foods and beverages. Vinegar produces an undesirable strong odor when used as a retardant for plaster. Therefore, a preferred retardant that may be added to a reaction of calcium oxide and water is a simple sugar such as ordinary table sugar (sucrose), lactose and glucose. In addition to being economical, such sugars are foods themselves and thus implicitly safe for incidental contact with the contents of the container to be heated. In addition, sugar produces no odor when used as a retardant. The sugar is preferably dissolved in the water, although mixing sugar with the calcium oxide powder may also be suitable.
When the reaction is complete, the user may invert the container and unscrew a cap 366 to allow the user to consume beverage 312. Cap 366 has a projection 368 made of an insulating material, such as plastic, that fits into the neck 370 of the container. Neck 370 is made of an insulating material, such as plastic, that minimizes the likelihood of scalding the user's lips that might otherwise be significant if the user were to drink directly from metal container body 310.
As illustrated in FIGS. 16 and 17, still another alternative embodiment of the container comprises a container body 372 having a tapered, tube-like or pouch-like shape and made of a flexible or pliable material such as soft plastic. Soft metal foil of the type commonly used in toothpaste tubes would also be suitable. This container body material is particularly advantageous for storing materials such as medicines that need to be heated or cooled uniformly throughout their volume because a user can facilitate uniform heating or cooling by gently kneading container body 372 after actuating the container.
A narrow end 374 of container body 372 is sealed in a suitable manner. In the illustrated embodiment, narrow end 374 of a plastic container body 372 is heat-welded to seal it. In an embodiment in which container body 374 is made of metal, the narrow end may be crimped to seal it. A thermic module 376 is disposed in the open end 378 of container body 372. Thermic module 376 includes a module body 380 and a module cap 382. Module body 380, which is preferably made of plastic, has a module flange 384 that is welded or bonded to a corresponding body flange 386. Flanges 384 and 386 facilitate welding because a welding tool can simultaneously contact both flanges 384 and 386.
Module body 380 defines a reactant cavity for containing the solid reactant 388. Module cap 382 seals the reactant cavity when it is retained in the open end of module body 380. Module body 380 has a corrugated or pleated wall 390 to increase surface area.
Module cap 382 is similar to those described above with respect to other embodiments and is thus described only briefly below. It is preferably of unitary construction and made of a semi-rigid plastic. It includes a cylindrical portion 392 and a flange 394. It also includes an actuator disc 396 with a living hinge 397 formed around its circumference. It further includes a cylindrical prong 398 with an elongated notch 400. It also includes a breakable barrier 402 made of metal foil that is adhesively attached to its open end to seal water 404 inside. Module cap 382 has multiple vent channels 406 distributed around its outside surface that channel gas between the outside surface of module cap 382 and the inside surface of module body 380.
A ring 408 crimped onto the rim of module body 380 retains module cap 382. A safety seal 410 that preferably comprises a peelable metal foil is adhered to ring 408.
A filter ring 412 of the same type as described above with respect to the embodiment illustrated in FIGS. 13 and 14 is disposed between the lower surface of flange 394 of module cap 382 and the upper surface of a corresponding step in the open end of module body 380. The lower surface of flange 394 has standoff prongs 414 as described above with respect to FIGS. 13 and 14.
To actuate the container, the user peels off safety seal 410, exposing actuator disc 396. The user presses the center of actuator disc 396, causing it to flex inwardly until the distal end of prong 398 punctures barrier 402. While the contents are changing temperature, the user may gently knead container body 372 to promote even heat distribution throughout the contents. When the contents have reached the desired temperature, the user may open the container by severing container body 372 along a line adjacent to narrow end 374. The user may then pour out the contents. In other embodiments, however, a container having a flexible container body may include a removable closure, such as a screw-cap, at the end opposite the thermic module, through which the user may squeeze the contents to consume them.
Obviously, other embodiments and modifications of the present invention will occur readily to those of ordinary skill in the art in view of these teachings. Therefore, this invention is to be limited only by the following claims, which include all such other embodiments and modifications when viewed in conjunction with the above specification and accompanying drawings.
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A container having a container body, a thermic module at one end of the body, and a closure at the other end, heats or cools its contents by initiating a chemical reaction inside the thermic module when a user activates the container. The thermic module may include a module cap and a module body. Two reactants, such as calcium oxide and water, are retained in portions of the thermic module and separated by a barrier that is punctured when a user activates the container, thus allowing them to mix. The cap may have vent channels between surfaces of the module cap and the module body that allow gases to vent, yet prevent escape of unsightly solid particles. A filter ring may be included in the path of each vent channel to further prevent such escape. The solid reactant may be contained in a porous bag in the thermic module to still further minimize leakage of particles. The container body may have double-walled construction, with a vacuum space between the inner and outer walls to slow heat transfer after the contents have reached the intended temperature. To facilitate use of the container, the container body may include instructions that can be read by a user when the container is inverted.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to sterilizing lamps and, more specifically, to a photocatalytic lamp, which is comprised of a lamp body, and a photocatalyst covering formed of a photocatalyst-coated breathing base material, which has a plurality of protruding flow guide portions that define with the periphery of the lamp body a respective buffer zone adapted to buffer the flowing of air.
[0003] 2. Description of the Related Art
[0004] Following fast development of industries and increase of the number of motor vehicles, the problem of air pollution becomes more and more series in most countries around the world. In order to breathe clean air, air conditioners, air purifiers, ventilators with wire gauze filters and the like may be used. However, these devices can simply remove solid matters from air. In recent years, various nanostructured photocatalysts have been developed for use with ultraviolet light sources to sterilize air. When a photocatalyst radiated by ultraviolet light, oxygen and water in air are caused to react and to produce negative oxygen ions and hydroxide free radicals. When encountered organic substances in air, negative oxygen ions transfer electrons to organic substances, and hydroxide free radicals catch electrons from organic substances. During the process, organic substances are caused to decompose into carbon dioxide and water. By means of the aforesaid chemical reaction, photocatalysts cause an oxidation to kill germs in air.
[0005] Various photocatalytic sterilizing products have been commercialized. However, the structural or space arrangement between the catalyst (for example, TiO 2 ) and the light source (for example, ultraviolet lamp) affects the sterilizing effect.
[0006] FIGS. 1A-1C show a photocatalytic lamp according to the prior art. This structure of photocatalytic lamp is comprised of an UV lamp tube 11 and a photocatalyst coating 12 covered on the surface of the UV lamp tube 11 . Because the photocatalyst coating 12 covers the whole area of the surface of the UV lamp tube 11 (except the base at each end of the lamp tube), less amount of UV energy passes out of the photocatalyst coating 12 , resulting in a low photocatalyst ionizing (activating) effect. There are other related prior art patents, which include U.S. Pat. Nos. 6,135,838 and 6336998. Further, because the photocatalyst coating 12 is smoothly covered on the surface of the UV lamp tube 11 , currents of air pass over the surface of the photocatalytic lamp rapidly, resulting in a short air and photocatalyst contact time. Therefore, this design of photocatalytic lamp is less effect in killing germs in air.
[0007] In order to extend the contact time of catalyst with air, another structure of photocatalytic lamp is developed. According to this design, the photocatalytic lamp comprises an UV lamp body and a photocatalytic light guide. The photocatalytic light guide is a formed of a panel like a honeycomb in structure. However, this design of photocatalytic lamp is still not satisfactory in function because the photocatalyst at the rear end of the photocatalytic light guide cannot receive sufficient radiation of ultraviolet light from the UV lamp body.
[0008] There is still known another structure of photocatalytic lamp, which uses a photocatalyst filter as covering means for the lamp. The photocatalyst filter is a substrate having openings in it. Due to the formation of the openings in the substrate, the structural strength of the photocatalyst filter is weakened. Further, when passing through the area around the openings in the substrate, air tends to be disturbed, forming a turbulent flow of air, which causes noises.
SUMMARY OF THE INVENTION
[0009] The present invention has been accomplished under the circumstances in view. It is the main object of the present invention to provide a photocatalytic lamp, which kills germs in air by means of a photocatalytic effect. It is another object of the present invention to provide a photocatalytic lamp, which has buffer zones to buffer the flowing of circulating air.
[0010] To achieve these and other objects of the present invention, the photocatalytic lamp comprises a lamp body, and a photocatalyst covering surrounding the lamp body. The photocatalyst covering comprises a breathing base material, and a photocatalyst in the breathing base material. The breathing base material has protruding flow guide portions each defining with the periphery of the lamp body a respective buffer zone adapted to buffer the flowing of circulating air. In one embodiment of the present invention, the flow guide portions extend in radial direction. In another embodiment of the present invention, the flow guide portions extend in axial direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is an elevational view of a photocatalytic lamp according to the prior art.
[0012] FIG. 1B is a cross-sectional view in an enlarged scale of the photocatalytic lamp shown in FIG. 1 .
[0013] FIG. 1C is a longitudinal view in section in an enlarged scale of a part of the photocatalytic lamp shown in FIG. 1 .
[0014] FIG. 2A is a schematic drawing showing the structure of a photocatalytic lamp according to the present invention.
[0015] FIG. 2B is a schematic drawing showing an alternate form of the photocatalytic lamp according to the present invention.
[0016] FIG. 3 is a schematic drawing showing a circulation of air through one buffering zone in the photocatalytic lamp according to the present invention.
[0017] FIG. 4 is a perspective view of another alternate form of the photocatalytic lamp according to the present invention.
[0018] FIG. 5 is a perspective view of still another alternate form of the photocatalytic lamp according to the present invention.
[0019] FIG. 6 is a schematic drawing of still another alternate form of the photocatalytic lamp according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring to FIGS. 2A and 2B , a photocatalytic lamp is shown comprising a lamp body 2 and a photocatalyst covering 3 formed of a breathing base material 31 attached with a photocatalyst and covered on the surface of the lamp body 2 . The breathing base material 31 is a thin sheet member selected from any of a variety of materials including non-woven fabric, polymeric sheet material, metal netting, filter paper, ceramics, and sponge. The photocatalyst can be obtained from any of a variety of oxide compounds such as TiO 2 , ZnO, SnO 2 , SrTiO 3 , WO 3 , Bi 2 O 3 , and Fe 2 O 3 . The best choice is TiO 2 . Most preferably, TiO 2 is selected.
[0021] The aforesaid photocatalyst can be mixed in the breathing base material 31 during the fabrication of the breathing base material 31 . Alternatively, the photocatalyst can be coated on the surface of the breathing base material 31 .
[0022] Referring to FIG. 3 and FIG. 2A , unlike the smooth tube-like conventional designs, the photocatalyst covering 3 is shaped like a corrugated tube having a plurality of protruded flow guide portions 32 . Each protruded flow guide portion 32 defines with the periphery of the lamp body 2 a flow buffer zone 33 . When currents of air pass through the photocatalyst covering 3 either from direction A or direction B, the buffer zones 33 buffer the flowing speed of currents of air, and at the same time, the radiation of light from the lamp body 2 excites the photocatalyst at the breathing base material 31 of the photocatalyst covering 3 , producing an ionized effect to sterilize air.
[0023] The aforesaid lamp body 2 can be formed of a lamp tube lamp bulb, or LED (light emitting diode) having a wavelength within 200˜800 nm. Preferably, the lamp body 2 is formed of a UV (ultraviolet) lamp tube, UV lamp bulb, or UV LED (light emitting diode).
[0024] In the embodiment shown in FIG. 3 , the lamp body 2 is formed of a UV lamp tube, which emits UV light to kill germs in air and to excite the photocatalyst at the breathing base material 31 of the photocatalyst covering 3 , achieving a photodissociation effect. Because the buffer zones 33 buffer the flowing speed of air and because currents of air are continuously circulated through the photocatalyst covering 3 , the invention effectively kill germs in air and remove bad smell from air.
[0025] The protruded flow guide portions 32 may be variously embodied. According to the embodiments shown in FIGS. 2A and 4 , the protruded flow guide portions 32 are arranged in parallel around the periphery of the lamp body 2 . According to the embodiment shown in FIG. 2B , the protruded flow guide portions 32 are spirally connected in series around the periphery of the lamp body 2 . According to the embodiment shown in FIG. 5 , the protruded flow guide portions 32 extend in axial direction, and are arranged in parallel around the periphery of the lamp body 2 .
[0026] FIG. 6 shows still another alternate form of the present invention. According to this embodiment, the lamp body 2 is formed of a lamp bulb, and the photocatalyst covering 3 comprises a plurality of protruded flow guide portions 32 arranged in parallel around the periphery of the lamp body 2 .
[0027] Further, the photocatalyst covering 3 may be used with an existing lamp tube (or lamp bulb). Because the breathing base layer 31 admits air and light, the photocatalyst covering 3 does not block the light of the lamp tube (or lamp bulb), and the photocatalytic lamp provides sufficient illumination when sterilizing air.
[0028] A prototype of photocatalytic lamp has been constructed with the features of FIGS. 2 ˜ 6 . The photocatalytic lamp functions smoothly to provide all of the features discussed earlier.
[0029] Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.
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A photocatalytic lamp is constructed to include a lamp body and a photocatalyst covering surrounding the lamp body, the photocatalyst covering being formed of a photocatalyst-coated breathing base material, which has a plurality of protruding flow guide portions that define with the periphery of the lamp body a respective buffer zone adapted to buffer the flowing of air.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a medical monitoring unit or device for the continued examination and care of a subject. More particularly, the present invention is directed to a medical monitoring device and system for the continuous storing of a subject's current physiological or medical data, the evaluation of said data enabling the early detection of adverse health conditions should they arise, and the providing of real time notification of such health conditions to the appropriate person or persons such that a proper and expeditious response may be taken.
[0003] 2. Prior Art
[0004] The benefits of being able to monitor and/or study various medical characteristics of a subject on a continuous basis, store and evaluate the data of those chosen aspects of the subject and initiate a particular response based on said evaluation are numerous. To accomplish such a feat in today's world would encompass a huge undertaking.
[0005] The most obvious use of the present invention would be in connection with individuals suffering from specific health problems. Any individual with a continuing illness such as heart disease or asthma, ideally needs to be monitored continually for the slightest recurring signs of those health problems. Although the medical industry has many tools for monitoring an individual's activities and evaluating their personal responses to those activities, a person must traditionally travel periodically to a medical facility in order to obtain the proper medical care and diagnosis. Once at the facility, the individual is often hooked up to some type of a monitoring instrument and is thereafter usually confined to the particular area for the duration of the session. In some cases, this may be several hours or more. While the monitoring equipment is attached to the individual, movement by the individual is either severely restricted or not permitted at all.
[0006] Moreover, the results of these existing procedures and tests, when they are finally reviewed and interpreted by the doctor or medical technician, only give a glimpse of the subject's activity and physiological data at the time of the monitoring. Today's monitoring equipment does not provide the physician or health care providers with nearly enough information on the subject's general conditions prior to or after the tests are performed. That is, in order to be able to establish a more accurate medical diagnosis, doctors would greatly benefit from observing the history of a subject's medical data for a longer duration than the time permitted in the medical facilities. For various obvious reasons, such as the time needed to perform these tests, the costs of the tests and the headaches of trying to schedule the required number of visits which would enable a full evaluation of a subject's health history, such an observation of an individual would be infeasible.
[0007] Another major problem for many individuals is getting prompt medical attention as soon as a medical problem occurs. The providing of expeditious medical care is sometimes crucial to the individual's ability to recover. For example, a heart attack victim has a significantly greater chance of full recovery if medical attention is received within the first few hours after signs of a heart attack are detected or the actual heart attack has occurred. Unfortunately, most of the time, an individual does not recognize the symptoms which would indicate that they were at risk. Often, by the time the individual does realize that help is needed, they are incapable of calling for emergency assistance. Yet another problem is providing the emergency medical services attending the individual with quick and accurate information which would lead to a successful diagnosis and treatment of the problem.
[0008] Portable EKG monitoring devices are known which collect medical data on cardiac functions from a plurality of sensors. After a predefined period, normally twenty-four hours, the data is transferred to a computer or strip recorder for analysis by skilled medical personnel in a conventional manner. Although such a device is very useful, there is still a time delay before the collected data is reviewed and analyzed.
[0009] Accordingly, there is still a need for a service that can provide for the continuous collection, monitoring and storing a subject's physiological data while allowing the subject complete freedom and mobility.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to the continuous real time collection, monitoring and storage of an individual's physiological data without interrupting or incapacitating any aspect of the individual's everday life. In addition, the monitoring device and system of the present invention can send out a distress call when the individual's vital signs reach a dangerous level or stop altogether.
[0011] The present invention uses a standard microcomputer in connection with various types of medical monitoring devices, and utilizes wireless communications technology known in the art. More particularly, the monitoring device employs software having the capability to monitor a subject's vital signs, record, collect and store the data. The stored information may then be downloaded into a computer to be analyzed. The computer may be located anywhere, including in a hospital, a clinic, the individual's home, or a physician's office. In addition, the monitoring device may also be able to provide real time information to the monitored subject at a touch of a button.
[0012] If the monitoring device detects abnormal behavior or stressful conditions in the subject being monitored, it can alert and notify the subject or the appropriate people such that the subject's current activities can be limited accordingly to combat the detected adverse conditions. When, and if, a subject's vital signs stop or reach a dangerous level, the monitoring device may emit some type of alarm, such as a loud beeping sound, to attract the attention of the subject and/or anyone in the immediate vicinity of the subject. If the subject is unable to respond to the alarm condition, the device may send out a distress call. The device may be programmed such that a call to 911 is immediately made and the subject's name and medical history are provided therewith. At the same time, the present device may also provide the 911 operator with the subject's exact location, by sending them a global positioning satellite (GPS) coordinate stored in the device.
[0013] Accordingly, it is an object of the present invention to provide a personal medical monitoring unit which may be worn on a subject and carried anywhere. The unit may be equipped to store current medical data and detect any pre-defined alarm conditions, such as heart failure. Upon an occurrence of one or more of such alarm conditions, the unit provides a central reporting system with emergency information for the efficient dispatching of emergency assistance.
[0014] It is another object of the present invention to combine the advantages of long-range navigation systems such as a global positioning system (GPS) for locating the subject at the time of the health crisis. The extensive communications capabilities of a cellular telephone or a two way pager would provide the most expeditious emergency assistance.
[0015] It is another object of the present invention to provide some type of notification feature, such as a beeper and/or vibrating mechanism, to inform the subject, or people nearby, of a detected condition.
[0016] It is still another object of the present invention to provide a service for continuous real time collection and long term storage of a remote subject's medical data via wireless communications technology.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0018] [0018]FIG. 1 is a block diagram illustrating the present invention in a preferred embodiment.
[0019] [0019]FIG. 2 is a diagram illustrating an example of an external layout of a personal data unit and a monitoring device.
[0020] [0020]FIG. 3 is a block diagram illustrating an example of a personal data unit's internal components.
[0021] [0021]FIG. 4 is a block diagram illustrating an example of a logical data configuration stored in a data storage device.
[0022] [0022]FIG. 5 illustrates an example of a dispense unit worn by a subject.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] [0023]FIG. 1 is a block diagram illustrating the present invention in its preferred embodiment. That is, FIG. 1 illustrates the present invention as a personal medical monitoring unit and system. The unit 12 is typically comprised of a personal data unit (PDU) 14 and a monitoring device 16 . It should be noted that the PDU 14 and the monitoring device 16 do not need to be in separate housings as illustrated in FIG. 1, but may be confined in a single unit as indicated at 12 . The system is generally comprised of the PDU 14 and the monitoring device 16 , in conjunction with a Central Reporting System (CRS) 18 , a Subject/Device Database 20 , and a communications network 22 as shown.
[0024] The monitoring device 16 is usually worn by a user, i.e. the subject to be monitored—typically a “patient”. Of course, the monitored subject is not limited to “patients” per se, but can be used with respect to anybody. That is, people with no past medical history can use the present monitoring device simply as a safeguard against any health risks that may arise; athletes may employ the present devices to monitor their own physical condition during competition, practice or training; parents may use the present invention to monitor and care for their children or infants; contained facilities, such as prisons, can monitor their inhabitants (such as the guards and prisoners); the present device can even be used to monitor the physical characteristics of an animal or pet. The possibilities are endless.
[0025] The monitoring device of the present invention can be any type of medical monitoring device, including those which monitor heart rate or pulse, breathing rate, blood pressure, heart EKG activity, or body temperature. The PDU 14 includes a transmitter, memory, and a processor. The transmitter may be an interactive pager, a Personal Communications Services (PCS) network digital or analog cellular phone.
[0026] The PDU 14 may also include a long-range navigation system receiver such as a global positioning system (GPS) receiver; data ports for uploading and downloading information such as medical information, addresses, and thresholds; and a number of input/output devices such as an LCD display monitor, push buttons, a beeper, and a vibration mechanism.
[0027] In a preferred embodiment, the PDU 14 continuously monitors a subject's medical data values as it receives them from the medical monitoring device 16 and stores them in its memory. In addition, the PDU 14 constantly receives communications signals from the well-known GPS satellites 24 , which is a group of three geostationary satellites used for determining one's geographical location. GPS coordinates are also stored in memory in the PDU 14 . When the monitoring device 16 detects a certain condition (e.g., loss of pulse), it triggers the PDU 14 to take action in accordance with pre-determined instructions stored in PDU memory. An exemplary action is to issue an emergency page or call via a wireless communications network 26 .
[0028] Two embodiments of communications networks are shown in FIG. 1. In one example, a two-way interactive paging network 28 is used, and the PDU's transmitter is an interactive paging device. The PDU issues an automatic page which includes an alphanumeric string retrieved from PDU memory. The page is sent over a paging network 28 to a Central Reporting System (CRS) 18 . Alternatively, the page may be sent over a Public Switched Telephone Network (PSTN) 32 to the CRS 18 .
[0029] In a second example of communications networks, a Personal Communications Services (PCS) 30 , which is a digital cellular network, or an analog cellular network is used. The PDU's transmitter is a PCS phone, for example. The PDU 14 , when triggered by the user or the monitoring device 16 , issues a PCS phone call. A dialing sequence is stored in PDU memory. The PDU PCS phone seizes a channel, sets up a call on the PCS network, and completes a call. A call may be completed to a 911 Call Center 34 , or to the CRS 18 . Calls may be completed over the PCS cellular network 30 , or via the PSTN 32 .
[0030] The CRS 18 is a server computer that receives emergency calls or pages from a plurality of PDUs 14 , and takes action in accordance with records and instructions previously entered in a Subject/Device Database 20 . Typically, the CRS 18 will notify a Call Center 36 of an emergency situation. When the CRS 18 receives the emergency call or page from the PDU 14 , it references the Subject/Device Database 20 to identify the device and subject, based on a device identifier that is included in the emergency page/call. Each device and/or subject has a record in the Subject/Device Database 20 . The record includes subject information (e.g., name, address, medical conditions, etc.) and medical instructions for responding to an emergency page or call. The CRS 18 may issue a call to an agent at a Call Center 36 . This call may be text-based, so that the CRS 18 can send a text message to the Call Center 36 agent to indicate that a certain PDU for a certain subject has detected a certain condition, and that medical attention may be needed.
[0031] The emergency page or call may also contain the subject's current GPS coordinates. The CRS 18 translates these coordinates to a recognizable geographical reference, and provides the subject's accurate location in the call information provided to the Call Center 36 .
[0032] [0032]FIG. 2 is a diagram illustrating an example of an external layout of a PDU and a monitoring device in accordance with the present invention. The monitoring device may be any standard medical monitoring device that is capable of providing data to another device. An example shown in FIG. 2 is a wrist or arm band 38 that can monitor pulse, blood pressure, or chemicals secreted by the subject's skin. Another example is a heart monitoring device that can detect heart fibrillation. Another example is a device which fits on a finger for measuring blood oxygenation.
[0033] Yet another example is a small chip that may be implanted in the subject's body for taking measurements and/or samples. In such a case, the device would, for example, be able to monitor blood, sugar levels for a subject with diabetes. The monitoring device sends data to the PDU, indicating the current status of the condition that is being monitored.
[0034] In addition, the monitoring device may include a dispense unit having a tube which may be implanted in the subject's body and allow for the flow of medicine stored in the tube to the subject's body. FIG. 5 illustrates an example of a dispense unit 90 worn by a subject. The monitoring device may dispense the medication when it receives a signal from the PDU indicating a necessity for medication. The dispense unit together with the monitoring unit may also regulate the subject's chemical levels.
[0035] The PDU 14 is a small device designed to be worn by a subject, providing the subject with great mobility. The PDU may include user input/output means. Output means includes a display 40 , such as a Liquid/Crystal Display (LCD) screen. The PDU 14 can also be designed with a vibrator and/or a beeper, to notify the subject and other people in the vicinity, of the subject's condition. These output means may be used in combination. For example, if the monitoring device detects a pulse rate above a threshold, the PDU will display a message on the LCD screen, and will also vibrate and/or beep to notify the subject. The message displayed may include the subject's current medical condition as well as brief instructions to the subject to limit their activities.
[0036] Input means may include several buttons. For example, a status button 42 , when depressed, could cause the PDU to display the current data from the monitoring device; this may include an English translation of any pertinent condition or status detected by the monitoring device.
[0037] Another example of an input/output means is a serial communications port 48 . A download button 44 may be used in conjunction with the serial communications port 48 . The port 48 may be connected to a computer, such as a hospital, clinic or doctor's personal computer, to transfer data stored in the PDU. In this manner, the PDU may be used to store a week's worth of most recent data, for example, while an external computer is used for storing long term data. When the download button 44 is depressed, the PDU transfers data stored in its memory to the external computer. This data can then be reviewed, for example by the subject's doctor, to determine the subject's progress or condition.
[0038] A store button 46 may also be used in conjunction with the serial communications port 48 for causing the PDU to receive data from an external source. Such a scheme may be used to reprogram the PDU with various instructions.
[0039] A 911 button 50 , when depressed could cause the PDU to issue a transmission of an emergency call to a 911 Call Center. This feature enables a user to manually send an emergency page or phone call. This enables the subject to manually seek emergency assistance for a variety of conditions, including injuries from a fall, an automobile malfunction or an imminent danger from criminal activity, and to provide GPS coordinate locations with the emergency call.
[0040] [0040]FIG. 3 is a block diagram illustrating an exemplary configuration of the PDU's internal components. It comprises a main microprocessor such as a Central Processing Unit (CPU) 52 , memory 54 , input/output means 56 , and a circuit bus 58 for data transfer. As is standard in most computers, memory includes both read only memory (ROM) for permanent data storage and random access memory.
[0041] The PDU 14 also includes a transmitter 62 . The transmitter 62 is a two-way interactive pager or a digital PCS phone. In a preferred embodiment, an interactive pager is used, because it may be implemented in a smaller device, and the mobility of a subject wearing the PDU is an important factor. The transmission sequence for issuing a page, as well as all alpha-numeric data sent as a page, are stored in PDU's memory 54 .
[0042] The PDU 14 may also include a GPS receiver 60 which receives signals from GPS satellites, and determines the PDU's current location. The GPS receiver 60 is programmed to write the current coordinates to a place in PDU memory 54 at fixed intervals of time (i.e., once per minute). The PDU memory 54 stores current GPS coordinates, for a pre-determined period, and may also store historical coordinates, up to a certain time period.
[0043] The PDU 14 may also include input/output means 56 for sequencing input and output calls to the CPU 52 and for formatting data to the appropriate output medium. The input means are buttons for status 42 , download 44 , store 46 , and 911 call 50 . The PDU 14 also has a connection for receiving input from the monitoring device 16 . All data received from the monitoring device 16 is stored in memory 54 . Output means include displays to an LCD screen 40 and downloads via the computer.
[0044] The device may also include a beeper and a vibration mechanism, as is standard in paging devices. These are binary state components (on/off) and are triggered by instructions that are stored in memory 54 and processed by the CPU 52 .
[0045] A communications port 48 is used to transfer data to and from an external computer, via a direct cable connection. When the download button 44 is depressed, select data values from memory 54 are output to an external computer via the communications port 48 ; when the store button 46 is depressed, selected data values are input from an external computer and stored in PDU memory 54 .
[0046] [0046]FIG. 4 is a block diagram illustrating one possible logical configuration of PDU memory. This configuration represents an example of the data stored in memory. Alternate embodiments are possible.
[0047] Device ID 66 comprises a unique identifier for each monitoring device. This identifier is included with every transmission performed by the PDU, and is used by the receiving end (e.g., CRS or 911 call center) to identify the source device of each transmission. Each device ID is mapped to a particular subject in the Subject/Device Database, so that the receiving CRS can identify the subject for which a PDU's transmission has been made.
[0048] Subject profile 68 includes data for the particular subject wearing the PDU. At a minimum, this may be a subject identifier. The subject identifier may be sent, either in place of or in addition to, the device ID 66 , in an emergency transmission. The subject profile 68 may also include other information on the subject, such as name, home address, and medical conditions.
[0049] Having a subject profile 68 stored in PDU memory is optional, and is not necessary to enable the present invention. In a first and preferred embodiment, in order to minimize size, a subject profile is not stored in PDU memory. The device ID 66 is included in all transmissions. The CRS uses the device ID as a key to look up the subject profile in the Subject/Device Database.
[0050] In a second embodiment, a subject profile 68 is stored in PDU memory 54 , but only includes a subject identifier. The subject identifier is included in transmissions, and is used to look up the subject profile in the Subject/Device Database. This embodiment is useful if the PDU (with a single device ID) is to be used by more than one subject. Another button may be added to the PDU for selecting a “current subject”, the selection of which causes a certain subject identifier to be used.
[0051] In a third embodiment, a complete subject profile is stored in PDU memory 54 , including data such as name and medical conditions. This is useful for situations in which a Subject/Device Database is not available. For example, if the PDU transmitter is a PCS phone, and a call is triggered to a 911 call center which does not have access to a CRS or the Subject/Device Database, the PDU may transmit the subject identifier, name, address, medical conditions, current location (from GPS coordinates), and other information as necessary, to the call center.
[0052] Thresholds field 70 includes thresholds for data collected from the monitoring device, and used to trigger an action by the PDU. Examples of thresholds include: heart rate or pulse above or below a threshold; body temperature above or below a threshold; blood pressure above or below a threshold; blood sugar level above or below a threshold; or any type of chemical imbalance that may be detected by the monitoring device. Examples of actions that may be triggered are an emergency transmission (page or phone call), activation of the beeper, activation of the vibrator, and an LCD screen display.
[0053] Instructions field 72 comprises instructions for the PDU to perform in response to some condition. Instructions are one or more application programs executed by PDU's CPU. Instructions may be grouped, but not limited, into following categories: auto-notification; emergency transmission; data store; and data download.
[0054] The auto-notification category includes procedures for triggering output, including displays to the LCD screen, activation of beeper, and activation of vibrator. For example, if pulse rate data collected from the monitoring device exceeds a threshold of 120 , auto-notification triggers the activation of the beeper and a display message to the LCD screen.
[0055] The emergency transmission category includes procedures for issuing pages or phone calls. These include detection of a threshold, determination of action, retrieval and execution of transmission sequence, and retrieval from memory of data to be included in the transmission (i.e., device ID and subject profile). For example, if data from the monitoring device indicates heart fibrillation, emergency transmission sends a page in accordance with an emergency dialing sequence and transmits device ID, current GPS coordinates, and current data from the monitoring device.
[0056] The data store category includes procedures for storing data in PDU memory 54 . Data may come from an external computer via the communications port, from the monitoring device, and from the PDU's GPS receiver. The various data are stored in specific allocations of PDU memory.
[0057] The data download category includes procedures for downloading data to an external computer via the communications port. The external computer will specify which data to download. PDU instructions specify where to find that data in memory. These instructions may also include security mechanisms, such as user validation of the external computer.
[0058] Transmission sequence field 74 includes data needed to issue an emergency transmission. This includes dialing sequences for issuing a page or phone call. A PDU may have more than one transmission sequence. For example, one sequence may be used to call a 911 call center for an emergency condition, and another sequence may be used to call the CRS for nominal status reporting.
[0059] Historical/current data field 76 include data collected from the monitoring device for a specified period of time, or for a specified number of data collections. Minimally, current data is stored here, such as the subject's current pulse. This data is extracted and sent in an emergency transmission. Optionally, historical data may also be stored. For example, heart rates collected every 15 minutes for the past week may be stored. This data may be extracted and downloaded to a doctor's computer on a periodic basis.
[0060] GPS coordinates field 78 contains current and historical records of GPS coordinates collected by the PDU's GPS receiver.
[0061] [0061]FIG. 5 illustrates an example of a dispense unit worn by a subject. A tube may be implanted in the subject's body and may allow for the flow of medicine. A dispense unit 90 may be worn by the subject 94 together with the monitoring devices or as a part of the device, and includes medication 92 to be dispensed. The dispensing may be triggered by a signal from the PDU. The PDU may trigger this signal when it determines, from evaluating the medical data collected from the monitoring device, a necessity to dispense medication.
[0062] Although shown and described is what is believed to be the most practical and preferred embodiments, it is apparent that departures from specific designs and methods described and shown will suggest themselves to those skilled in the art and may be used without departing from the spirit and scope of the invention. The present invention is not restricted to the particular-constructions described and illustrated, but should be construed to cohere with all modifications that may fall within the scope of the appended claims.
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A portable unit worn by a subject, comprising a medical monitoring device, a data processing module with memory and transmitter for collecting, monitoring, and storing the subject's physiological data and also issuing the subject's medical alarm conditions via wireless communications network to the appropriate location for expeditious dispatch of assistance. The unit also works in conjunction with a central reporting system for long term collection and storage of the subject's physiological data. The unit may have the capability to automatically dispense chemicals that may alleviate or assist in recovery from an illness.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional application which claims benefit under 35 USC §119(e) of and priority to U.S. Provisional Application Ser. No. 61/824,811 filed 17 May 2013 , entitled “ELECTRICALLY CONDUCTIVE PROPPANT COATING AND RELATED METHODS,” which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present disclosure generally relates to an electrically conductive proppant coating and a method for applying the coating to the proppant, whereby the coated electrically conductive proppant can determine formation characteristics, such as dimensions, orientation, and conductivity.
BACKGROUND OF THE INVENTION
[0003] Retrieving hydrocarbons from subterranean reservoirs is becoming more difficult, as existing reserves are depleted and production becomes more expensive. It has been estimated that mature fields account for up to 70% of the world's production or more. In order to increase production, reservoirs are often “fractured” through explosions, pressure, heat, and other known methods. The cracks and spaces made after fracturing are filled with sands and small particles to keep the fracture open and allow the flow of hydrocarbons through the proppants. The total amount of fracturing including length, width, and volume of the fractures, size of openings, and penetration into the reservoir are directly related to the flow of hydrocarbons from the fractured reservoir.
[0004] It has become common practice to induce higher production rates from low permeability reservoirs by creating fractures via application of hydraulic pressure downhole (aka “frac'ing a well”). These fractures are held open by placing “proppant”, commonly sand or other highly permeable, inert material into the fracture. Hydrocarbons (usually gas) can then flow at increased rates to the wellbore via these highly permeable artificial fractures.
[0005] Some technologies have tried to determine the extent and position of a fracture using various imaging techniques. For example, William Shuck, U.S. Pat. No. 4,446,433, discloses transmitting and receiving antennae that penetrate the fracture and indicate fracture orientation and length. Funk, et al., US2008062036, measure propped fractures and down-hole formation conditions using radar imaging. Further, McCarthy, et al., WO2007013883, teach introducing a target proppant; transmitting electromagnetic radiation from about 300 megahertz-100 gigahertz; and analyzing a reflected signal from the target particle to determine fracture geometry. Lastly, Nguyen and Fulton, U.S. Pat. No. 7,073,581, describe electroconductive proppant compositions and related methods of obtaining data from a portion of a subterranean formation. Downhole imaging methods that both transmit and receive signals from within the borehole are extremely limited because detection is not separated from the formation. Because downhole detection is nearly linear, variations in the length of the fracture cannot be distinguished. Likewise fluctuations in the depth and width of the fracture will be obscured by downhole detection. Fracture visualization must be improved to assess fractures quickly and inexpensively.
[0006] Because aging wells often produce from multiple intervals, some very thin, the ability to place these stimulation treatments with pinpoint accuracy is a key to more effective remediation and increased ultimate recovery. An accurate method of visualizing fracture length, proppant penetration, and estimated flow in the new fracture are required to accurately assess production capabilities and the need for further remediation before production is initiated.
[0007] A need exists for an alternative solution to the manufacture and supply of electrically conductive proppant to enable additional fracturing to maximize the areas reached and also ease some concerns that produced fractures do not extent into acquirers.
SUMMARY OF THE INVENTION
[0008] In an embodiment, a method for producing an electrically conductive proppant includes: (a) obtaining a proppant; (b) suspending the proppant in a coating material thereby producing a coated proppant, wherein the coating material includes a mixture of carbon residue forming material and a solvent or combination of solvents; (c) stabilizing the coated proppant with an oxidizing agent; (d) subsequently carbonizing the coated proppant; and (e) graphitizing the coated proppant thereafter.
[0009] In another embodiment, a method for determining the geometry of a fracture in a subterranean formation includes: (a) injecting a proppant coated with an electrically conductive coating into the fracture thereby producing a coated proppant, wherein the electrically conductive coating includes a coating material wherein the proppant is suspended in the coating material, stabilized with an oxidizing agent, subsequently carbonized and graphitized, wherein the coating material includes a mixture of carbon residue forming material and a solvent or combination of solvents, wherein the carbon residue forming material is petroleum pitch, wherein the solvent or combination of solvents includes is selected from a group consisting of toluene, xylene, quinoline, tetrahydrofuran, tetralin, naphthalene or combinations thereof; (b) charging the coated proppant with an electrical signal; (c) detecting the electrical signal with one or more surface antennae; and (d) determining the geometry of the fracture.
[0010] In yet a further embodiment, a method for determining the geometry of a fracture in a subterranean formation includes: (a) injecting a proppant coated with an electrically conductive coating into the fracture thereby producing a coated proppant, wherein the electrically conductive coating includes a coating material wherein the proppant is suspended in the coating material, stabilized with an oxidizing agent, subsequently carbonized and graphitized; (b) charging the coated proppant with an electrical signal; (c) detecting the electrical signal with one or more surface antennae; and (d) determining the geometry of the fracture.
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 in which:
[0012] FIG. 1 depicts proppant visualization within a subterranean formation, according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not as a limitation of the invention. It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations that come within the scope of the appended claims and their equivalents.
[0014] Proppant is coated with a coating material, transforming the proppant into an electrically conductive proppant. As used herein a “proppant” is a composition of sized particles mixed with fracturing fluid to open and/or hold fractures open during and after a hydraulic fracturing treatment. In addition to naturally occurring sand grains, the sized proppant particles can be man-made or specially engineered particles, such as high-strength ceramic materials like sintered bauxite. Proppant particles are carefully sorted for size and sphericity to provide an efficient conduit for hydrocarbon production to the wellbore.
[0015] The coating material includes a mixture of carbon residue forming materials and a solvent or combination of solvents. The carbon residue forming materials may include compounds with a high melting point and a high carbon yield after decomposition. Useful carbon residue forming materials may include heavy aromatic residues from petroleum, chemical process pitches; lignin from pulp industry; phenolic resins, and carbohydrate materials such as sugars and polyacrylonitriles. Petroleum and coal tar pitches, and lignin may also be used as carbon residue forming materials. As used herein, “pitch” refers to a residue derived from pyrolysis of organic material or tar distillation that is solid at room temperature and consists primarily of a complex mixture of aromatic hydrocarbons and heterocyclic compounds.
[0016] The carbon residue forming materials may further by any material which can react with an oxidizing agent. Upon reacting with the oxidizing agent, the carbon residue forming material may be thermally decomposed.
[0017] The carbon residue forming material is then combined with a solvent or combination of solvents. The solvent should be compatible with the carbon residue forming material. Solvents include pure organic compounds or a mixture of different solvents. The choice of solvent(s) depends on the particular carbon residue forming materials used. Suitable solvents for dissolving the carbon residue forming material include, for example, benzene, toluene, xylene, quinoline, tetrahydrofuran, naphthalene, acetone, cyclohexane, tetrahydronaphthalene, ether, methylpyrrolidinone, etc. When a petroleum or coal tar pitch is used as the carbon residue forming material, for example, solvents such as toluene, xylene, quinoline, tetrahydrofuran, tetralin and naphthalene are preferred.
[0018] The mixture of carbon residue forming material and solvent or combination of solvents is then heated to a desired temperature, preferably below the boiling point of the solvent(s). The proppant is then suspended in the mixture causing a certain portion of the coating material to be deposited substantially uniformly on the surface of the proppant.
[0019] Upon completion, the coated proppants are separated from the coating material using conventional methods such as, for example, centrifugal separation, or filtration. The coated proppant is then optionally washed with solvent to remove residual pitch (or other carbon forming residue material) solution and dried using conventional methods.
[0020] The coated proppant is then stabilized by subjecting the proppant to an oxidizing agent under appropriate reaction conditions. Generally, only mild or moderate conditions are required. The oxidation reaction may be performed by contacting the coated proppant with an oxidizing agent at elevated temperatures or by contacting the coated proppant with an oxidizing agent at mild conditions and activating the oxidizing agent at elevated temperatures.
[0021] The coated proppant are subsequently carbonized and then graphitized.
[0022] The coated particles can be graphitized by heating them to a still higher elevated temperature. The advantage of graphitization is many-fold, and most significantly the graphitization process frequently allows for the generation of a more-ordered crystal lattice in the coated proppant. Graphitization also removes impurities.
[0023] With respect to appropriate graphitization conditions, these are understood to vary according to the specific nature of the carbonized coated proppant. Typically, graphitization occurs in the temperature range of about 200° C.-3,200° C., although lower or higher temperature may also be used in this step. It is required that only satisfactory degree of graphitization be obtained during this step.
[0024] Graphitization can immediately follow carbonization, in which case the carbonized coated proppants are retained in a reaction apparatus, i.e., an oven, and the temperature is raised up to an appropriate graphitization temperature. With regard to the rate of this temperature rise, desirably this is maintained in the same rate as used for the carbonization step although, greater or lesser rates of temperature rise can also be utilized depending upon the nature of the carbonized coated proppants.
[0025] The electrically conductive coated proppant may then be injected into a subterranean formation. A wireline tool may be run into the formation to the fracture and electrical signal maybe sent into the fracture. Alternatively, the electric signal may be introduced into the fracture from the surface via electrical connections to the casing or the mud pit. Either an AC or reversing DC current maybe used to generate a time-varying signal or pulse. Since the proppant has been coated with an electrically conductive material, the entire fracture (where the proppant is located) may carry the electrical signal and behave like an emitting antenna. One or more surface antenna may detect and record the emitted signal to determine the geometry of the fracture.
[0026] In an embodiment, a monitoring station, such as, for example, a truck, backpack, recorder, or transmitter, is set up near the subterranean formation to be fractured. The fracture device and an electromagnetic source are placed in the formation, electromagnetic receivers are dispersed over the fracture area and a background signal is measured. An electrically conductive coated proppant is injected into the fracture and held the fracture open. The fracture is visualized as shown in FIG. 1 . In one alternative, the electrically conductive coated proppant is visualized during fracturing.
[0027] In closing, it should be noted that the discussion of any reference is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. At the same time, each and every claim below is hereby incorporated into this detailed description or specification as an additional embodiment of the present invention.
[0028] Although the systems and processes described herein have been described in detail, it should be understood that various changes, substitutions, and alterations can be made without departing from the spirit and scope of the invention as defined by the following claims. Those skilled in the art may be able to study the preferred embodiments and identify other ways to practice the invention that are not exactly as described herein. It is the intent of the inventors that variations and equivalents of the invention are within the scope of the claims while the description, abstract and drawings are not to be used to limit the scope of the invention. The invention is specifically intended to be as broad as the claims below and their equivalents.
REFERENCES
[0029] All of the references cited herein are expressly incorporated by reference. The discussion of any reference is not an admission that it is prior art to the present invention, especially any reference that may have a publication data after the priority date of this application. Incorporated references are listed again here for convenience:
1. U.S. Pat. No. 7,323,120 (Mao et al.); “Coated Carbonaceous Particles Particularly Useful as Electrode Materials in Electrical Storage Cells, and Methods of Making the Same” (2008). 2. US Publ. No. 2010/0147512 (Cramer et al.); “Controlled Source Fracture Monitoring” (2010).
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An electrically conductive proppant coating and a method for applying the coating to the proppant, whereby the coated electrically conductive proppant can determine formation characteristics, such as dimensions, orientation, and conductivity.
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This is continuation of application Ser. No. 09/115,571, filed Jul. 14, 1998, now U.S. Pat. No. 6,256,882.
BACKGROUND OF THE INVENTION
The present invention relates to probe assemblies of the type commonly used for testing integrated circuits (IC) and, in particular, the present invention relates to a membrane probing assembly having contacts which scrub, in a locally controlled manner, across the respective input/output conductors of each device so as to reliably wipe clear the surface oxides that are normally found on those conductors thereby ensuring good electrical connection between the probing assembly and each device.
The trend in electronic production has been toward increasingly smaller geometries particularly in integrated circuit technology wherein a very large number of discrete circuit elements are fabricated on a single substrate or “wafer.” After fabrication, this wafer is divided into a number of rectangular-shaped chips or “dice” where each die presents a rectangular or other regular arrangement of metallized contact pads through which input/output connections are made. Although each die is eventually packaged separately, for efficiency sake, testing of the circuit formed on each die is preferably performed while the dies are still joined together on the wafer. One typical procedure is to support the wafer on a flat stage or “chuck” and to move the wafer in X, Y and Z directions relative to the head of the probing assembly so that the contacts on the probing assembly move from die to die for consecutive engagement with each die. Respective signal, power and ground lines are run to the probing assembly from the test instrumentation thus enabling each circuit to be sequentially connected to the test instrumentation.
One conventional type of probing assembly used for testing integrated circuits provides contacts that are configured as needle-like tips. These tips are mounted about a central opening formed in a probe card so as to radially converge inwardly and downwardly through the opening. When the wafer is raised beyond that point where the pads on the wafer first come into contact with these tips, the tips flex upwardly so as to skate forwardly across their respective pads thereby removing oxide buildup on the pads.
The problem with this type of probing assembly is that the needle-like tips, due to their narrow geometry, exhibit high inductance so that signal distortion is large in high frequency measurements made through these tips. Also, these tips can act in the manner of a planing tool as they wipe across their respective pads, thereby leading to excessive pad damage. This problem is magnified to the extent that the probe tips bend out of shape during use or otherwise fail to terminate in a common plane which causes the more forward ones of the tips to bear down too heavily on their respective pads. Also, it is impractical to mount these tips at less than 100 micron center-to-center spacing or in a multi-row grid-like pattern so as to accommodate the pad arrangement of more modern, higher density dies. Also, this type of probing assembly has a scrub length of the needle tips of 25 microns or more, which increases the difficulty of staying within the allowed probing area.
In order to reduce inductive losses, decrease pad wear and accommodate smaller device geometries, a second type of probing assembly has been developed that uses a flexible membrane structure for supporting the probing contacts. In this assembly, lead lines of well-defined geometry are formed on one or more plies of flexible insulative film, such as polyimide or MYLAR™. If separate plies are used, these plies are bonded together to form, for example, a multilayered transmission line structure. In the central portion of this flexible structure or membrane, each conductive line is terminated by a respective probing contact which is formed on, and projects outwardly from, an outer face of the membrane. These probing contacts are arranged in a predetermined pattern that matches the pattern of the device pads and typically are formed as upraised bumps for probing the flat surfaces conventionally defined by the pads. The inner face of the membrane is supported on a supporting structure. This structure can take the form, for example, of a truncated pyramid, in which case the inner face of the center portion of the membrane is supported on the truncated end of the support while the marginal portions of the membrane are drawn away from the center portion at an angle thereto so as to clear any upright components that may surround the pads on the device.
With respect to the membrane probing assembly just described, excessive line inductance is eliminated by carefully selecting the geometry of the lead lines, and a photolithographic process is preferably used to enable some control over the size, spacing, and arrangement, of the probing contacts so as to accommodate higher density configurations. However, although several different forms of this probing assembly have been proposed, difficulties have been encountered in connection with this type of assembly in reducing pad wear and in achieving reliable clearing of the oxide layer from each of the device pads so as to ensure adequate electrical connection between the assembly and the device-under-test.
One conventional form of membrane probing assembly, for example, is exemplified by the device shown in Rath European Patent Pub. No. 259,163A2. This device has the central portion of the sheet-like membrane mounted directly against a rigid support. This rigid support, in turn, is connected by a resilient member comprising an elastomeric or rubber block to the main body of the assembly so that the membrane can tilt to match the tilt of the device. Huff U.S. Pat. No. 4,918,383 shows a closely related device wherein radially extending leaf springs permit vertical axis movement of the rigid support while preventing it from tilting so that there is no slippage or “misalignment” of the contact bumps on the pads and further so that the entire membrane will shift slightly in the horizontal plane to allow the contacts to “scrub” across their respective pads in order to clear surface oxides from these pads.
In respect to both of these devices, however, because of manufacturing tolerances, certain of the contact bumps are likely to be in a recessed position relative to their neighbors and these recessed bumps will not have a satisfactory opportunity to engage their pads since they will be drawn away from their pads by the action of their neighbors on the rigid support. Furthermore, even when “scrub” movement is provided in the manner of Huff, the contacts will tend to frictionally cling to the device as they perform the scrubbing movement, that is, there will be a tendency for the pads of the device to move in unison with the contacts so as to negate the effect of the contact movement. Whether any scrubbing action actually occurs depends on how far the pads can move, which depends, in turn, on the degree of lateral play that exists as a result of normal tolerance between the respective bearing surfaces of the probe head and chuck. Hence this form of membrane probing assembly does not ensure reliable electrical connection between each contact and pad.
A second conventional form of membrane probing assembly is exemplified by the device shown in Barsotti European Patent Pub. No. 304,868A2. This device provides a flexible backing for the central or contact-carrying portion of the flexible membrane. In Barsotti, the membrane is directly backed by an elastomeric member and this member, in turn, is backed by a rigid support so that minor height variations between the contacts or pads can be accommodated. It is also possible to use positive-pressure air, negative-pressure air, liquid or an unbacked elastomer to provide flexible backing for the membrane, as shown in Gangroth U.S. Pat. No. 4,649,339, Ardezzone U.S. Pat. No. 4,636,772, Reed, Jr. et al. U.S. Pat. No. 3,596,228 and Okubo et al. U.S. Pat. No. 5,134,365, respectively. These alternative devices, however, do not afford sufficient pressure between the probing contacts and the device pads to reliably penetrate the oxides that form on the pad surfaces.
In this second form of membrane probing assembly, as indicated in Okubo, the contacts may be limited to movement along the Z-axis in order to prevent slippage and resulting misalignment between the contacts and pads during engagement. Thus, in Barsotti, the rigid support underlying the elastomeric member is fixed in position although it is also possible to mount the support for Z-axis movement in the manner shown in Huff U.S. Pat. No. 4,980,637. Pad damage is likely to occur with this type of design, however, because a certain amount of tilt is typically present between the contacts and the device, and those contacts angled closest to the device will ordinarily develop much higher contact pressures than those which are angled away. The same problem arises with the related assembly shown in European Patent Pub. No. 230,348A2 to Garretson, even though in the Garretson device the characteristic of the elastomeric member is such as to urge the contacts into lateral movement when those contacts are placed into pressing engagement with their pads. Yet another related assembly is shown in Evans U.S. Pat. No. 4,975,638 which uses-a pivotably mounted support for backing the elastomeric member so as to accommodate tilt between the contacts and the device. However, the Evans device is subject to the friction clinging problem already described insofar as the pads of the device are likely to cling to the contacts as the support pivots and causes the contacts to shift laterally.
Yet other forms of conventional membrane probing assemblies are shown in Crumly U.S. Pat. No. 5,395,253, Barsotti et al. U.S. Pat. No. 5,059,898 and Evans et al. U.S. Pat. No. 4,975,638. In Crumly, the center portion of a stretchable membrane is resiliently biased to a fully stretched condition using a spring. When the contacts engage their respective pads, the stretched center portion retracts against the spring to a partially relaxed condition so as to draw the contacts in radial scrub directions toward the center of the membrane. In Barsotti, each row of contacts is supported by the end of a respective L-shaped arm so that when the contacts in a row engage their respective pads, the corresponding arm flexes upwardly and causes the row of contacts to laterally scrub simultaneously across their respective pads. In both Crumly and Barsotti, however, if any tilt is present between the contacts and the device at the time of engagement, this tilt will cause the contacts angled closest to the device to scrub further than those angled further away. Moreover, the shorter contacts will be forced to move in their scrub directions before they have had the opportunity to engage their respective pads due to the controlling scrub action of their neighboring contacts. A further disadvantage of the Crumly device, in particular, is that the contacts nearer to the center of the membrane will scrub less than those nearer to the periphery so that scrub effectiveness will vary with contact position.
In Evans et al. U.S. Pat. No. 5,355,079 each contact constitutes a spring metal finger, and each finger is mounted so as to extend in a cantilevered manner away from the underlying membrane at a predetermined angle relative to the membrane. A similar configuration is shown in Higgins U.S. Pat. No. 5,521,518. It is difficult, however, to originally position these fingers so that they all terminate in a common plane, particularly if a high density pattern is required. Moreover, these fingers are easily bent out of position during use and cannot easily be rebent back to their original position. Hence, certain ones of the fingers are likely to touch down before other ones of the fingers, and scrub pressures and distances are likely to be different for different fingers. Nor, in Evans at least, is there an adequate mechanism for tolerating a minor degree of tilt between the fingers and pads. Although Evans suggests roughening the surface of each finger to improve the quality of electrical connection, this roughening can cause undue abrasion and damage to the pad surfaces. Yet a further disadvantage of the contact fingers shown in both Evans and Higgins is that such fingers are subject to fatigue and failure after a relatively low number of “touchdowns” or duty cycles due to repeated bending and stressing.
Referring to FIG. 1 , Cascade Microtech, Inc. of Beaverton, Oregon has developed a probe head 40 for mounting a membrane probing assembly 42 . In order to measure the electrical performance of a particular die area 44 included on the silicon wafer 46 , the high-speed digital lines 48 and/or shielded transmission lines 50 of the probe head are connected to the input/output ports of the test instrumentation by a suitable cable assembly, and the chuck 51 which supports the wafer is moved in mutually perpendicular X,Y,Z directions in order to bring the pads of the die area into pressing engagement with the contacts included on the lower contacting portion of the membrane probing assembly.
The probe head 40 includes a probe card 52 on which the data/signal lines 48 and 50 are arranged. Referring to FIGS. 2 -- 3 , the membrane probing assembly 42 includes a support element 54 formed of incompressible material such as a hard polymer. This element is detachably connected to the upper side of the probe card by four Allen screws 56 and corresponding nuts 58 (each screw passes through a respective attachment arm 60 of the support element, and a separate backing element 62 evenly distributes the clamping pressure of the screws over the entire back side of the supporting element). In accordance with this detachable connection, different probing assemblies having different contact arrangements can be quickly substituted for each other as needed for probing different devices.
Referring to FIGS. 3-4 , the support element 54 includes a rearward base portion 64 to which the attachment arms 60 are integrally joined. Also included on the support element 54 is a forward support or plunger 66 that projects outwardly from the flat base portion. This forward support has angled sides 68 that converge toward a flat support surface 70 so as to give the forward support the shape of a truncated pyramid. Referring also to FIG. 2 , a flexible membrane assembly 72 is attached to the support after being aligned by means of alignment pins 74 included on the base portion. This flexible membrane assembly is formed by one or more plies of insulative sheeting such as KAPTON™ sold by E.I. Du Pont de Nemours or other polyimide film, and flexible conductive layers or strips are provided between or on these plies to form the data/signal lines 76 .
When the support element 54 is mounted on the upper side of the probe card 52 as shown in FIG. 3 , the forward support 66 protrudes through a central opening 78 in the probe card so as to present the contacts which are arranged on a central region 80 of the flexible membrane assembly in suitable position for pressing engagement with the pads of the device under test. Referring to FIG. 2 , the membrane assembly includes radially extending arm segments 82 that are separated by inwardly curving edges 84 that give the assembly the shape of a formee cross, and these segments extend in an inclined manner along the angled sides 68 thereby clearing any upright components surrounding the pads. A series of contact pads 86 terminate the data/signal lines 76 so that when the support element is mounted, these pads electrically engage corresponding termination pads provided on the upper side of the probe card so that the data/signal lines 48 on the probe card are electrically connected to the contacts on the central region.
A feature of the probing assembly 42 is its capability for probing a somewhat dense arrangement of contact pads over a large number of contact cycles in a manner that provides generally reliable electrical connection between the contacts and pads in each cycle despite oxide buildup on the pads. This capability is a function of the construction of the support element 54 , the flexible membrane assembly 72 and their manner of interconnection. In particular, the membrane assembly is so constructed and connected to the support element that the contacts on the membrane assembly preferably wipe or scrub, in a locally controlled manner, laterally across the pads when brought into pressing engagement with these pads. The preferred mechanism for producing this scrubbing action is described in connection with the construction and interconnection of a preferred membrane assembly 72 a as best depicted in FIGS. 6 and 7 a - 7 b.
FIG. 6 shows an enlarged view of the central region 80 a of the membrane assembly 72 a . In this embodiment, the contacts 88 are arranged in a square-like pattern suitable for engagement with a square-like arrangement of pads. Referring also to FIG. 7 a , which represents a sectional view taken along lines 7 a - 7 a in FIG. 6 , each contact comprises a relatively thick rigid beam 90 at one end of which is formed a rigid contract bump 92 . The contact bump includes thereon a contacting portion 93 which comprises a nub of rhodium fused to the contact bump. Using electroplating, each beam is formed in an overlapping connection with the end of a flexible conductive trace 76 a to form a joint therewith. This conductive trace in conjunction with a back-plane conductive layer 94 effectively provides a controlled impedance data/signal line to the contact because its dimensions are established using a photolithographic process. The backplane layer preferably includes openings therein to assist, for example, with gas venting during fabrication.
The membrane assembly is interconnected to the flat support surface 70 by an interposed elastomeric layer 98 , which layer is coextensive with the support surface and can be formed by a silicone rubber compound such as ELMER'S STICK-ALL™ made by the Borden Company or Sylgard 182 by Dow Corning Corporation. This compound can be conveniently applied in a paste-like phase which hardens as it sets. The flat support surface, as previously mentioned, is made of incompressible material and is preferably a hard dielectric such as polysulfone or glass.
In accordance with the above-described construction, when one of the contacts 88 is brought into pressing engagement with a respective pad 100 , as indicated in FIG. 7 b , the resulting off-center force on the rigid beam 90 and bump 92 structure causes the beam to pivot or tilt against the elastic recovery force provided by the elastomeric pad 98 . This tilting motion is localized in the sense that a forward portion 102 of the beam moves a greater distance toward the flat support surface 70 than a rearward portion 104 of the same beam. The effect is such as to drive the contact into lateral scrubbing movement across the pad as is indicated in FIG. 7 b with a dashed-line and solid-line representation showing the beginning and ending positions, respectively, of the contact on the pad. In this fashion, the insulative oxide buildup on each pad is removed so as to ensure adequate contact-to-pad electrical connections.
FIG. 8 shows, in dashed line view, the relative positions of the contact 88 and pad 100 at the moment of initial engagement or touchdown and, in solid-line view, these same elements after “overtravel” of the pad by a distance 106 in a vertical direction directly toward the flat support surface 70 . As indicated, the distance 108 of lateral scrubbing movement is directly dependent on the vertical deflection of the contact 88 or, equivalently, on the overtravel distance 106 moved by the pad 100 . Hence, since the overtravel distance for each contact on the central region 80 a will be substantially the same (with differences arising from variations in contact height), the distance of lateral scrubbing movement by each contact on the central region will be substantially uniform and will not, in particular, be affected by the relative position of each contact on the central region.
Because the elastomeric layer 98 is backed by the incompressible support surface 70 , the elastomeric layer exerts a recovery force on each tilting beam 90 and thus each contact 93 to maintain contact-to-pad pressure during scrubbing. At the same time, the elastomeric layer accommodates some height variations between the respective contacts. Thus, referring to FIG. 9 a , when a relatively shorter contact 88 a is situated between an immediately adjacent pair of relatively taller contacts 88 b and these taller contacts are brought into engagement with their respective pads, then, as indicated in FIG. 9 b , deformation by the elastomeric layer allows the smaller contact to be brought into engagement with its pad after some further overtravel by the pads. It will be noted, in this example, that the tilting action of each contact is locally controlled, and the larger contacts are able, in particular, to tilt independently of the smaller contact so that the smaller contact is not urged into lateral movement until it has actually touched down on its pad.
Referring to FIGS. 10 and 11 , the electroplating process to construct such a beam structure, as schematically shown in FIG. 8 , includes the incompressible material 68 defining the support surface 70 and the substrate material attached thereon, such as the elastomeric layer 98 . Using a flex circuit construction technique, the flexible conductive trace 76 a is then patterned on a sacrificial substrate. Next, a polyimide layer 77 is patterned to cover the entire surface of the sacrificial substrate and of the traces 76 a , except for the desired location of the beams 90 on a portion of the traces 76 a . The beams 90 are then electroplated within the openings in the polyimide layer 77 . Thereafter, a layer of photoresist 79 is patterned on both the surface of the polyimide 77 and beams 90 to leave openings for the desired location of the contact bumps 92 . The contact bumps 92 are then electroplated within the openings in the photoresist layer 79 . The photoresist layer 79 is removed and a thicker photoresist layer 81 is patterned to cover the exposed surfaces, except for the desired locations for the contacting portions 93 . The contacting portions 93 are then electroplated within the openings in the photoresist layer 81 . The photoresist layer 81 is then removed. The sacrificial substrate layer is removed and the remaining layers are attached to the elastomeric layer 98 . The resulting beams 90 , contact bumps 92 , and contacting portions 93 , as more accurately illustrated in FIG. 12 , provides the independent tilting and scrubbing functions of the device.
Unfortunately, the aforementioned construction technique results in a structure with many undesirable characteristics.
First, several beams 90 , contact bumps 92 , and contacting portions 93 (each of which may be referred to as a device) proximate one another results in different localized current densities within the electroplating bath, which in turn results in differences in the heights of many of the beams 90 , contact bumps 92 , and contacting portions 93 . Also, different densities of the ions within the electroplating bath and “random” variations in the electroplating bath also results in differences in heights of many of the beams 90 , contact bumps 92 , and contacting portions 93 . The different heights of many of the beams 90 , contact bumps 92 , and contacting portions 93 is compounded three fold in the overall height of many of the devices. Accordingly, many devices will have a significantly different height than other devices. Using membrane probes having variable device height requires more pressure to ensure that all the contacting portions 93 make adequate contact with the test device than would be required if all the devices had equal overall height. For high density membrane probes, such as 2000 or more devices in a small area, the cumulate effect of the additional pressure required for each device may exceed the total force permitted for the probe head and probe station. The excess pressure may also result in bending and breaking of the probe station, the probe head, and/or the membrane probing assembly. In addition, the devices with the greatest height may damage the pads on the test device because of the increased pressure required to make suitable contact for the devices with the lowest height.
Second, the ability to decrease the pitch (spacing) between the devices is limited by the “mushrooming” effect of the electroplating process over the edges of the polyimide 77 and photoresist layers 79 and 81 . The “mushrooming” effect is difficult to control and results in a variable width of the beams 90 , contact bumps 92 , and contacting portions 93 . If the height of the beams 90 , the contact bumps 92 , or the contacting portions 93 are increased then the “mushrooming” effect generally increases, thus increasing the width of the respective portion. The increased width of one part generally results in a wider overall device which in turn increases the minimum spacing between contacting portions 93 . Alternatively, decreasing the height of the beams 90 , the contact bumps 92 , or the contacting portions 93 generally decreases the width of the “mushrooming” effect which in turn decreases the minimum spacing between contacting portions 93 . However, if the height of the contacting portions 93 relative to the respective beam 90 is sufficiently reduced, then during use the rearward end of the beam 90 may sufficiently tilt and contact the test device in an acceptable location, i.e., off the contact pad.
Third, it is difficult to plate a second metal layer directly on top of a first metal layer, such as contacting portions 93 on the contact bumps 92 , especially when using nickel. To provide a bond between the contact bumps 92 and the contacting portions 93 , an interface seed layer such as copper or gold is used to make an improved interconnection. Unfortunately, the interface seed layer reduces the lateral strength of the device due to the lower sheer strength of the interface layer.
Fourth, applying a photoresist layer over a non-uniform surface tends to be semi-conformal in nature resulting in a non-uniform thicknesses of the photoresist material itself. Referring to FIG. 13 , the photoresist layer 79 (and 81 ) over the raised portions of the beams 90 tends to be thicker than the photoresist layer 79 (and 81 ) over the lower portions of the polyimide 77 . In addition, the thickness of the photoresist 79 (and 81 ) tends to vary depending on the density of the beams 90 . Accordingly, regions of the membrane probe that have a denser spacing of devices, the photoresist layer 79 (and 81 ) will be thicker on average than regions of the membrane probe that have a less dense spacing of devices. During the exposing and etching processing of the photoresist layer 79 (and 81 ), the duration of the process depends on the thickness of the photoresist 79 (or 81 ). With variable photoresist thickness it is difficult to properly process the photoresist to provide uniform openings. Moreover, the thinner regions of photoresist layer 79 (or 81 ) will tend to be overexposed resulting in variably sized openings. Also, the greater the photoresist layer thickness 79 (or 81 ) the greater the variability in its thickness. Accordingly, the use of photoresist presents many processing problems.
Fifth, separate alignment processes are necessary to align the beams 90 on the traces 76 a , the contact bumps 92 on the beams 90 , and the contacting portions 93 on the contact bumps 92 . Each alignment process has inherent variations that must be accounted for in sizing each part. The minimum size of the contacting portions 93 is defined primarily by the lateral strength requirements and the maximum allowable current density therein. The minimum size of the contacting portions 93 , accounting for the tolerances in alignment, in turn defines the minimum size of the contact bumps 92 so that the contacting portions 93 are definitely constructed on the contact bumps 92 . The minimum size of the contact bumps 92 , in view of the contacting portions 93 and accounting for the tolerances in alignment, defines the minimum size of the beams 90 so that the contact bumps 92 are definitely constructed on the beams 90 . Accordingly, the summation of the tolerances of the contact bumps 92 and the contacting portions 93 , together with a minimum size of the contacting portions 93 , defines the minimum device size, and thus defines the minimum pitch between contact pads.
What is desired, therefore, is a membrane probe construction technique and structure that results in a more uniform device height, decreased spacing between devices, maximized lateral strength, desired geometries, and proper alignment.
SUMMARY OF THE INVENTION
The present invention overcomes the aforementioned drawbacks of the prior art by providing a substrate, preferably constructed of a ductile material. A tool having the desired shape of the resulting device for contacting contact pads on a test device is brought into contact with the substrate. The tool is preferably constructed of a material that is harder than the substrate so that a depression can be readily made therein. A dielectric (insulative) layer, that is preferably patterned, is supported by the substrate. A conductive material is located within the depressions and then preferably planarized to remove excess from the top surface of the dielectric layer and to provide a flat overall surface. A trace is patterned on the dielectric layer and the conductive material. A polyimide layer is then preferably patterned over the entire surface. The substrate is then removed by any suitable process.
The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view of a membrane probing assembly bolted to a probe head and a wafer supported on a chuck in suitable position for probing by this assembly.
FIG. 2 is a bottom elevational view showing various parts of the probing assembly of FIG. 1 , including a support element and flexible membrane assembly, and a fragmentary view of a probe card having data/signal lines connected with corresponding lines on the membrane assembly.
FIG. 3 is a side elevational view of the membrane probing assembly of FIG. 1 where a portion of the membrane assembly has been cut away to expose hidden portions of the support element.
FIG. 4 is a top elevational view of an exemplary support element.
FIGS. 5 a - 5 b are schematic side elevational views illustrating how the support element and membrane assembly are capable of tilting to match the orientation of the device under test.
FIG. 6 is an enlarged top elevational view of the central region of the construction of the membrane assembly of FIG. 2 .
FIGS. 7 a - 7 b are sectional views taken along lines 7 a - 7 a in FIG. 6 first showing a contact before touchdown and then showing the same contact after touchdown and scrub movement across its respective pad.
FIG. 8 is a schematic side view showing, in dashed-line representation, the contact of FIGS. 7 a - 7 b at the moment of initial touchdown and, in solid-line representation, the same contact after further vertical overtravel by the pad.
FIGS. 9 a and 9 b illustrate the deformation of the elastomeric layer to bring the contacts into contact with its pad.
FIG. 10 is a longitudinal sectional view of the device of FIG. 8 .
FIG. 11 is a cross sectional view of the device of FIG. 8 .
FIG. 12 is a more accurate pictorial view of the device shown in FIGS. 10 and 11 .
FIG. 13 is a detailed view of the device shown in FIG. 11 illustrating the uneven layers that result during processing.
FIG. 14 is a pictorial view of a substrate.
FIG. 15 is a pictorial view of an exemplary embodiment of a tool, and in particular a dimpling tool, of the present invention.
FIG. 16 is a pictorial view illustrating the tool of FIG. 15 coming into contact with the substrate of FIG. 14 .
FIG. 17 is a pictorial view of the substrate of FIG. 14 after the tool of FIG. 15 has come into contact therewith.
FIG. 18 is a sectional view of the substrate of FIG. 14 with a polyimide layer supported thereon.
FIG. 19 is a pictorial view of the tool of FIG. 16 together with a z-axis stop.
FIG. 20 is a sectional view of the substrate of FIG. 14 with a trace, conductive material in the depression, and additional polyimide layer thereon.
FIG. 21 is a pictorial view of the device of FIG. 20 , inverted, with the substrate removed.
FIG. 22 is a breakaway sectional view of the contacting portion of FIG. 21 .
FIG. 23 is a schematic view illustrating one arrangement of the devices of the present invention.
FIG. 24 is a schematic view illustrating the contact of a traditional contacting portion and the oxide layer of a solder bump.
FIG. 25 is a plan view of an alternative device with an elongate probing portion.
FIG. 26 is a side view of the device of FIG. 25 with an elongate probing portion.
FIG. 27 is a pictorial view of a solder bump with a mark therein as a result of the device of FIGS. 25 and 26 .
FIG. 28 is a pictorial view of another alternative probing device.
FIG. 29 is a pictorial view of a further alternative probing device suitable for solder bumps.
FIG. 30 is a side view of a true Kelvin connection using the devices of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The currently employed construction techniques for membrane probes involves starting with the flat rigid substrate to support additional layers fabricated thereon. To decrease the pitch and provide devices with increased uniformity requires increasingly more complex and expensive processing techniques. In direct contrast to the current techniques of constructing layers from the “bottom up” upon a supporting substrate, the present inventors came to the realization that by using a suitable tool a substrate may be coined to create the desired beams, contact bumps, and contacting portions. The remaining layers are then constructed “top down” on the beam. The substrate itself is thereafter removed.
Referring to FIG. 14 , a substrate 200 is preferably constructed from a ductile material such as aluminum, copper, lead, indium, brass, gold, silver, platinum, or tantalum, with a thickness preferably between 10 mills and ⅛ inch. The top surface 202 of the substrate 200 is preferably planar and polished for optical clarity to improve viewing, as described later.
Referring to FIG. 15 , a tool and in particular a “dimpling” tool 210 is constructed with a head 212 having the desired shape of the resulting device for contacting the contact pads on the test device. The dimpling tool 210 includes a projection 214 to connect to a dimpling machine (not shown). The tool 210 is supported by the dimpling machine with the head 212 oriented to come into contact with the top surface 202 of the substrate 200 . The tool 210 is preferably constructed of a material that is harder than the substrate 200 so that a dimple can be readily made therein. Suitable material for the tool 210 is, for example, tool steel, carbide, chromium, and diamond. The preferred dimpling machine is a probe station which has accurate x, y, and z control. It is to be understood that any other suitable dimpling machine may likewise be used. Referring to FIG. 16 , the tool 210 is pressed into contact with the top surface 202 of the substrate 200 resulting in a depression 216 matching the shape of the tool 210 upon its removal from the substrate 200 , as shown in FIG. 17 . The tool 210 is used to create a plurality of depressions 216 in the substrate 200 matching the desired pattern, such as the pattern shown in FIG. 6 . Conversely, the tool 210 can be held stationary and the substrate 200 can be moved in the z-direction until the top surface 202 of the substrate is pressed into contact with the tool 210 resulting in the same depression 216 matching the shape of the tool 210 upon its removal from the substrate 200 , as shown in FIG. 17 .
Referring to FIG. 18 , a polyimide layer 220 is patterned around the depressions 216 . It is to be understood that any other suitable insulative layer or dielectric layer may likewise be used. In the process of patterning the polyimide layer 220 , it is somewhat difficult to remove the polyimide from the depressions 216 during the exposing and etching process for the polyimide layer 220 . This is especially true when the depressions 216 are relatively deep with steeply inclined sides. Alternatively, the polyimide layer 220 may be patterned on the top surface 202 of the substrate 200 with openings located therein where the depressions 216 are desired. Thereafter, the tool 210 is used to create the depressions 216 in the substrate 200 through the openings provided in the polyimide layer 220 . This alternative technique eliminates the difficult process of adequately removing the polyimide layer 220 from the depressions 216 .
It is expensive to manufacture masks for exposing the polyimide layer 220 that have tolerances sufficient to precisely align the openings for the depressions 216 . The tool 210 , in combination with the dimpling machine, can be aligned to the actual location of one of the openings that results from exposing and etching the polyimide layer 220 with a relatively inexpensive, and somewhat inaccurate mask. The present inventors came to the realization that localized regions of the mask, and thus the openings resulting therefrom, tend to be relatively well aligned for purposes of dimpling. Likewise, regions of the mask distant from one another tend not to be relatively well aligned for purposes of dimpling. Accordingly, automatically dimpling the substrate 200 to match an anticipated pattern with many depressions 216 distant from one another, with an accurate dimpling machine, will result in the dimpling tool not accurately being aligned with the openings at regions distant from the initial alignment point. To improve the accuracy of the alignment process the present inventors came to the realization that the dimpling machine may be realigned to the actual openings in the polyimide layer 220 at different remote locations, so that each localized region is relatively accurately aligned, while the overall alignment may be somewhat off. In this manner a relatively inexpensive mask may be used.
Preferably the dimpling machine includes accurate z-axis movement so that the depth of each depression is identical, or substantially identical. Referring to FIG. 19 , if sufficiently accurate z-axis movement is not available then an alternative dimpling tool 240 with a built in z-axis stop 242 may be used. The z-axis stop 242 is a projection extending outward from the head 244 that comes to rest on the top surface of the polyimide 220 or top surface 202 of the substrate 200 . The z-axis stop 242 is positioned with respect to the head 244 such that the proper depth is obtained, taking into account whether or not the polyimide layer 220 is previously patterned before using the dimpling tool 240 .
Referring to FIG. 20 , a conductive material 250 is electroplated onto the polyimide 220 and substrate 200 thereby filling up the depressions 216 with the conductive material 250 , such as nickel and rhodium. It is to be understood that any other suitable technique may be used to locate conductive material within the depressions 216 . The conductive material 250 is then preferably lapped to remove excess from the top surface of the polyimide layer 220 and to provide a flat overall surface. The preferred lapping process is a chemical-mechanical planarization process. A trace 252 is patterned on the polyimide layer 220 and the conductive material 250 . The trace 252 is preferably a good conductor such as copper, aluminum, or gold. A polyimide layer 254 is then patterned over the entire surface. Further layers of metal and dielectric may be formed. The substrate 200 is then removed by any suitable process, such as etching with hydrochloric acid (HCL 15%) or sulfuric acid (H 2 SO 4 ). Hydrochloric acid and sulfuric acid are not reactive with the polyimide layer 220 nor the conductive material 250 , such as nickel or rhodium. It is to be understood that the polyimide layer 254 may alternatively be any suitable insulator or dielectric layer.
Referring to FIG. 21 , the contacting portion 260 of the resulting device is preferably selected to have a low contact resistance so that a good electrical connection may be made with the test device. While nickel has a relatively low contact resistance, rhodium has an even lower contact resistance and is more resistant to wear than nickel. Accordingly, the depressions 216 are preferably coated with a layer of rhodium. Using normal processing techniques the thickness of rhodium is limited to approximately 5 microns. The resulting device includes an exterior layer of rhodium, and in particular the contacting portion 260 , which is then filled with the remaining conductive material, such as nickel or a nonconductive fill. The conductive material need not fill the entire depression.
The aforementioned “top-down” construction process provides numerous advantages over the traditional bottom-up” processing technique of constructing layers upon a supporting substrate. These advantages also permit the capability of constructing devices with improved characteristics.
First, there are no limitations to the height of the resulting devices which were previously imposed by limitations of photoresist processing. The ability to construct devices having any suitable height also relieves the limitations imposed by attempting to electroplate into a tall narrow openings in photoresist, which is difficult.
Second, the elevation of the contacting portions 260 of the devices is extremely uniform because it is defined solely by the tooling process, which is mechanical in nature. Different localized current densities of the electroplating bath, different densities of the ions within the electroplating bath, and “random” variations in the electroplating bath are eliminated from impacting the overall shape and height of the resulting devices. With substantially uniform elevation of the devices, less force is required for the devices to make adequate contact with the test device which, in turn, decreases the likelihood of bending and breaking the probe station, the probe head, and/or the membrane probing assembly. Also, the substantially uniform elevation of the devices decreases the likelihood of damaging contact pads on the test device with excessive pressure.
Third, the contacting portion 260 of the devices are stronger because the device is constructed of a single homogenous material during one depositing process requiring no interfacial layers, as previously required for the multiple processing steps. This permits reducing the size of the contacting portions to the limitation of the maximum current density allowable therein during testing and not the minimum sheer force of the interfacial layers.
Fourth, the shape of the resulting devices are customizable to effectively probe different materials. The shape of the device may have steep sidewall angles, such as 85 degrees, while still providing mechanical strength, stability, and integrity. The steep sidewalls permit narrower devices to be constructed which allows for a greater density of devices for increasingly denser arrangements of contact pads on the test device. Moreover, the angle of the sidewalls are not dependent (e.g. independent) on the crystalline structure of the substrate.
Fifth, the shape of the contacting portion is known precisely, and is uniform between devices, which permits uniform contact with the contact pads of the test device.
Sixth, the alignment of the different portions of the resulting device are exactly uniform between devices because each device was constructed using the same tooling process. With exact alignment of the lower portions of each device (beam and contact bump) in relation to the contacting portion, there is no need to provide additional leeway to accommodate processing variations inherent in photoresist processes and in electroplating processes. Also, the “mushrooming” effect of the electroplating process is eliminated which also reduces the required size of the device. The alignment variability reduction, and virtual elimination, of different devices 300 allows a significantly decreased pitch to be obtained, suitable for contact pads on the test device that have increased density.
Seventh, the shape of the resulting devices may be tailor shaped to provide optimal mechanical performance. To provide the scrubbing function, as described in the background portion, the device should have a beam and bump structure that tilts upon contact. The device 300 may include an inclined surface 304 between its tail 302 and the contacting portion 260 . The inclined surface 304 provides for increased strength along portions of the length of the device 300 which permits the tail 302 to be thinner than its head 306 . The torque forces applied to the device 300 during the tilting process of the device 300 tend to decrease over the length of the device 300 which has a correspondingly thinner material defined by the inclined surface 304 . With a thinner tail 302 and material proximate the tail 302 , the tail 302 of the device 300 has less likelihood of impacting the test device if excess tiling occurs. The improved shape of the device 300 also decreases the amount of metal material required.
Eighth, “look-up” cameras are used to obtain an image of the lower portion of the membrane probe to determine the precise location of the devices 300 relative to the contact pads on the test device. Using “look-up” cameras permits automatic alignment of the membrane devices relative to the contact pads so that automatic testing may be performed. In order to obtain an image of the devices 300 on the membrane probe the “look-up” cameras normally utilize light to illuminate the devices 300 . Unfortunately, the traditional planar processing techniques result in relatively flat surfaces on the beams, contact bumps, and contacting portions, in a perpendicular orientation to the look up” cameras each of which reflects light back to the “look-up” camera. The light reflecting back to the “look up” camera from all the surfaces frequently results in some confusion regarding the exact location of the contacting portions 260 . The inclined surface 304 of the devices 300 tends to reflect incident light away from lowerly disposed “look-up” cameras, while the contacting portions 306 tend to reflect incident light back to lowerly disposed “look-up” cameras. Light returning to the “look-up” camera primarily from the contacting portions 306 results in less potential confusion regarding the exact location of the contacting portions.
Ninth, the initial polishing of the top surface 202 of the substrate 200 results in a matching smooth lower surface for the polyimide layer 220 patterned thereon. After etching away, or otherwise removing, the substrate 200 the lower surface of the polyimide layer 220 is smooth and the resulting polyimide layer 220 is generally optically clear. Accordingly, the spaces between the traces and the metallized devices 300 is relatively optically transmissive so that an operator positioning the device can readily see through the device between the traces and devices. This assists the operator in manually positioning the membrane probe on the devices which are otherwise obscured. In addition, the pyramidal shape of the devices 300 allows the operator to more easily determine the exact location of the contacting portions relative to the contact pads on the test device, which were previously obscured by the wide beam structures (relative to the contacting portions).
Tenth, referring to FIG. 22 , the contacting portions 260 of the device are preferably constructed with an exterior surface of rhodium 340 , which typically can be effectively plated to only approximately a thickness of 5 microns. The plating process of rhodium is semi-conformal, so the resulting layer is approximately 5 microns thick in a perpendicular direction to the exterior sides 352 and 354 . The width of the top 350 of the contacting portion and the angle of the sides 352 and 354 of the tool 210 is selected so that the rhodium 340 plated on both sides 352 and 254 preferably join together forming a v-shape. The remainder of the device is preferably nickel. While the thickness of the rhodium 340 is only 5 microns in a perpendicular direction, the thickness of the rhodium 340 in a perpendicular direction from the top 350 of the device is greater than 5 microns. Accordingly, the contacting portion which wears during use in a generally perpendicular direction from the top 350 will last longer than if the top portion were merely plated to a thickness of 5 microns of rhodium.
Eleventh, the texture of the contacting portion 260 may be selected to provide the described scrubbing effect on the contact pads of the test device. In particular, the tool may include a roughened surface pattern on the corresponding contacting portion to provide a uniform texture for all devices.
Thirteenth, using the construction technique of the present invention is relatively quick to construct the devices because of the decreased number of processing steps, resulting in a substantial cost savings.
The aforementioned construction technique also provides several advantages related to the shape of the devices which would be otherwise difficult, if not impossible, to construct.
First, the tool may provide any desired shape, such as a simple bump, if no scrubbing action is desired.
Second, the inclined supporting sides of the test device up to the contacting portion 260 provides superior mechanical support for the contacting portion 260 , as opposed to merely a portion of metal supported by a larger contact bump. With such support from the inclined sides, the contacting portion may be smaller without risk of it becoming detached from the device. The smaller contacting portion provides improved contact with the contact pad of the test device when the device tilts to penetrate the oxide buildup on the surface of the contact pad. In addition, the tail 302 of the device may be substantially thinner than the remainder of the device which decreases the likelihood of the tail 302 portion impacting the contact pad of the test device during testing when the device tilts.
Third, the pressure exerted by the contacting portions of the devices, given a predefined pressure exerted by the probe head, is variable by changing the center of rotation of the device. The center of rotation of the device can be selected by selecting the length of the device and the location/height of the contacting portion relative thereto. Accordingly, the pressures can be selected, as desired, to match characteristics of two different contact pads.
Fourth, referring to FIG. 23 , a triangular shape of the footprint of the device allows for high lateral stability of the devices while permitting a decrease in the pitch between devices. The contacting portions 403 of the device are preferably aligned in a linear arrangement for many contact pads of test devices. The triangular portions of the device are aligned in alternatively opposing directions.
Fifth, the capability of constructing contacting portions that are raised high from the lower surface of the device, while still maintaining uniformity in the device height and structural strength, allows the device to provide scrubbing action while the lower surface of the device requires little movement. The small movement of the lower surface of the device to make good electrical contact during testing decreases the stress on the layers under the lower surface of the device. Accordingly, the likelihood of cracking the polyimide layers and the conductive traces is reduced.
When probing an oxide layer on solder bumps, or solder balls on wafers that are to be used with “flip-chip” packaging technology, such as the solder bumps on the printed circuit boards, the oxide layer developed thereon is difficult to effectively penetrate. Referring to FIG. 24 , when contacting a traditional contacting portion of a membrane probe onto the solder bump, the oxide 285 tends to be pressed into the solder bump 287 together with the contacting portion 289 resulting in a poor interconnection. When using conventional needle probes on solder bumps, the needles tend to skate on the solder bumps, bend under within the solder bumps, collect debris on the needles, flake the debris onto the surface of the test device, and cleaning the needle probes is time consuming and tedious. Moreover, needle probes leave non-uniform probe marks on the solder bumps. When probing solder bumps used on flip-chips, the probe marks left in the upper portion of the solder bump tends to trap flux therein, which when heated tends to explode, which degrades, or otherwise destroys, the interconnection. Referring to FIGS. 25 and 26 , an improved device construction suitable for probing solder bumps is shown. The upper portion of the device includes a pair of steeply inclined sides 291 and 293 , such as 15 degrees off vertical, with preferably polished sides. The inclined sides 291 and 293 preferably form a sharp ridge 295 at the top thereof. The angle of the sides 291 and 293 is selected with regard to the coefficient of friction between the sides and the oxide on the solder bump, so that the oxide coated surface tends to primarily slide along the surfaces of the sides 291 and 293 , or otherwise shear away, and not be significantly carried on the sides as the device penetrates a solder bump. Referring to FIG. 27 , the substantially sharp ridge also provides for a mark (detent) after contact that extends across the entire solder bump. Subsequent heating of the solder bumps, together with flux, result in the flux exiting from the sides of the solder bump thereby avoiding the possibility of explosion. In addition, the resulting mark left on the solder bumps is uniform in nature which allows manufacturers of the solder bumps to account for the resulting marks in their design. Also, less force is required to be applied to the device because it tends to slice through the solder bump rather than make pressing contact with the solder bump. The flatter surface 405 prevents slicing too deeply into the solder ball (bump).
Referring to FIG. 28 , to provide a larger contact area for testing solder bumps a waffle pattern may be used.
Referring to FIG. 29 , an alternative device includes a pair of projections 311 and 313 that are preferably at the ends of an arch 315 . The spacing between the projections 311 and 313 is preferably less than the diameter of the solder bump 317 to be tested. With such an arrangement the projections 311 and 313 will strike the sides of the solder bump 317 thereby not leaving a mark on the upper portion of the solder bump 317 . With marks on the sides of the solder bump 317 , the subsequent flux used will be less likely to become trapped within the mark and explode. In addition, if the alignment of the device is not centered on the solder bump 317 then it is highly likely that one of the projections 311 and 313 will still strike the solder bump 317 .
Previous device construction techniques resulted in devices that included contacting portions that were rather large and difficult to assure alignment of. Referring to FIG. 30 , with the improved construction technique the present inventors came to the realization that membrane probes may be used to make a “true” Kevlin connection to a contact pad on the test device. A pair of devices 351 and 353 are aligned with their contacting portions 355 and 357 adjacent one another. With this arrangement one of the devices may be the “force” while the other device is the “sense” part of the Kelvin testing arrangement. Both contacting portions 355 and 357 contact the same contact pad on the test device. A more detailed analysis of Kelvin connections is described in Fink, D. G., ed., Electronics Engineers' Handbook, 1st ed., McGraw-Hill Book Co., 1975, Sec. 17-61, pp. 17-25, 17-26, “The Kelvin Double Bridge”, and U.S. patent application Ser. No. 08/864,287, both of which are incorporated by reference herein.
It is to be noted that none to all of the aforementioned advantages may be present in devices constructed accordingly to the present invention, depending on the technique used, desired use, and structure achieved.
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A method of constructing a probe which includes providing a substrate and creating a first substantially asymmetrical recess within the substrate. A conductive material is located within the recess and a conductive trace is electrically connected with the conductive material. A membrane supports the conductive trace, wherein the conductive material is located between the membrane and the substrate. The substrate is removed from the conductive material.
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BACKGROUND OF THE INVENTION
The present invention relates to aircraft control systems and, in particular, to a flare control system which directs the aircraft onto a specific curvilinear path.
Known landing systems commonly employ a glide slope detector which carries the aircraft to within a certain distance of the landing strip after which a flare coupler is engaged. This flare coupler is commonly controlled by a radar altimeter, a normal accelerometer but no other aircraft sensors. Because of the relatively few controlling parameters, the dispersion of the touchdown point can be relatively large.
Conventional flare couplers attempt to direct an aircraft along an exponential path by keeping the descent rate proportional to altitude. However, these flare couplers do not measure and respond to the longitudinal displacement of the aircraft. As a result, wind gusts and other atmospheric disturbances can deflect the aircraft from the initial exponential path to another one of a family of exponential paths. Therefore, the final touchdown point is uncertain and its scattering will depend upon atmospheric conditions and disturbances.
An important consideration for flare control systems is the effect of noise produced by aircraft sensors controlling the flare maneuver. When only one aircraft sensor is employed to control the flare maneuver, its noise becomes an independent cause of scattering of the touchdown point.
An example of an integrated glide path/flare automatic flight control system is disclosed in U.S. Pat. No. 3,892,373.
SUMMARY OF THE INVENTION
In accordance with the illustrative embodiments demonstrating features and advantages of the present invention, there is provided a control system for directing an aircraft along a predetermined curvilinear descent path. The aircraft carries a plurality of sensors. The system includes a longitudinal means, a height means and a command means. The longitudnal means responds to at least one of the aircraft sensors for providing a longitudinal signal related to longitudinal displacement of the aircraft. The height means responds to the longitudinal signal for producing a height signal functionally related to the altitude required to follow the path. The command means responds to the height signal and a given one of the sensors for producing an error signal bearing a predetermined relation to the extent of deviation of the aircraft from the predetermined curvilinear descent path.
According to a related aspect of the present invention an aircrat motion monitoring system is provided which may cooperate with a control system such as the foregoing. This aircraft motion monitoring system has a velocity sensing means, a travel integrating means and a feedback means. The velocity sensing means can provide a velocity signal signifying ground speed of the aircraft. The travel integrating means can integrate the output of a longitudinal acceleration sensor carried on the aircraft. The feedback means is coupled around the travel integrating means. This feedback means includes a combinational means responsive to the longitudinal acceleration sensor and the velocity signal for driving the travel integrating means.
In another related aspect of the present invention, another aircraft motion monitoring system is provided that may advantageously cooperate with a control system such as the foregoing. This motion monitoring system has a descending means, an altitude differentiating means and a transfer means. The descending means responds to one of the aircraft sensors to produce a descent signal signifying aircraft descent rate. The altitude differentiating means operates to differentiate the output of the altitude sensor. The transfer means operates to produce a signal, the controlling influence in its production being transferred from the descending means to the altitude differentiating means in response to arrival of the aircraft at a predetermined position.
By employing the foregong equipment a flight control system is provided which can accurately control the flare maneuver of an aircraft on a definite curvilinear descent path. The system can respond to perturbations by continually converging the aircraft onto this path. Therefore the aircraft is not perturbed from the original descent path to another, but instead converges back to the original descent path.
In a preferred embodiment the flare descent path is a circular arc. This circular flare maneuver has the advantage of producing a small, constant normal acceleration and a regularly increasing pitch. The aircraft follows a circle having a radius of approximately 44,000 feet commencing at an altitude of 50 feet after leaving a glide slope of approximately 2.75°. The point of commencement of the circular flare maneuver is displaced 0.048 radians from vertical. Since the radius of this circle in this embodiment exceeds the elevation of the center by approximately 2.68 feet, the flare path definitely intersects the ground to avoid excessive "floating". It is to be appreciated that the above dimensions are merely exemplary.
The preferred control system responds to inertial sensors, radio sensors or other sensors typically carried on an aircraft. These sensors are employed by computing systems which derive the required positional data without incurring excessive noise or transients. Each positional datum may be developed by more than one aircraft sensor so that the noise inherent in each tends to cancel and produce a quieter signal. Also, aircraft sensors providing relevant data to the monitoring system to establish initial conditions but which are not considered sufficiently reliable to control the critical flare maneuver are subsequently decoupled when the flare maneuver is initiated. For example, a longitudinal accelerometer and a distance measuring radar can together initially establish the ground speed. However, during the subsequent flare maneuver the distance measuring radar is decoupled so that the typically more reliable accelerometer has the primary influence in developing a ground speed signal. For aircraft not carrying distance measuring radar an alternate technique employing a barometric altimeter is disclosed.
Also in a preferred embodiment, a glide slope system is used to determine the initial value of the descent rate. In this embodiment a signal from a normal accelerometer combines with those of a glide slope system and a distance measuring radar (or with that of a barometric altimeter) to provide a less noisy combined signal. Since the glide slope signals become unreliable during a flare maneuver, control is transferred to the radar altimeter and the normal accelerometer, equipment considered sufficiently reliable to control a flare maneuver.
The preferred embodiment also drives a control loop whose output error signal is clamped at zero prior to flare engagement thereby avoiding large transfer transients. This embodiment also employs a "nose down" circuit which responds to a command to pitch the aircraft downwardly by hastening the recovery time to such a command. This feature is significant since commanding a quick descent during a flare maneuver may lead to a dangerous condition and ought to be terminated as soon as possible.
BRIEF DESCRIPTION OF THE DRAWINGS
The above brief description, as well as other objects, features and advantages of the present invention will be more fully understood by reference to the following detailed description of presently preferred, but nonetheless illustrative embodiments, when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is an illustration of a curvilinear descent path provided by the control system of the present invention;
FIG. 2 is a schematic illustration of a control system according to the present invention;
FIG. 3 is a schematic illustration of a longitudinal monitoring system which may cooperate with the control system of FIG. 1;
FIG. 4 is a schematic illustration of a descent monitoring system which may cooperate with the control system of FIG. 1; and
FIG. 5 is a schematic illustration of an alternate longitudinal monitoring system which may cooperate with the control system of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, an example of a predetermined curvilinear descent path 10 is given for an aircraft 21. Path 10 is essentially the arc of a circle having center 12 and a radius r of 44,000 feet. In this embodiment the elevation of center 12 is 2.68 feet less than radius 4. Arc 10 begins at point 14, a position 0.048 radians from vertical and continues to touchdown point 16. Arc 10 is tangent at beginning point 14 to glide slope path 20 which slopes 2.75° from horizontal. Glide slope path 20 extends as indicated by the dotted line to a glide slope transmitter 22 at ground level. Glide slope transmitter 22 is located a distance L from touchdown point 16, in this embodiment 500 feet. The horizontal distance between center 12 and beginning point 14 of arc 10 is marked as dimension a, in this embodiment 2,111.19 feet. Also the elevation of beginning point 14 of arc 10, marked as dimension d, is in this embodiment 50 feet.
Since the flare maneuver follows a circular arc, pitch regularly increases and normal acceleration is a small constant value. It is to be appreciated, however, that apparatus according to the principles of the present invention may cause an aircraft to follow another curvilinear descent path which is not circular.
Referring to FIG. 2, a control system is illustrated as a height means having function generator 26. The input of function generator 26 is connected to terminal x which receives from a longitudinal means (described hereinafter) a longitudinal signal signifying the horizontal displacement of aircraft 21 with respect to beginning point 14 (FIG. 1). The output H of function generator 26 is according to a function F(x). The transfer characteristics of this and other function generators will be described shortly, hereinafter. Line H of generator 26 is connected to the summing input of a command means shown comprising subtractive device 28, whose subtracting input is connected to a terminal h for receiving from a subsequently illustrated system a signal corresponding to the altitude of the aircraft.
Terminal h is also connected to one input of a speed means, shown herein as function generator 30, whose other input is connected to terminal Vg which receives from a subsequently illustrated device a signal corresponding to the ground speed of the aircraft. Generator 30 produces an output on line Vh that is a function G(h,Vg) of its input. Output line Vh is connected to the summing input of subtractive device 32 whose subtracting input is connected to terminal v h . Terminal v h receives from the subsequently illustrated descent means a descent signal signifying the descent velocity of the aircraft. An acceleration means, shown herein as function generator 34, is connected to an input terminal Vg which is identical to that previously described. The output A'n of generator 34, a function P(vg) of its inputs, is connected to the summing input of subtractive device 35. Its subtractive input is connected to the terminal An which is referred to as a rate means and which receives a signal from a well known normal accelerometer mounted in the aircraft.
Summing device 36, also part of the above mentioned command means, has its three inputs separately connected to the outputs of scaling amplifiers K1, K2 and K3, whose inputs are connected to the outputs of subtractive devices 28, 32 and 35, respectively.
The functions F, G and P of function generators 26, 30 and 34 respectively, are preferably designed to constrain the aircraft to a circular flare path. To understand their operation first consider the general equation for a circular path of radius r:
(x-a).sup.2 +(h-b).sup.2 =r.sup.2 (1)
wherein the variables x and h are the horizontal and vertical displacement, respectively, of the aircraft with respect to a given origin. Quantities a and b are the horizontal and vertical displacement, respectively, of the center of the circle with respect to that origin. The above equation may be differentiated with respect to time and rearranged to arrive at the following relation: ##EQU1## wherein V h is h and V g is x. Substituting in the latter equation the value of (x-a) obtainable from equation 1, the following relation is obtained: ##EQU2## As indicated by the functional notation G, this equation defines the response characteristics of function generator 30. By differentiating equation 1 with respect to time twice the following relationship is obtained:
V.sub.g.sup.2 +V.sub.h.sup.2 +(x-a)A.sub.x +(h-b)A.sub.h =0 (4)
wherein A h is h and A x is x. Assuming in the latter equation that V g >>V h , its second additive term containing V h may be dropped. Also assuming that b>>h, the term h may be eliminated from the latter equation. Finally, if the term A x is considered sufficiently negligible as to be set approximately equal to zero then the third additive term containing it may be deleted. Consequently, the latter equation may be rearranged as follows:
A.sub.h =V.sub.g.sup.2 /b (5)
However, since An is approximately equal to A h and b is approximately equal to r then the latter equation may be expressed as follows (An is normal acceleration):
An=Vg.sup.2 /r=P(Vg) (6)
wherein the functional notation P is also used to identify the response characteristics of function generator 34. Finally, equation 1 may be rearranged so that the term h appears as a function F of the term x as follows: ##EQU3## Summarizng the foregoing, the three functional expressions F, G and P (equations 7, 3 and 6, respectively) define the set of functions which the present system employs to determine deviation of an aircraft from a predetermined curvilinear descent path, an arc of a circle in this embodiment.
The individual error signals are summed at summing device 36 to produce a combined error signal which is applied to an activating means shown herein as control integrator 38 and its associated circuitry. The output of control integrator 38 is applied to one input of summing device 40 whose other input is connected to the output of scaling amplifier Ka. The input of amplifier Ka is connected to the junction of the output of summing device 36 and the summing input of subtractive device 44. The output of subtractive device 44 is applied to the summing input of subtracting device 46 whose output is coupled to the input of limiting device 48, a device whose transfer characteristic is linear until it saturates when its input exceeds a predetermined magnitude. The output of limiting device 48 drives the input of control integrator 38. The output of summing device 40 is applied to an input of another limiting device 50 which is constructed similarly to limiting device 48. The output of limiting device 50 is applied to a control input of integrator 38 to freeze its output value when the input of limiting device 50 exceeds a predetermined magnitude.
The output of summing device 40 is applied to the summing input of subtractive device 52 whose subtracting input is connected terminal θ. The latter terminal receives a signal proportional to the pitch angle of the aircraft. The output of subtractive device 52 is applied to input of scaling amplifier Kb whose output drives the summing input of subtractive device 54. Its subtracting input is coupled to the output of scaling amplifier Kc whose input is connected to terminal θ which terminal receives a signal that is the time rate of change of the signal on terminal θ. The output of subtractive device 54, terminal De, is the overall error signal used to control the pitch of the controlled aircraft.
A clamping signal is fed back around the activating means by a clamping means, shown herein as the serial combination of scaling amplifier Ks and flare switch 56. As described hereinafter the clamping means keeps integrator 38 and the output of subtractive device 52 in a state corresponding to zero error. Flare switch 56 is connected between the subtracting input of subtractive device 44 and the output of scaling amplifier Ks whose input is connected to the output of subtractive device 52. Flare switch 56 opens as shown by its directional arrow when the aircraft commences a flare maneuver as further described hereinafter. Such actuation may be initiated manually or automatically when the aircraft reaches a preset altitude.
An overcorrection limiting means is shown herein as scaling amplifier Knd and automatic switch 58. Switch 58 is connected between the subtracting input of subtractive device 46 and the output of scaling amplifier Knd whose input is connected to the output of subtractive device 40. Automatic switch 58 closes and limits the rate of change of integrator 38 whenever the current command signals might require the aircraft to fly downwardly (nose down condition). The latter situation must not be prolonged during a flare maneuver since a significant and dangerous loss in altitude may ensue. Accordingly, in this embodiment scaling amplifier Knd and switch 58 operate to moderate the changes in integrator 38 whenever the polarity of the output of device 40 requires the aircraft to pitch toward a nose down condition.
Referring to FIG. 3, a portion of an aircraft motion monitoring system employing a longitudinal means is shown herein as a pair of travel integrating means comprising precedent integrator 62 and subsequent integrator 64. A switching device 66 is connected between the output of integrator 62 (terminal Vg) and the input of integrator 64. Prior to closure of switch device 66 integrator 64 produces an output of zero. Precedent integrator 62 has a combinational feedback means coupled around it which includes a travel summing means comprising summing device 68 and subtractive device 70 whose subtracting terminal is connected to the output of integrator 62. A switching means 72 is connected between the output of subtractive device 70 and an input of summing device 68 whose other input is connected to terminal Ax which receives a signal from a longitudinal acceleration sensor. This sensor is an accelerometer typically found on an aircraft for measuring acceleration forces along the length of an aircraft.
The input and output of integrator 62 are separately connected to the output of summing device 68 and the subtracting input of subtractive device 70, respectively. It is to be noted that switches 72 and 66 transfer in the direction indicated by their respective arrows when the aircraft commences a flare maneuver in a manner similar to switch 56 of FIG. 2.
Coupled to the summing input of subractive device 70 is the output of a velocity sensing means shown herein as a travel differentiating means 74. Device 74 in this embodiment not only differentiates but also provides some low pass filtering which may be expressed by a Laplace transform of the form: s/(s+1). An example of such a device would be a resistive-capacitive divider, the output across the resistor, scaled for a time constant of one second. Alternatively, a digital filter or a computer processing technique can be implemented to provide such a transfer characteristic. The input to differentiating means 74 is derived from a longitudinal displacement sensor identified as input terminal DME. In this embodiment terminal DME connects to the distance measuring radar equipment frequently carried by an aircraft.
The output of differentiating means 74 is also coupled to a glide means (sometimes referred to herein as a fall means) comprising multiplier 76. Multiplier 76 has one input connected to the output of differentiating means 74 and its other output connected to terminal No. The signal applied to terminal No is proportional to the nominal glide slope angle (identified as angle g in FIG. 1). The output of multiplier 76 is connected to one of the inputs of summing device 78 whose other input is driven by the output of scaling amplifier Ro. Scaling amplifier Ro provides an output signal proportional to its input on terminal Nd by a factor Ro. The signal on terminal Nd is the time rate of change of the well known desensitized beam output of a glide slope instrument. A desensitized signal is derived by multiplying the angular beam error by the altitude to provide a signal approximately proportional to the altitude error with respect to the glide slope beam. Thereafter amplifier Ro multiplies the desensitized beam signal by a scale factor (referred to herein as Ro) to provide a signal directly related to altitude error.
The output Hn of summing device 78 may be expressed as follows:
Hn=V.sub.x (No)+(Nd) Ro (8)
wherein the term v x , the output of differentiator 74, is a measure of ground speed. Accordingly, since the term No is approximately equal to its tangent, the first additive term after the equal sign is approximately the vertical velocity an aircraft would achieve for a given ground speed if it followed the nominal glide slope without error. The second additive term, the rescaled rate of change of the desensitized beam error signal, is a measure of the vertical velocity of the aircraft with respect to the nominal glide slope. Therefore, the two additive terms on the right hand side of the above equation, constituting all of the vertical velocity components, together equal the total vertical velocity, term Hn.
As previously mentioned, the signal on terminal Ax signifies the output of an accelerometer sensing acceleration along with the longitudinal axis of the aircraft. Accordingly, when switch 72 is open, as it is during a flare maneuver, integrator 62 produces in a well understood manner an output on terminal Vg signifying the velocity of the aircraft along its longitudinal axis. Since the pitch of the aircraft is relatively small, the signal on terminal Vg approximates the ground speed of the aircraft. Prior to the opening of switch 72 the signals on terminals Ax and DME are related as follows to the output of integrator 62 on terminal Vg: ##EQU4## wherein the term D is equal to DME/(s+1), DME being the distance signal present on terminal DME. From the foregoing equation it is apparent that the output signal on terminal Vg is a combination derived from the signals on terminals Ax and DME and in the same proportion. Since two independent sensors are cooperating their respective noise components do not correlate so that the combined system is less noisy than a system employing only one sensor. The foregoing equation can be simplified by assuming that D=x and that Ax=s 2 x (x being actual horizontal displacement). With the foregoing assumptions the equation 9 reduces to Vg=sx.
It will be appreciated that the foregong equipment, supplying signals to the apparatus of FIG. 2, has alternate forms. While signals may be obtained from a pair of sensors such as a distance measuring radar and a longitudinal acceleromer, other sensors can be used. Also the type of filtering can be altered depending upon system requirements and the expected noise spectrum. Furthermore, while the system has been illustrated in terms of discrete circuit blocks, much of the foregoing can be implemented by digital filters, by a microcomputer or similar equipment.
Referring to FIG. 4, another portion of an aircraft motion monitoring system is illustrated which employs a descent means having an altitude differentiating means shown herein as block 80. In this embodiment block 80 is a device having a transfer characteristic which may be expressed in terms of the following Lapace transform: s/(s+1). This device may be characterized as a differentiating circuit having an output filtered by a single pole low pass filter such as a resistive-capacitive divider. The input to the altitude differentiating means 80 is coupled to the output of the additive means shown herein as summing device 82 whose two inputs are separately connected to terminal Hra and the output of a signal conditioning means, shown herein as block 84 having the following transfer characteristic expressed as a Laplace transform: 20/20(20s+1). Block 84 is a filtering device which may be characterized as a single pole low pass filter such as a resistive-capacitive divider having a time constant of 1/20 of a second. The input of device 84, terminal An, is the output of a normal acceleration sensor which is in this embodiment a normal accelerometer carried on the aircraft. Terminal Hra is the output terminal of an altitude sensor such as a radar altimeter.
A descending means operating as a descent integrating means employs an integrator 86 whose input and output are connected to the output of summing device 88 and the subtracting input of subtractive device 90, respectively. A controlled flare switch 92 is connected between the output of subtracting device 90 and one of the inputs of device 88, its other input being connected to the output of multiplier 94. Switch 92 opens in the direction indicated by its directional arrow when the aircraft commences a flare maneuver. Multiplier 94 has input terminals cos θ and An, the latter being the same as the terminal above bearing the identical reference character. Terminal cos θ receives a signal corresponding to the cosine of the pitch angle of the aircraft. The summing input of subtractive device 90, terminal Hn, is connected to the terminal of FIG. 3 bearing the identical reference character. As explained in connection with an alternate embodiment terminal Hn may be connected instead to a sensor producing a signal signifying the time rate of change of a barometric altimeter.
A transfer means is shown herein as summing device 96 having an output terminal v h and two summing input terminals separately connected to the outputs of gradual switching devices 98 and 100. Switching devices 98 and 100 work in unison to gradually reduce the influence on device 96 of switch 98 while grandually increasing the influence on device 96 of switch 100. Switches 98 and 100 each have a transfer characteristic that varies between zero and unity, their sum equalling unity. The inputs of switching devices 98 and 100 are connected to the outputs of devices 86 and 80, respectively.
A transistion means of a height means is shown herein as a pair of switching devices 102 and 104 which operate identically as previously described switches 98 and 100, respectively. The input of switching device 104, terminal Hra, receives the same signal, the identically labelled input of device 82. The outputs of switches 102 and 104 are separately connected to different inputs of summing device 106 whose output is identified as terminal h. The input of switching device 102 is connected to the output of a height integrating means, shown herein as integrator 108. Connected between the output of integrator 86 and the input of integrator 108 is a switching device 110 which transfers to a closed position as shown by its directional arrow when the aircraft commences a flare maneuver.
The equipment surrounding integrator 86 is similar to that previously described in connection with integrator 62 of FIG. 3. Accordingly, the output of integrator 86 may be characterized as follows: ##EQU5## wherein a is the output of multiplier 94. Since the output of multiplier 94 is approximately s 2 h and since the signal on terminal Hn may be approximated as sh (wherein h is the actual altitude of the aircraft) then the above expression reduces to sh, the actual descent rate of the aircraft. It is apparent that when switch 92 opens during a flare maneuver that the output of integrator 86 will correspond to (An cos θ)/s. Referring to the above assumptions, this latter expression is approximately sh, that is, the vertical descent rate.
Referring to integrator 80 it is apparent that its output may be expressed as follows: ##EQU6## If it is assumed that the terms An and Hra are approximately equal to s 2 h and h, respectively, wherein h is the actual aircraft altitude, then the foregoing expression may be simplified as follows: ##EQU7## Since the fractional Laplace operator in the above expression is approximately equal to unity, the output of differentiator 80 is approximately equal to h, the actual altitude of the aircraft. Again, the combining of sensors produces a less noisy, complimented signal since the noise does not correlate.
Alternate configurations are contemplated for the apparatus of FIG. 4. For example, alternate aircraft sensors may be substituted to obtain the signal outputs of terminals v h and h. It is also anticipated that the filtering can be altered depending on the desired response time. Furthermore, it is expected that signal transformations described herein may be implemented in some embodiments by a microcomputer or other digital device.
Referring to FIG. 5, an aircraft motion monitoring system is shown which is an alternate to that illustrated in FIG. 3. This embodiment is useful where a distance measuring radar is unavailable or where it is preferable to use a barometric altimeter. In this embodiment elements 62, 64, 66, 68, 70 and 72 together with their terminals Ax, Vg, and x are identical to similarly labelled elements of FIG. 3, except that the summing terminal of subtractive device 70 is connected to the output of divider 112. Divider 112 has an input connected to the output of subtractive device 114 to divide that output by the magnitude of the signal appearing on terminal tan (No). The signal applied to the latter terminal is the tangent of the nominal glide slope angle (identified as angle g of FIG. 1). Subtractive device 114 has its summing input connected to terminal Hb and its subtracting input connected to the output of scaling amplifier Ro whose input is connected to terminal Nd. Scaling amplifier Ro and terminal Nd are identical to similarly identified components of FIG. 3. Applied to terminal Hb is a signal signifying the time rate of change of the barometric altimeter. It is clear that the output of divider 112 may be expressed as follows: ##EQU8## This output Vx may be shown to be the ground speed of the aircraft by rearranging equation 13 as follows:
Hb=Vx tan (No)+Ro(Nd) (14)
The first term after the equal sign is the altitude rate which the aircraft would maintain if it followed the nominal glide slope without error. The second additive term is the altitude rate of the aircraft with respect to the nominal glide slope as measured by the desensitized beam output Nd. As before the desensitized beam is corrected by the factor Ro to achieve the proper scaling of altitude. Since the two foregoing additive terms comprise all of the altitude rate components, they equal the total altitude rate Hb. Therefore, the output Vx of divider 112 is a measure of ground speed.
Since this ground speed signal applied to the summing input of subtracting device 70 is an analog of the output of the differentiator 74 of FIG. 3, the balance of the equipment of FIG. 5 operates similarly as that of FIG. 3.
To facilitate an understanding of the principles associated with the apparatus of FIGS. 2, 3 and 4, its operation will be briefly described. It is appreciated, however, that the equipment of FIG. 5 may be substitued for that of FIG. 4 and that the operation after such substitution will be similar.
Initially, aircraft 21 (FIG. 1) follows glide slope 20 defined by glide slope transmitter 22 in a conventional manner. The glide slope detector on board the aircraft 21 develops a desensitized beam error signal which is proportional to the altitude error of aircraft 21 with respect to glide slope 20.
During this interval switch 56 (FIG. 2) is closed causing large negative feedback from the output of subtractive device 52 to integrating circuit 38. Consequently, integrator 38 is driven in a direction to cause the output from subtractive device 52 to be zero. Therefore, integrator 38 produces an offset signal which initially counterbalances any error signals which may be produced from the calculations performed by function generators 26, 30, and 34. As will be clear from subsequent description, establishing this initial condition is important since it tends to avoid transient disturbances that might otherwise occur when flight control is transferred to devices 26, 30 and 34. Also at this time, switch 72 (FIG. 3 ) is closed so that the accelerometer signal on terminal Ax and the distance measuring radar signal on terminal DME produce a combined output Vg from integrator 62 signifying the ground speed of the aircraft, in a manner already described.
It should be noted that the distance measuring radar (output terminal DME) in the present invention does not have redundancy or other features which would render it sufficiently reliable to justify having it control an aircraft during the very critical flare maneuver. However, the distance measuring radar in this embodiment is required to establish definite initial conditions for ground speed. In contrast, the accelerometer signal of terminal Ax since it must be integrated to provide velocity information, is by itself ambiguous to the extent the constant of integration is unknown.
Also at this time, the velocity signal obtained from differentiator 74 together with the rate of change of the desensitized beam error signal (terminal Nd) are combined in summing device 78 to produce a signal at terminal Hn which signifies the vertical descent rate of the aircraft, in a manner previously described. During the glide slope maneuver, switch 92 (FIG. 4) is closed so that the vertical descent rate signal on terminal Hn (this Figure and FIG. 3) combines with the normal accelerometer signal of terminal An to produce on the output of integrator 86 a combined signal signifying the descent rate of the aircraft in a manner previously described. It should be noted that the signal on terminal Hn being partly derived from the distance measuring radar, is not deemed sufficiently reliable in this embodiment to control aircraft flight during the critical flare maneuver. However, since this radar output is a direct measure of the vertical descent rate it can resolve ambiguities regarding initial conditions or constants of integration. Such ambiguities could airse from relying only upon the accelerometer signal on terminal An which must be integrated to determine the descent rate.
During this interval, switch 98 connects the output of integrator 86 directly to one input of summing device 96 while switch 100 is effectively open. Consequently, the descent rate signal on terminal v h is directly derived from integrator 86.
Integrators 108 and 64 have open inputs since their associated switches 110 (FIG. 4) and 66 (FIG. 3), respectively, are open. Consequently, integrators 64 and 108 produce preset constant signals corresponding to 0 feet and 50 feet, respectively. The latter quantity corresponds to the altitude of the flare engage point 14 (FIG. 1).
As the aircraft arrives at a predetermined position, flare engage point 14 (FIG. 1), switches 66 (FIG. 3) and 110 (FIG. 4) both close so that their respective integrators 64 and 108 can now change value. Since integrator 64 integrates the ground speed signal Vg, its output on terminal x signifies the longitudinal position of the aircraft with respect to point 14 (FIG. 1). Correspondingly, integrator 108 (FIG. 4) integrates the descent rate signal from integrator 86 to provide on terminal h a signal signifying the altitude of the aircraft.
Also at this time switch 72 (FIG. 3) opens thereby removing the influence of the output of the distance measuring radar (terminal DME). Consequently, integrator 62, whose initial conditions were correctly established by the distance measuring radar, now responds only to the signal applied to terminal Ax by the longitudinal accelerometer, a device sufficiently reliable to control the flare maneuver.
Also at this time, switch 92 opens thereby eliminating the influence of the signal on terminal Hn derived from the desensitized beam error signal. Instead, integrator 86, whose initial conditions were correctly established by the desensitized beam error signal, integrates on the signal on terminal An from the normal accelerometer, a device sufficiently reliable to control aircraft flight during the critical flare maneuver.
As a result, the measured and processed positional data are applied to inputs terminals x, h, Vg, v h , An and Vg of FIG. 2. At this time also, clamping switch 56 (FIG. 2) opens so that integrator 38 is free to produce from subtractive device 52 a non-zero error signal. Instead integrator 38 is now influenced by the error signals produced by function generators 26, 30 and 34. However, since integrator 38 was initially clamped, its error signal from subtractive device 52 does not instantaneously change but, instead, changes gradually to avoid violent aircraft maneuvers. Eventually, however, function generators 26, 30 and 34 produce error signals to command the aircraft to flare from its linear glide slope and pitch upwardly. Accordingly, the aircraft follows circular arc 10 (FIG. 1). Since the error signal from device 36 responds to more than one positional datum it is able to cause definite convergence of the aircraft onto path 10 even after perturbations from wind gusts or other atmospheric disturbances.
These error signals are scaled by amplifiers K1, K2 and K3, combined by summing device 36 and fed forward through integrator 38 and parallel scaling amplifier Ka. With this arrangement integrator 38 may change to a value approximating the required nominal pitch, scaling amplifier Ka transmitting high speed corrections in response to various disturbances. Since integrator 38 produces most of the correction signal, the dynamic range required of scaling amplifier Ka is reduced. Limiting devices 48 and 50 in the input and output, respectively, of integrator 38 prevent it from changing its value too quickly or too much. This feature is important since an unusual disturbance might draw integrator 38 so far from its ordinary nominal value that it may take an unacceptably long time to resettle. The outputs from integrator 38 and scaling amplifier Ka are combined in summing device 40 to produce a pitch command signal which is compared by subtractive device 52 to the actual pitch measurement applied to transducer terminal θ. Subtractive device 52 transmits its pitch error signal through scaling amplifier Kb to a subtractive device 54 which incorporates rate feedback through scaling amplifier Kc whose input (terminal θ) signifies the time rate of change of aircraft pitch. The final error signal of terminal De is coupled to a conventional servo loop (not shown) to operate the aircraft control surfaces such as the elevator.
Since commanding a downward pitch during a flare maneuver is dangerous, switch 58 responds to such a command from summing device 40 by closing and thereby providing negative feedback around integrator 38. This feedback effectively limits changes in integrator 38 so it is not drawn to an enduring value which may continue to direct the aircraft into a nose down condition.
As aircraft 21 continues along flare path 10 (FIG. 1) switches 98, 100, 102 and 104 (FIG. 4) gradually alter their transfer characteristics. Switches 98 and 102, initially having a unity transfer characteristic and switches 100 and 104 initially having a zero transfer characteristic, commence after aircraft 21 arrives at transfer point 14 (FIG. 1) to reverse their roles. Switches 98 and 100, as well as switches 102 and 104, gradually change but keep the sum of their transfer characteristics equal to unity. This transfer, occuring within several seconds, avoids transients which might otherwise occur were control abruptly shifted to different aircraft sensors. The net effect of the foregoing transfer is to substitute the radar altimeter (terminal Hra) for the glide slope detector (terminal Hn). This feature is significant since the glide slope detector becomes unreliable during flare as the radar altimeter, now operating over flat terrain, becomes accurate.
In this manner the aircraft sensors cooperating with the foregoing equipment keep aircraft 21 on path 10 unitl it touches down at touchdown point 16.
It is to be appreciated that modifications and alterations may be implemented with respect to the apparatus just described. For example, the functions of various devices described, including the function generators 26, 30 and 34 may be implemented by analog circuitry or digital computing equipment. In addition, filters having different bandpass characteristics may be substituted for those previously described depending upon the expected noise spectrum. Moreover, the scaling factors used in various scaling amplifiers may be modified depending upon the physical requirements of a specific aircraft. Also, various aircraft sensors may be substituted for those previously described as a matter of convenience. It is also to be understood that while a circular flare path was shown, other paths may be chosen depending upon the aircraft geometry, the runway length, expected wind conditions, the tolerable complexity of the control system, etc.
Obviously many other modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A control system directs an aircraft along a predetermined curvilinear descent path (10). The aircraft carries a plurality of sensors, for example, an altitude sensor. The system has a longitudinal device (64) responsive to at least one of these sensors for providing a longitudinal signal related to longitudinal displacement of the aircraft. The system also has a height device (26) responsive to the longitudinal signal for producing a height signal functionally related to the altitude required to follow the path. Also, a command subsystem (36) responds to the height signal and a given one of the sensors to produce an error signal bearing a predetermined relation to the extent of deviation from the descent path. In one embodiment dispersion otherwise occurring during a flare maneuver is reduced by definitely directing the aircraft onto a specific path such as a circular arc. Such a control system may employ an aircraft motion monitoring system (FIG. 4) having a descending subsystem (86) responsive to at least one of the aircraft sensors for producing a descent signal signifying aircraft descent rate. Also included is an altitude differentiating device (80) for differentiating the output of the altitude sensor. Also a transfer subsystem (98, 100) produces a signal, controlling influence in its production being transferred from the descending subsystem to the altitude differentiating device in response to arrival of the aircraft at a predetermined position. The control system preferably employs another motion monitoring system (FIGS. 3 or 5) having a velocity sensing device (74, 112) providing a velocity signal signifying ground speed and a travel integrating device (62) for integrating the output of a longitudinal acceleration sensor carried by the aircraft. A feedback device (72) is coupled around the travel integrating device. This feedback device has a combinational subsystem (70, 68) responsive to the longitudinal acceleration sensor and the velocity signal for driving the travel integrating device. The foregoing motion monitoring systems can be highly reliable and can produce initial conditions which reduce transients.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit under 35 U.S.C. § 119 of U.S. provisional application Ser. No. 60/468,767 filed May 8, 2003 and entitled “Concentric Expandable Reamer”, hereby incorporated herein by reference for all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to expandable downhole tools. More particularly, the present invention relates to a concentric expandable downhole tool having fewer components and thus a shorter length than conventional expandable tools. Still more particularly, the present invention relates to a robust, concentric expandable reamer having an advanced cutting structure and a mechanical/hydraulic activation mechanism.
2. Description of the Related Art
In the drilling of oil and gas wells, a plurality of casing strings are installed concentrically and then cemented into the borehole as drilling progresses to increasing depths. Thus, each new casing string is supported within the previously installed casing string, such that the largest diameter casing string is disposed at the uppermost end of the borehole and the smallest diameter casing string is disposed at the lowermost end of the borehole.
As successively smaller diameter casing strings are suspended, the annular area between the casing and the borehole wall is increasingly limited for the cementing operation. Further, as successively smaller diameter casing strings are suspended, the flow area for the production of oil and gas is reduced. Therefore, to increase the annular space for the cementing operation, and to increase the production flow area, it is often desirable to enlarge the borehole below the terminal end of the previously cased borehole. By enlarging the borehole, a larger annular area is provided for subsequently installing and cementing a larger casing string than would have been possible otherwise. Further, by enlarging the borehole, the bottom of the formation can be reached with comparatively larger diameter casing, thereby providing a larger flow area for the production of oil and gas.
Various methods have been devised for passing a drilling assembly through an existing cased borehole and enlarging the borehole below the casing. One such method includes using a winged reamer behind a conventional drill bit. In such an assembly, a conventional pilot drill bit is disposed at the lowermost end of the drilling assembly with a winged reamer disposed at some distance behind the drill bit. The winged reamer generally comprises a tubular body with one or more longitudinally extending “wings” or blades projecting radially outwardly from the tubular body. Once the winged reamer has passed through any cased portions of the wellbore, the pilot bit rotates about the centerline of the drilling axis to drill a lower borehole on center in the desired trajectory of the well path, while the eccentric winged reamer follows the pilot bit and engages the formation to enlarge the pilot borehole to the desired diameter.
Another method for enlarging a borehole below a previously cased borehole section includes using a bi-center bit, which is a one-piece drilling structure that provides a combination reamer and pilot bit. The pilot bit is disposed on the lowermost end of the drilling assembly, and the eccentric reamer bit is disposed slightly above the pilot bit. Once the bi-center bit has passed through any cased portions of the wellbore, the pilot bit rotates about the centerline of the drilling axis and drills a pilot borehole on center in the desired trajectory of the well path, while the eccentric reamer bit follows the pilot bit and engages the formation to enlarge the pilot borehole to the desired diameter. The diameter of the pilot bit is made as large as possible for stability while still being capable of passing through the cased borehole. Examples of bi-center bits may be found in U.S. Pat. Nos. 6,039,131 and 6,269,893.
As described above, winged reamers and bi-center bits each include reamer portions that are eccentric. A number of disadvantages are associated with this design. In particular, due to directional tendency problems, these eccentric reamer portions have difficulty reliably enlarging the borehole to the desired diameter. With respect to a bi-center bit, the eccentric reaming section tends to cause the pilot bit to wobble and undesirably deviate off center, and any off-center rotation will cause the reaming section to drill an enlarged borehole that is undersized. A similar problem is experienced with respect to winged reamers, which only enlarge the borehole to the desired diameter if the pilot bit remains centralized in the borehole during drilling. Accordingly, it is desirable to provide a reamer that remains concentrically disposed in the borehole while enlarging the previously drilled borehole to the desired diameter.
There are several different types of concentric reamers, which are used in conjunction with a conventional pilot drill bit positioned below or downstream of the reamer. The pilot bit drills the borehole while the reamer follows to enlarge the borehole formed by the bit. One type of concentric reamer is a fixed-blade reamer, which includes a plurality of concentric blades (sometimes also referred to as arms) with cutters on the ends extending radially outwardly and spaced azimuthally around the circumference of the reamer housing. The outer edges of the blades contact the wall of the existing cased borehole, thereby defining the maximum reamer diameter that will pass through the casing, and also defining the maximum diameter of the enlarged borehole. Thus, although a fixed-blade reamer remains concentrically disposed as it rotates to enlarge the borehole, it is limited to enlarging the borehole only to the drift diameter of the existing cased borehole, whereas winged reamers and bi-center bits can enlarge the borehole beyond the drift diameter of the casing. Accordingly, a fixed-blade reamer often will not enlarge the borehole to the desired diameter.
More recently, concentric expandable reamers have been developed. Most expandable reamers have two operative states—a closed or retracted state, where the diameter of the tool is sufficiently small to allow the tool to pass through the existing cased borehole, and an open or expanded state, where one or more arms with cutters on the ends thereof extend from the body of the tool. In this latter position, the reamer enlarges the borehole diameter to the required size as the reamer is rotated and lowered in the borehole.
Expandable reamers are available in a variety of configurations, each having different activation mechanisms and blade configurations. One type of expandable reamer includes hinged arms with roller cone cutters attached thereto. This type of reamer may utilize swing out cutter arms that are pivoted at an end opposite the cutting end of the arms. The cutter arms are actuated by mechanical or hydraulic forces acting on the arms to extend or retract them. Typical examples of this type of reamer are found in U.S. Pat. Nos. 3,224,507; 3,425,500 and 4,055,226, and they have several disadvantages. First, the pivoted arms may break during the drilling operation, requiring that the arms be removed or “fished” out of the borehole before the drilling operation can continue. Accordingly, due to the limited strength of the pivoted arms, this type of reamer may be incapable of underreaming harder rock formations, or may have unacceptably slow rates of penetration. Further, if the pivoted arms do not fully retract, the drill string may easily hang up when attempting to remove it from the borehole. Therefore, it would be advantageous to provide a reamer that is more robust and has improved blade retraction mechanisms.
Other expandable reamers are activated by weight-on-bit to extend the blades. With such designs, the internal components of the reamer rather than the reamer body support the weight of drilling assembly components extending below the reamer. Accordingly, if too much weight is applied to the internal components, the reamer may not have enough hydraulic power to lift the weight below the reamer, and the reamer will not open. Further, it may not be possible to set weight-on-bit when the reamer should be activated to extend the blades. Also, during drilling, the weight-on-bit is sometimes unevenly distributed, and a false indication may be provided to the surface that the reamer blades are expanded when they are not.
Still other types of expandable reamers are activated by hydraulic or differential pressure, sometimes in combination with a mechanical component. With such designs, there is no certainty that all of the blades will be fully extended because the blades do not activate in unison. Therefore, one blade might extend while another blade is stuck in a partially extended position. Further, in some embodiments, drilling fluid pressure is the only force holding the blades in an extended position. Thus, if the strength of the formation is greater than the fluid pressure, the blades will partially retract and drill an undersized borehole. Some embodiments include a mechanical component, such as, for example, a piston with a continuously tapered surface that engages the blades to drive them radially outwardly as the piston moves downwardly. In such embodiments, the piston is activated by hydraulic pressure to drive the blades radially outwardly, but if the strength of the formation is greater than the fluid pressure, the blades will tend to retract along the continuously tapered surface. Thus, existing expandable reamers raise such concerns as whether the tool will expand to the desired borehole diameter when required, whether the tool will remain in the expanded position to enlarge the borehole to the desired diameter, and whether the tool will reliably retract prior to re-entering the casing as the drilling assembly is removed from the borehole.
Further, most expandable tools include a large number of moving parts, thereby increasing the probability of malfunction. The number of moving parts also affects the tool length, which may be up to 14 feet long, for example. There are also disadvantages associated with existing reamer blades. Specifically, to adjust the expanded diameter of the reamer, the entire arm must be removed and replaced, or in some cases, a different reamer may be required. Further, most blades fail to include pads on the gage configuration for stability and durability, or if pads are included, the blades fail to include active cutting structures near the pads.
The present invention addresses the deficiencies of the prior art.
SUMMARY OF THE INVENTION
In various embodiments, the concentric expandable tool that may be used as a reamer to enlarge the diameter of a borehole below a restriction, or alternatively, may be used as any other type of downhole expandable tool, such as a stabilizer, for example, depending upon the configuration of the blades.
An expandable downhole tool is disclosed for use with a drilling assembly in a wellbore comprising a tubular body, at least one moveable arm disposed within the tubular body and being radially translatable between a retracted position and a wellbore engaging position, and at least one piston operable to mechanically support the at least one moveable arm in the wellbore engaging position when an opposing force is exerted. In an embodiment, the piston is axially translatable in response to a differential pressure between an axial flowbore within the tool and the wellbore. In an embodiment, the moveable arm includes at least one set of cutting structures for reaming the wellbore in the wellbore engaging position. The moveable arm may also comprise a back-reaming cutter. The expandable downhole tool may further comprise at least one gage pad for stabilizing the drilling assembly in the wellbore engaging position. The gage pad may be removable and replaceable. Cutters may also be provided adjacent the at least one gage pad. In an embodiment, the tool further comprises a sliding sleeve biased to isolate the at least one piston from the axial flowbore, thereby preventing the at least one moveable arm from translating between the retracted position and the wellbore engaging position. A droppable or pumpable actuator may be provided for aligning the sliding sleeve to expose the at least one piston to the axial flowbore. In an embodiment, the tool further comprises at least one nozzle disposed adjacent the at least one moveable arm.
Also disclosed is a method of reaming a formation to form an enlarged borehole in a wellbore comprising disposing an expandable reamer in a retracted position in the wellbore, expanding at least one movable arm of the expandable reamer radially outwardly into engagement with the formation, reaming the formation with the at least one moveable arm to form the enlarged borehole; and mechanically supporting the at least one moveable arm in the radially outward direction during reaming. The method may further comprise back-reaming the formation with the at least one moveable arm. In an embodiment, the method further comprises flowing a fluid through the expandable reamer, and selectively driving the at least one movable arm radially outwardly in response to the flowing fluid. The method may further comprise mechanically retracting the at least one moveable arm radially inwardly. In an embodiment, the method further comprises flowing a portion of the fluid across a wellbore engaging portion of the at least one moveable arm. The method may further comprise providing a pressure indication during or after the at least one moveable arm is expanded radially outwardly. In an embodiment, the method further comprises providing stability and gage protection as the reaming progresses. The method may further comprise removing and/or replacing a formation engaging portion of the expandable reamer without removing the at least one moveable arm. In an embodiment, the expanding step is performed without substantially axially moving the expandable reamer within the wellbore.
Further, an expandable downhole tool is disclosed for use in a drilling assembly positioned within a wellbore comprising a tubular body including an axial flowbore extending therethrough, a piston disposed within the axial flowbore having at least one cam portion with a substantially flat surface, and at least one moveable arm engaging the piston, wherein the piston is axially translatable in response to a differential pressure between the axial flowbore and the wellbore, and wherein the at least one moveable arm is radially translatable between a retracted position and an expanded position. In an embodiment, the substantially flat surface on the cam portion engages a substantially flat surface on the at least one moveable arm in the expanded position. The at least one cam portion may further comprise a tapered piston surface that engages a tapered blade surface on the at least one moveable arm as the at least one moveable arm is radially translated from the retracted position to the expanded position. In an embodiment, the piston comprises a plurality of cam portions separated by at least one notch. The at least one moveable arm may comprise at least one blade portion that resides in the at least one notch in the retracted position.
The expandable downhole tool may further include a biasing spring to bias the at least one moveable arm to the retracted position. The biasing spring may comprise at least one radial spring. In various embodiments, the biasing spring is disposed in a spring chamber filled with fluid from the wellbore or in an oil-filled spring chamber. The at least one moveable arm may further comprise a tapered surface to engage a casing and radially translate the arm from the expanded position to the retracted position. The at least one moveable arm may include a plurality of cylindrical blades. In an embodiment, the blades comprise a fixed blade portion and a removeable blade portion. In various embodiments, the at least one moveable arm includes at least one set of cutting structures, at least one gage pad, a back-reaming cutter, or a combination thereof. In an embodiment, the tool comprises three moveable arms each having a gage surface area, which may include at least one cutting structure and at least one gage pad area. The combination of the gage surface areas of the three moveable arms may comprise a complete overlap of an aggressive cutting structure and a complete overlap of a smooth gage pad.
The tool may further comprise ports in fluid communication with the flowbore and the piston. In an embodiment, the tool further comprises a sliding sleeve biased to close the ports, thereby preventing the at least one moveable arm from translating between the retracted position and the expanded position in response to the differential pressure. A bullet actuator may be provided for aligning the sliding sleeve to open the ports. In an embodiment, the at least one moveable arm is radially translatable between the retracted position and the expanded position via a combination of hydraulic and mechanical activation. The tool may further comprise shear pins that prevent the at least one moveable arm from radially translating to the expanded position until the differential pressure is sufficient to break the shear pins. In an embodiment, the tool further comprises at least one nozzle disposed adjacent the at least one moveable arm. The tool may be shorter than about 14-feet, and in an embodiment, the tool is approximately 4-feet long.
Also disclosed is a drilling assembly comprising an expandable downhole tool wherein the tool is positionable anywhere on the drilling assembly upstream of the drill bit.
Thus, the concentric expandable tool comprises a combination of features and advantages that enable it to overcome various problems of prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more detailed description of the various embodiments of the concentric expandable tool, reference will now be made to the accompanying drawings, wherein:
FIG. 1 is a cross-sectional side view of one embodiment of a concentric expandable tool with removeable arms in the retracted position;
FIG. 2 is an external perspective view of the expandable tool of FIG. 1 in the retracted position;
FIG. 3 is a cross-sectional side view of the expandable tool of FIG. 1 , with the moveable arms in the expanded position;
FIG. 4 is an external perspective view of the expandable tool of FIG. 1 in the expanded position;
FIG. 5 is an enlarged, cross-sectional side view of a piston engaging blades on a moveable arm of the expandable tool of FIG. 1 ;
FIG. 6 is a cross-sectional side view of another embodiment of a concentric expandable tool with a pressure compensation system, with the moveable arms in the retracted position;
FIG. 6A is an enlarged, cross-sectional side view of a portion of FIG. 6 ;
FIG. 7 is a cross-sectional side view of the concentric expandable tool of FIG. 6 , with the moveable arms in the expanded position;
FIG. 7A is an enlarged, cross-sectional side view of a portion of FIG. 7 ;
FIG. 8 is an enlarged cross-sectional side view of one embodiment of a moveable arm;
FIG. 9 is an enlarged cross-sectional side view of another embodiment of a moveable arm having removable blade portions;
FIG. 10 is an enlarged cross-sectional side view of the moveable arm of FIG. 9 , with the removable blade portions separated from fixed blade portions;
FIG. 11 is top plan view of three moveable arms with one embodiment of a gage configuration;
FIG. 12 is a cross-sectional side view of an exemplary bullet activation mechanism before a bullet has landed on a sliding sleeve;
FIG. 13 is a cross-sectional side view of the bullet activation mechanism of FIG. 12 with the bullet seated on the sliding sleeve;
FIG. 14 is a cross-sectional side view of the bullet activation mechanism of FIG. 12 with the bullet driven downwardly to open fluid ports leading to the tool piston;
FIG. 15 is a cross-sectional side view of the bullet activation mechanism of FIG. 12 with the tool piston moved downwardly to expand the tool arms;
FIG. 16 is a cross-sectional side view of an exemplary centrifugal activation mechanism in the locked position;
FIG. 17 is a cross-sectional side view of the centrifugal activation mechanism of FIG. 16 in the unlocked position to open fluid ports leading to the tool piston; and
FIG. 18 is a cross-sectional side view of the centrifugal activation mechanism of FIG. 16 in the unlocked position and with the tool piston moved downwardly to expand the tool arms.
DETAILED DESCRIPTION
The concentric expandable tool is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the tool with the understanding that the disclosure is to be considered an exemplification of the principles of the tool, and is not intended to limit the tool to that illustrated and described herein.
In particular, various embodiments of the concentric expandable tool provide a number of different constructions and methods of operation. Each of the various embodiments may be used to enlarge a borehole, or to perform another downhole function with an expandable tool, such as stabilization, for example. Thus, the concentric expandable tool may be utilized as a reamer, a stabilizer, or as any other type of expandable tool. The various embodiments of the tool also provide a plurality of methods for use in a drilling assembly. It is to be fully recognized that the different teachings of the embodiments disclosed herein may be employed separately or in any suitable combination to produce desired results.
FIG. 1 depicts a cross-sectional side view of one embodiment of an expandable tool, generally designated as 100 , in the retracted position, and FIG. 2 depicts a perspective external view of the retracted tool 100 . Similarly, FIG. 3 depicts a cross-sectional side view of the tool 100 in the expanded position, and FIG. 4 depicts a perspective external view of the expanded tool 100 . FIG. 1 and FIG. 3 depict the tool 100 in a wellbore 50 thereby forming a wellbore annulus 75 between the tool 100 and the wellbore 50 . The tool 100 comprises an upper section 110 with a flowbore 114 extending therethrough, a generally cylindrical tool body 120 with a flowbore 152 extending therethrough, and an internal sleeve 130 with a flowbore 132 extending therethrough. The flowbores 114 , 152 , 132 align axially to form a single flowbore 105 extending through the tool 100 .
The upper section 110 includes upper and lower connection portions 116 , 118 for connecting to a drill string (not shown) and the tool body 120 , respectively. The tool body 120 includes upper and lower connection portions 124 , 126 for connecting to the upper section 110 via threads 119 and a drilling assembly (not shown), respectively. The sleeve 130 is disposed within the lower connection end 126 of the tool body 120 .
One or more outer pockets 127 are formed through the wall 122 of the body 120 and spaced apart azimuthally around the circumference of the body 120 to accommodate the radial movement of one or more moveable tool arms 160 . Each pocket 127 stores one moveable arm 160 in the retracted position as shown in FIGS. 1-2 . The arms 160 are biased inwardly to the retracted position by radial springs (not shown) disposed behind dovetail blocks 170 , 172 that may have flow ports 174 , 176 extending therethrough to allow fluid flow between the wellbore annulus 75 and the pockets 27 . The flow ports 174 , 176 may also be provided in other locations. Thus, the dovetail blocks 170 , 172 retain radial springs that bias the arms 160 radially inwardly to the retracted position of FIGS. 1-2 . In another embodiment, the dovetail blocks 170 , 172 are eliminated, and the tool body 120 forms a solid section in the vicinity of the arms 160 . In this embodiment, the arms 160 are biased inwardly to the retracted position by radial springs (not shown) disposed between the solid section of the tool body 120 and the arms 160 . Preferably, the expandable tool 100 includes three moveable arms 160 disposed within three pockets 127 , and spaced apart azimuthally at 120° from one another. In the discussion that follows, the one or more pockets 127 and the one or more arms 160 may be referred to in the plural form, i.e. pockets 127 and arms 160 . Nevertheless, it should be appreciated that the scope of the present invention also comprises one pocket 127 and one arm 160 .
The body 120 further includes an internal axial recess 128 to accommodate the axial movement of in internal piston 150 having an upper tapered surface 154 that engages the upper section 110 and connecting at its lower end to the sleeve 130 via threads 159 . The piston 150 includes cam portions 153 , 155 , 157 that provide a drive mechanism for the moveable tool arms 160 to move radially outwardly to the expanded position of FIGS. 3-4 . The piston 150 further includes a leg portion 156 that will engage a shoulder 129 at the lower end of the recess 128 in the body 120 when the piston 150 travels. Thus, the shoulder 129 limits the axial movement of the piston 150 . The piston 150 sealingly engages the body 120 at 102 , 104 , 106 , and the sleeve 130 sealingly engages the body 120 at 108 , 109 . The uppermost seal 102 and the lowermost seal 109 are pressure containing to prevent fluid from the flowbore 105 from getting into the internal recesses 128 and 142 , respectively.
A biasing spring 140 is provided to bias the piston 150 upwardly, thereby moving the cam portions 153 , 155 , 157 away from engagement with the arms 160 so that the radial springs behind the dovetail blocks 170 , 172 can bias the arms 160 to the retracted position of FIG. 1 . Thus, the arms 160 are moved inwardly in a separate operation from the upward axial movement of the piston 150 . The biasing spring 140 is disposed within a spring chamber 142 surrounding the sleeve 130 , which is filled with drilling fluid that enters the spring chamber 142 from the wellbore annulus 75 via ports 144 extending through the wall 122 of the body. Because drilling fluid can enter the spring chamber 142 through ports 144 , there is no need for a pressure compensation system for the biasing spring 140 . Thus, as the biasing spring 140 collapses or expands, the ports 144 allow for volume changes within the spring chamber 142 , as needed. The lower end of the biasing spring 140 engages a stop 146 , and the upper end of the biasing spring 140 engages a shoulder 134 on the sleeve 130 .
Below the moveable arms 160 , one or more nozzles 125 extend at an angle through the wall 122 of the body 120 . The number and position of nozzles 125 may correspond to the number and position of the arms 160 , for example, or the nozzles 125 may be positioned away from the arms 160 . The piston 150 includes apertures 158 that extend therethrough. With the tool 100 in the retracted position of FIGS. 1-2 , the piston 150 blocks flow to the nozzles 125 . However, when the tool 100 is in the expanded position of FIGS. 3-4 , the apertures 158 in the piston 150 align with the nozzles 125 to allow fluid communication between the piston flowbore 152 and the wellbore annulus 75 . Seals 104 , 106 are provided around the apertures 158 to prevent fluid from flowing above and below the seals 104 , 106 when the apertures 158 are aligned with the nozzle 125 .
The moveable arms 160 include cylindrical blades 162 , 164 , 166 that fit within notches 151 in the piston 150 when the tool 100 is in the retracted position of FIGS. 1-2 . The blades 162 , 164 , 166 are provided with structures 180 , 190 that engage the borehole 50 when the arms 160 are extended outwardly to the expanded position of the tool 100 shown in FIGS. 3-4 . In the expanded position, the arms 160 will ream the borehole 50 and/or stabilize the drilling assembly, depending upon how the blades 162 , 164 , 166 are configured. In the configuration of FIGS. 1-4 , cutting structures 180 on blades 164 , 166 ream the borehole 50 , while a gage pad 190 on blade 162 provides stabilization and gage protection as the reaming progresses. Although the embodiment of tool 100 depicted in FIGS. 1-4 comprises three blades 162 , 164 , 166 , a different number of blades may be provided on each arm 160 . Providing three blades 162 , 164 , 166 with cutting structures 180 on two of the blades 164 , 166 increases the cutting capacity of the tool 100 as compared to conventional tools, which typically have only one blade. All three of the blades 162 , 164 , 166 may include cutting structures 180 so that back-reaming capabilities are provided. Alternatively, the expandable tool 100 could easily be converted into a concentric, expandable stabilizer by providing gage pads 190 on all three blades 162 , 164 , 166 rather than cutting structures 180 on blades 164 , 166 .
During assembly, the arms 160 are positioned within the pockets 127 of the body 120 . Then the piston 150 is installed so that the blades 162 , 164 , 166 reside within notches 151 between cam portions 153 , 155 , 157 on the piston 150 . The sleeve 130 is threaded onto the piston 150 at 159 with the biasing spring 140 surrounding the sleeve 130 . The biasing spring 140 pushes the piston 150 upwardly until the piston 150 engages the upper section 110 , such that the biasing spring 140 is set to a certain preload. Then, radial springs (not shown) are provided between the cylindrical blades 162 , 164 , 166 , and dovetail blocks 170 , 172 are installed over the radial springs to hold the arms 160 into the retracted position.
In operation, the tool 100 is run into the borehole 50 through casing in the retracted position of FIGS. 1-2 . In one embodiment, shear pins 107 are positioned through the body 120 around the blades 162 , 164 , 166 to retain the arms 160 in the retracted position as depicted in FIG. 1 until drilling fluid is pumped downhole at a pressure sufficient to break the shear pins 107 . After the shear pins 107 break, the differential pressure between the flowbore 105 and the wellbore annulus 75 must overcome the force of the biasing spring 140 . Then drilling fluid engaging the tapered surface 154 of the piston 150 will cause the piston 150 to move downwardly to expand the arms 160 as depicted in FIG. 3 . The design of the shear pins 107 is rig dependent, such that the shear pin material and the number of shear pins 107 will be determined based upon the desired expansion pressure of a particular tool 100 . In another embodiment, there are no shear pins 107 so that when pressurized drilling fluid reaches the tool 100 , the piston 150 will move downwardly to extend the arms 160 . Thus, the concentric expandable tool 100 will actuate when the differential pressure exceeds the force of the biasing spring 140 that pushes the piston 150 and the sleeve 130 upwardly.
Unlike conventional tools, the expandable tool 100 of FIGS. 1-4 utilizes hydraulic force as well as mechanical force to cause the arms 160 to extend outwardly from the retracted position of FIGS. 1-2 to the expanded position of FIGS. 3-4 , and to maintain the arms 160 in the expanded position. When the drilling fluid flows through the flowbore 105 at a pressure sufficient to break the shear pins 107 , and when the differential pressure between the flowbore 105 and wellbore annulus 75 is adequate to overcome the force of the biasing spring 140 , then the piston 150 will move downwardly, thereby creating a gap 205 between the upper tapered surface 154 of the piston 150 and the upper section 110 as shown in FIG. 3 . Each of the dovetail blocks 170 , 172 has a port 174 , 176 extending therethrough that allows fluid from the wellbore annulus 75 to flow into the recess 128 of the body 120 . Therefore, the outer surface of the piston 150 is exposed to wellbore annulus pressure while the piston bore 152 is exposed to pump pressure from the surface. This difference in pressure drives the piston 150 downwardly within the recess 128 , and as the piston 150 moves, the biasing spring 140 compresses, while the piston cam portions 153 , 155 , 157 push against the blades 162 , 164 , 166 to drive the arm 160 radially outwardly.
In more detail, FIG. 5 depicts an enlarged view of the piston 150 engaging a tool arm 160 in the extended position. Referring first to the piston 150 , the cam portions 153 , 155 , 157 each preferably include a steep tapered surface 251 , 254 , 258 , respectively, and a substantially flat surface 253 , 255 , 257 , respectively. The steep tapered surfaces 251 , 254 , 258 may have a 20° taper, and the substantially flat surfaces 253 , 255 , 257 may have a slope ranging from approximately 0-5°, for example. With respect to the arms 160 , the blades 162 , 164 , 166 each preferably include a tapered surface 261 , 263 , 265 , respectively, and a substantially flat bottom surface 262 , 264 , 266 , respectively. As depicted in FIG. 1 , the blades 162 , 164 , 166 reside in notches 151 between the piston cam portion 153 , 155 , 157 when the arm 160 is in the retracted position. However, when the piston 150 begins to move downwardly, tapered blade surfaces 261 , 263 , 265 engage steep tapered piston surfaces 251 , 254 , 258 , respectively to begin moving the arm 160 radially outwardly. The piston 150 will continue to move downwardly until the piston leg 156 engages the shoulder 129 within the body recess 128 , which corresponds to the fully expanded position of the arm 160 . Thus, the biasing spring 140 does not entirely support the weight of the piston 150 , but rather the body 120 also supports the weight of the piston 150 at shoulder 129 .
When the blades 162 , 164 , 166 are in the expanded position of FIG. 3 and FIG. 5 , substantially flat surfaces 253 , 255 , 257 of the piston cam portions 153 , 155 , 157 , respectively, engage substantially flat bottom surfaces 262 , 264 , 266 of the cylindrical blades 162 , 164 , 166 , respectively. Thus, the substantially flat surfaces 253 , 255 , 257 of the piston 150 exert a mechanical force against the flat bottom surfaces 262 , 264 , 266 to hold the blades 162 , 164 , 166 in the expanded position. In contrast to conventional expandable tools that rely entirely on hydraulic pressure to hold the blades against the formation, the concentric expandable reamer 100 relies on hydraulic pressure to push the piston 150 , but substantially flat surfaces 253 , 255 , 257 on the piston 150 mechanically act against the blades 162 , 164 , 166 to hold them in place as they cut into the formation. Thus, in terms of activation, the hydraulic pressure does not act directly on the arms 160 but rather acts on the piston 150 , which then mechanically acts on the arms 160 to move them to the expanded position as well as maintain the arms 160 in the expanded position to ream the borehole 50 .
In the expanded position of FIGS. 3-4 , the nozzles 125 that extend at an angle through the wall 122 of the body 120 allow fluid to flow from the flowbore 105 into the wellbore annulus 75 , and this achieves two purposes. Namely, when the piston 150 is moved downwardly to extend the arms 160 , the piston apertures 158 align with the nozzles 125 in the body wall 122 so that fluid flows outwardly from the flowbore 105 of the tool to the wellbore annulus 75 . Because the nozzles 125 are angled, fluid will flow across the blades 164 , 166 to cool and clean the cutting structures 180 . In addition, the operator at the surface will get an indication that the tool 100 is in the expanded position due to the pressure drop caused by the alignment of the apertures 158 and the nozzles 125 to allow fluid communication between the flowbore 105 and the annulus 75 .
Once the surface pumps are shut off to remove the pressure on the expandable tool 100 , the biasing spring 140 will exert a force upwardly against the shoulder 134 of the sleeve 130 to push the sleeve 130 and piston 150 upwardly. The cam surfaces 153 , 155 , 157 of the piston 150 thereby move upwardly so that the substantially flat portions 253 , 255 , 257 of the piston 150 no longer act against the substantially flat bottom surfaces 262 , 264 , 266 of the blades 162 , 164 , 166 . The piston 150 moves to a position where the notches 151 are aligned with the blades 162 , 164 , 166 , thereby providing a space for the arm 160 to move back into the retracted position of FIGS. 1-2 . The radial springs (not shown) below the dovetail blocks 170 , 172 actually force the arm 160 back into the retracted position. Thus, the piston 150 and sleeve 130 combination moves upwardly due to the force of biasing spring 140 , and the arms 160 retract separately via another set of radial springs behind the dovetail blocks 170 , 172 .
The expandable tool 100 described above has several important features and advantages. For example, it solves the problems experienced with bi-center bits and winged reamers because it is designed to remain concentrically disposed within the borehole 50 . In particular, the tool 100 preferably includes three extendable arms 160 spaced apart circumferentially at the same axial location on the tool 100 . In one embodiment, the circumferential spacing would be 120° apart. This three-arm design provides a full gage reaming tool 100 that remains centralized in the borehole 50 at all times. Another feature of the expandable tool 100 is the ability to provide a hydraulic indication to the surface, thereby informing the operator whether the tool 100 is in the retracted position shown in FIGS. 1-2 or the expanded position shown in FIGS. 3-4 . Further, the tool 100 has very few moving parts. In particular, only the piston 150 , the sleeve 130 , and the arms 160 move in contrast to other tools that may have as many as forty (40) moving parts. Thus, because there are comparatively fewer parts, and also because the arms 160 move radially rather than both radially and axially, the expandable tool 100 can be significantly shorter than conventional expandable tools. For example, the expandable tool 100 may be approximately 4-feet long as compared to other tools, which range up to approximately 14-feet long. Further, the tool 100 does not rely solely on a single activation technique to expand the arms 160 but instead combines hydraulic and mechanical activation techniques to provide a more robust activation mechanism. Since the tool 100 does not function solely by hydraulic pressure, the formation strength must overcome the mechanical strength of the blades 162 , 164 , 166 acting against the piston 150 in order to collapse the arms 160 . Further, the blades 162 , 164 , 166 extend in unison because the piston 150 has three cam portions 153 , 155 , 157 that simultaneously engage the three cylindrical blades 162 , 164 , 166 . In addition, the tool 100 is activated completely independently of weight-on-bit, such that the tool 100 components are not required to operate and support any devices beneath them simultaneously with expanding the tool 100 , and allowing for the tool 100 to be placed anywhere within the drilling assembly.
Referring now to FIGS. 6-7 , cross-sectional side views are depicted of a second embodiment of the present invention, generally designated as 500 , in the retracted and expanded positions, respectively. FIG. 6A and FIG. 7A depict enlarged cross-sectional side views of a portion of FIG. 6 and FIG. 7 , respectively, depicting the pressure-compensating features of the tool 500 . Many components of the tool 500 are the same as the components of the first embodiment of the tool 100 , and those components maintain the same reference numerals. There are, however, several differences, some of which may be incorporated into the first embodiment of the tool 100 as well. In particular, instead of a one-piece body 120 with a connection portion 126 for connecting to a drilling assembly component (not shown), either embodiment of the expandable tool 100 , 500 may comprise a tool body 520 connected via threads 522 to a lower section 525 . The lower section 525 includes a lower connection portion 528 for connecting via threads 526 to another component of the drilling assembly (not shown). When mating the tool 500 to another drilling assembly component, the lower section 525 or the threads 526 on the connection portion 528 could be damaged. When such damage occurs, the lower section 525 can easily be removed from the body 520 and replaced without having to replace the body 520 itself. Therefore, the lower section 525 is provided as a replaceable component that protects the tool body 520 from damage.
Further, instead of shear pins 107 being positioned at the arms 160 , either embodiment of the expandable tool 100 , 500 may include a shear sleeve 590 disposed within the tool body 520 below the spring sleeve 130 to retain shear pins 107 . As shown in FIGS. 6 and 6A , when the tool 500 is in the retracted position, the shear pins 107 extend radially outwardly from the shear sleeve 590 to engage an upper surface 529 of the lower section 525 .
In addition, instead of a one-piece piston 150 , either embodiment of the expandable tool 100 , 500 may comprise three separate components: a piston driver 550 , a piston coupling 540 , and an o-ring sleeve 530 . The piston driver 550 connects to the piston coupling 540 via threads 542 , and the o-ring sleeve 530 connects to the piston coupling 540 via threads 534 . The piston driver 550 includes the cam portions 153 , 155 , 157 that drive the arms 160 outwardly, the piston coupling 540 includes the ports 158 that align with the nozzles 125 when the tool 500 is in the expanded position, and the o-ring sleeve 530 sealingly engages the tool body 520 at o-ring seals 104 , 106 , 108 . Thus, these three piston components 550 , 540 , 530 are provided separately for ease of manufacturing and act together to perform essentially the same functions as the piston 150 depicted in FIGS. 1-4 .
Unlike the tool 100 of FIGS. 1-4 , the pressure-compensated tool 500 is entirely sealed and filled with oil rather than with drilling fluid from the wellbore annulus 75 . Thus, rather than having ports 144 that extend through the wall 122 of the body 120 into the spring chamber 142 as depicted in FIGS. 1-4 , the pressure-compensated tool 500 comprises a pressure compensation assembly 565 having a spring base 560 on the upper end, a compensation sleeve 580 on the lower end, and a floating compensation piston 570 therebetween. The spring base 560 connects via threads 562 , 564 to the tool body 520 and to the compensation sleeve 580 , respectively. The compensation sleeve 580 sealingly engages the tool body 520 and the spring sleeve 130 at seals 582 , 584 , respectively. The floating piston 570 sealingly engages the tool body at seal 572 and sealingly engages the compensation sleeve 580 at seals 574 , 576 .
The floating piston 570 comprises an upper surface 573 exposed to an oil-filled chamber 542 and a lower surface 575 exposed to fluid from the wellbore annulus 75 that enters the tool 500 through a port 544 extending through the tool body 520 above the compensation sleeve 580 . Oil fills the tool 500 from the upper surface 573 of the floating piston 570 , through the spring chamber 142 , and through a gap 532 in the o-ring sleeve 530 , into the pockets 127 and axial recess 128 within the tool body 520 to surround the piston driver 550 . The port 544 allows for fluid from the wellbore annulus 75 to enter and exit the tool 500 to allow for volume changes in the oil-filled portion of the tool 500 as the arms 160 are expanded and retracted. The floating piston 570 has a certain stroke length within the chamber 542 to allow for volume displacement as the biasing spring 140 moves within the oil-filled spring chamber 142 . Thus, the pressure compensation assembly 565 compensates for wellbore pressure and volumetric changes between the retracted position of the tool 500 as depicted in FIGS. 6 and 6A , and the expanded position of the tool 500 as depicted in FIGS. 7 and 7A .
In operation, the tool 500 is run into the wellbore 50 in the retracted position of FIG. 6 and 6A , and because the lower surface 575 of the floating piston 570 is exposed to wellbore annulus pressure via port 544 , a force is exerted on the floating piston 570 , thereby compressing the oil inside the tool 500 . As drilling fluid is introduced from the surface into the flowbore 105 of the tool 500 , differential pressure between the tool flowbore 105 and the wellbore annulus 75 will cause the piston driver 550 , piston coupling 540 , and spring sleeve 130 to exert a downward force on the shear sleeve 590 until the differential pressure is sufficient to break the shear pins 107 . The shear sleeve 590 will then move downwardly into an enlarged bore area 527 of the lower section 525 as depicted in FIGS. 7 and 7A , thereby providing a gap 595 between the spring sleeve 130 and the shear sleeve 590 . Meanwhile, the broken portions of the shear pins 107 will be trapped within an area 585 provided between the lower section 525 and the compensation sleeve 580 . Then, as the piston driver 550 and piston coupling 540 move downwardly against the biasing spring 140 to extend the arms 160 as depicted in FIG. 7 , oil from the spring chamber 142 flows into the oil-filled chamber 542 to exert pressure on the floating piston 570 . Thus, the floating piston 570 will move axially while pushing drilling fluid out through the ports 544 into the annulus 75 to compensate for the volume change in the spring chamber 142 .
When removing either embodiment of the expandable tool 100 , 500 from the borehole 50 , one of the failsafe mechanisms is the ability for the arms 160 to be collapsed should the radial springs behind the dovetail blocks 170 , 172 fail. As best depicted in FIG. 3 and FIG. 7 , the upper cylindrical blade 162 includes an upper tapered surface 161 that will engage casing if the arm 160 is still in the extended position as the tool 100 , 500 is being raised out of the borehole 50 . By engaging the casing on the tapered surface 161 , the arm 160 will be forced inwardly as the tool 100 , 500 is pulled upwardly through the casing.
Another failsafe withdrawal option would be to extend a grappling mechanism on a wireline through the tool bore 105 to attach to the lower end 136 of the spring sleeve 130 in case the biasing spring 140 should fail. The wireline pulls the piston 150 and spring sleeve 130 , or alternatively, the piston driver 550 , piston coupling 540 and spring sleeve 130 upwardly to align the piston notches 151 with the blades 162 , 164 , 166 , thereby allowing the arms 160 to retract via the radial springs behind the dovetail blocks 170 , 172 .
If the substantially flat piston surfaces 253 , 255 , 257 are disposed at a slope greater than 0°, such as 5° for example, the arms 160 can be collapsed if the biasing spring 140 fails, or the radial springs fail, or both. In more detail, when the expandable tool 100 , 500 is raised out of the borehole 50 , the upper cylindrical blades 162 will engage the casing at tapered surface 161 , and the force of the casing on the arms 160 will cause the blades 162 , 164 , 166 to act against the piston surfaces 253 , 255 , 257 having a 5° slope. The piston 150 or piston driver 550 will thereby be forced upwardly to align the piston notches 151 with the blades 162 , 164 , 166 so that the arms 160 may be retracted either by the radial springs or, if the radial springs have failed, by the force of the casing as the tool 100 , 500 is pulled upwardly through the casing.
Accordingly, in various embodiments, the expandable tool 100 , 500 is specifically designed not to get hung up in the borehole 50 or stuck in the expanded position.
Referring now to FIG. 8 , a cross-sectional side view of the moveable arm 160 is depicted in more detail. The arm 160 comprises a structural support beam 165 with one-piece blades 162 , 164 , 166 connected thereto. O-ring grooves 163 are provided on each of the blades 162 , 164 , 166 . FIG. 9 depicts a cross-sectional side view of another embodiment of a moveable arm 300 that may be utilized instead of the moveable arm 160 in either embodiment of the expandable tool 100 , 500 . The moveable arm 300 comprises the same structural support beam 165 , but instead of one-piece blades 162 , 164 , 166 connected thereto, the moveable arm 300 comprises fixed blade portions 302 , 304 , 306 connected to the support beam 165 and removable blade portions 312 , 314 , 316 connected to the fixed blade portions 302 , 304 , 306 . Thus, the support beam 165 and fixed blade portions 302 , 304 , 306 form an internal arm 310 disposed within the body 120 , 520 and the removable blade portions 312 , 314 , 316 can be detached from the internal arm 310 as shown in FIG. 10 . There are several advantages to the alternative moveable arm 300 . First, the removable blade portions 312 , 314 , 316 provide another possible failsafe for removing the tool 100 , 500 from the borehole should the tool 100 , 500 get stuck in the expanded position. In particular, by pulling the tool 100 , 500 upwardly in the borehole 50 , the removable blade portions 312 , 314 , 316 would engage the casing and simply shear off from the internal arm 310 so that the tool 100 , 500 could then be removed.
The moveable arms 300 also allow for more flexibility to expand the tool 100 , 500 to a different diameter. The internal arm portion 310 always moves radially outwardly by the same distance; whereas, the removable blade portions 312 , 314 , 316 may extend past the body 120 , 520 and can be provided in different sizes depending upon the desired enlarged diameter of the reamed borehole. Thus, rather than replacing the entire standard moveable arm 160 every time an enlarged borehole diameter change is required, the operator could simply change the removable blade portions 312 , 314 , 316 , and an inventory of various diameter sizes could be provided at the rig site. The removable blade portions 312 , 314 , 316 are comparatively small and inexpensive versus replacing an entire one-piece arm 160 . For exemplary purposes, if the diameter of a standard expandable tool 100 , 500 is approximately 8½ inches drift diameter, the tool 100 , 500 may be capable of enlarging a borehole to approximately 9⅞ inches in diameter. To create a larger sized borehole, the removable blade portions 312 , 314 , 316 may extend past the body 120 , 520 such that the drift diameter is in the range of 9⅞ inches, in which case the borehole could be enlarged to approximately 12¼ inches in diameter, for example. Thus, the moveable arms 300 always expand the same distance, but depending upon the size of the removable blade portions 312 , 314 , 316 , the diameter of the reamed borehole can be changed accordingly.
Still another advantage of the alternative moveable arm 300 is that the pads 190 and cutting structures 180 can be optimized for a particular formation since the removable blade portions 312 , 314 , 316 can be removed and replaced easily. Accordingly, the removable blade portions 312 , 314 , 316 of the alternative moveable arms 300 could comprise a variety of structures and configurations utilizing a variety of different materials. When the tool 100 , 500 is used in a reaming function, a variety of different cutting structures 180 could be provided, depending upon the formation characteristics. Preferably, the cutting structures 180 for reaming and back reaming are specially designed for the particular cutting function. More preferably, the cutting structures 180 comprise the cutting structures disclosed and claimed in co-pending U.S. patent application Ser. No. 09/924,961, filed Aug. 8, 2001, entitled “Advanced Expandable Reaming Tool,” assigned to Smith International, Inc., which is hereby incorporated herein by reference for all purposes.
FIG. 11 illustrates another feature of the expandable tool 100 , 500 . In particular, unlike conventional expandable tools that either fail to include a gage pad 190 , or fail to include cutting structures, such as cutters 192 , near the gage pad 190 , the present expandable tool 100 , 500 allows excellent durability and stability. In particular, proper gage pads 190 are provided while also providing aggressive cutting structures 192 near the gage pad 190 so that either embodiment of the moveable arms 160 , 300 can move from the retracted to the expanded position while the tool 100 , 500 remains in the same axial location in the wellbore 50 .
In more detail, FIG. 11 depicts a top plan view of three exemplary arms 160 A, 160 B, 160 C disposed side by side for illustrative purposes. However, these arms 160 A, 160 B, 160 C would actually be spaced apart azimuthally around the circumference of a tool body 120 , 520 . For the arms 160 A, 160 B, 160 C to extend without drilling ahead in the borehole 50 , an aggressive side cutting structure 192 must be provided. However, it is not desirable for the entire gage section provided by the combination of surfaces 162 A, 162 B, 162 C to comprise an aggressive side-cutting structure 192 since this can lead to poor durability. Thus, FIG. 11 depicts one exemplary gage configuration designed to achieve aggressive side cutting while retaining good gage pad area for stability and durability. In particular, the gage surface 162 A of expandable arm 160 A includes an upper gage pad area 190 A, two cutters 192 A in the middle, and a lower gage pad area 190 A. The gage surface 162 B of expandable arm 160 B includes a gage pad area 190 B above two cutters 192 B. The gage surface 162 C of expandable arm 160 C includes an upper gage pad area 190 C, a single middle cutter 192 C, and a lower gauge pad area 190 C. Thus, the gage surfaces 162 A, 162 B, 162 C of arms 160 A, 160 B, 160 C, when combined, comprise a complete overlap of an aggressive cutting structure 192 and a complete overlap of a smooth gage pad 190 for stability and durability. In another embodiment, the gage surfaces 162 A, 162 C of arms 160 A, 160 C, respectively, could comprise all gage pad area 190 , while the gage surface 162 B of arm 160 B could comprise all cutters 192 . Various other configurations may also be provided to achieve the same purpose. Regardless of the configuration of the gage surfaces 162 A, 162 B, 162 C, back-reaming cutters 194 A, 194 B, 194 C may also be provided on upper tapered surfaces 161 A, 161 B, 161 C of the three arms 160 A, 160 B, 160 C, respectively. As one of ordinary skill in the art will readily understand, instead of the moveable arms 160 A, 160 B, 160 C described above, the alternative moveable arms 300 could also be utilized.
FIGS. 12-15 depict enlarged cross-sectional side views of one embodiment of an exemplary bullet activation mechanism 600 for selectively expanding either embodiment of tool 100 , 500 without using shear pins 107 . In particular, FIGS. 13-16 depict a series of activation steps for the exemplary bullet activation mechanism 600 , which is disposed in the flow bore 114 of the upper 110 section and extends into the flow bore 152 of the tool piston 150 , 550 . The bullet activation mechanism 600 comprises a sliding sleeve 650 biased upwardly by an axial spring 640 disposed in an oil-filled spring chamber 642 . The sliding sleeve 650 comprises a plunger portion 655 with an internal tapered surface 654 , a cylindrical body portion 656 , and a flow bore 652 extending through both portions 655 , 656 . The sliding sleeve 650 extends into an internal recess 115 in the tool piston 150 , 550 , the recess 115 including a shoulder 117 to limit the downward movement of the sliding sleeve 650 . The sliding sleeve 650 sealingly engages the upper section 110 at 604 , 606 and sealingly engages the tool piston 150 , 550 at 608 . Ports 644 extend through the wall 112 of the upper section 110 , providing fluid communication between the upper section flowbore 114 and a flat upper surface 605 of the tool piston 150 , 550 . A bullet 610 is the activation device and comprises a lower tapered surface 614 , an upper flat surface 616 , and a bore 612 extending therethrough.
FIG. 12 depicts the bullet activation system 600 with the sliding sleeve 650 and the piston 150 , 550 in their uppermost positions, corresponding to the retracted position of the tool 100 , 500 . When the operator wants to activate the tool 100 , 500 and expand moveable arms 160 , 300 , the bullet 610 is dropped into the wellbore from the surface. In FIG. 12 , the bullet 610 has almost reached the sliding sleeve 650 , which blocks the fluid ports 644 so that drilling fluid flows downwardly from the surface through the bullet bore 612 , through the sliding sleeve bore 652 , and through the piston flowbore 152 as depicted by the flow arrows. Thus, the piston 150 , 550 has not moved downwardly to drive the arms 160 of the tool 100 radially outwardly from the retracted position.
FIG. 13 depicts the bullet 610 just as the lower tapered bullet surface 614 seats on the upper internal tapered surface 654 within the plunger portion 655 of the sliding sleeve 650 . In FIG. 13 , the sliding sleeve 650 still blocks the fluid ports 644 so that the drilling fluid flows through the bullet bore 612 , through the sliding sleeve bore 652 , and downwardly through the piston flowbore 152 as depicted by the flow arrows. Thus, the piston 150 , 550 has not moved downwardly to drive the arms 160 of the tool 100 radially outwardly from the retracted position.
FIG. 14 depicts the bullet activation mechanism 600 after the bullet 610 has moved the sliding sleeve 650 downwardly due to pressure build up behind the bullet 610 from drilling fluid being pumped from the surface. Thus, the pressure of the drilling fluid on the flat upper surface 616 of the bullet 610 , which is now seated on the sliding sleeve 650 , causes the bullet 610 and sliding sleeve 650 to move downwardly against the axial spring 640 . The sliding sleeve 650 will stop moving downwardly when the lower end of the sleeve body 656 engages the shoulder 117 within the recess 115 in the tool piston 150 , 550 . By moving downwardly, the sliding sleeve 650 opens the ports 644 so that a small amount of flow can move around the bullet 610 and into the ports 644 as depicted by the flow arrows in FIG. 14 . The remaining fluid continues along the flow path through the bullet flowbore 612 , through the sliding sleeve flowbore 652 , and downwardly into the tool piston flowbore 152 .
As depicted in FIG. 15 , the pressure of the drilling fluid flowing through the ports 644 and acting against the upper surface 605 of the tool piston 150 , 550 will cause the piston 150 , 550 to move downwardly, thereby forming a gap 205 between the upper section 110 and the piston 150 , 550 . The downward movement of the piston 150 , 550 expands the arms 160 , 300 of the tool 100 , 500 as previously described. In summary, when the bullet 610 is not seated on the sliding sleeve 650 , the fluid will flow directly through the tool 100 , 500 so that the arms 160 will not expand. However, when the bullet 610 is dropped into the borehole 50 and seats with the sliding sleeve 650 , pressure on the upper surface 616 of the bullet 610 will force the bullet 610 and sliding sleeve 650 down, thereby opening lateral ports 644 through the upper section wall 112 to allow fluid pressure to engage the upper surface 605 of the piston 150 , 550 . This fluid pressure causes the piston 150 , 550 to move downwardly and extend the arms 160 to the expanded position. Thus, the bullet activation mechanism 600 eliminates the need for shear pins 107 because the piston 150 , 550 will not actuate until the bullet 610 is dropped into the borehole 50 and seats on the sliding sleeve 650 .
In another embodiment, the bullet 610 has no bore 612 therethrough such that when the bullet 610 seats on the sliding sleeve 650 , all flow is blocked through the tool until the bullet 610 and sliding sleeve 650 move downwardly to open ports 644 , and then flow through the ports 644 causes the piston 150 , 550 to move downwardly away from the upper section 110 . In yet another embodiment, there are no ports 644 through the upper section 110 , and the sliding sleeve 650 either engages or connects to the tool piston 150 , 550 . In this embodiment, when the bullet 610 seats on the sliding sleeve 650 , the sliding sleeve 650 will move downwardly, thereby causing downward movement of the tool piston 150 , 550 .
FIGS. 16-18 depict enlarged cross-sectional side views of one embodiment of an exemplary centrifugal activation mechanism 700 , which allows for selective expansion of the tool 100 , 500 without using shear pins 107 . In particular, FIGS. 16-18 depict a series of activation steps for the centrifugal activation mechanism 700 , which is disposed in the flow bore 114 of the upper 110 section and extends into the flow bore 152 of the tool piston 150 , 550 . The centrifugal activation mechanism 700 comprises a sliding sleeve 750 biased upwardly by an axial spring 740 disposed in an oil-filled spring chamber 742 . The sliding sleeve 750 comprises a plunger portion 755 with a flat upper surface 715 and a side-notch 754 disposed therein, a cylindrical body portion 756 , and a flowbore 752 extending through both portions 755 , 756 . The sliding sleeve 750 extends into an internal recess 115 in the tool piston 150 , 550 , the recess 115 including a shoulder 117 to limit the downward movement of the sliding sleeve 750 . The sliding sleeve 750 sealingly engages the upper section 110 at 704 , 706 and sealingly engages the tool piston 150 , 550 at 708 . Ports 644 extend through the wall 112 of the upper section 110 , providing fluid communication between the upper section flowbore 114 and a flat upper surface 605 of the tool piston 150 , 550 . The centrifugal activation mechanism 700 further comprises a latching assembly 710 disposed in an oil-filled cavity 116 within the wall 112 of the upper section 110 . The latching assembly 710 comprises an outer plate 720 , a heavy T-shaped member 730 , and a radial spring 745 . The T-shaped member 730 can move radially and is disposed on linear bearings 726 , 728 surrounding guideposts 722 , 724 extending from the plate 720 .
FIG. 16 depicts the centrifugal activation mechanism 700 with the sliding sleeve 750 in the uppermost, locked position and the piston 150 , 550 in its uppermost position, corresponding to the retracted position of the tool 100 , 500 . The T-shaped member 730 is biased radially inwardly with respect to the plate 720 by the radial spring 745 , and a locking portion 734 of the T-shaped member 730 engages the side-notch 754 of the sliding sleeve 750 . In this position, the sliding sleeve 750 blocks ports 644 that extend through the wall 112 of the upper section 110 between the upper section flowbore 114 and a flat upper surface 605 of the piston 150 , 550 .
In operation, the centrifugal activation mechanism 700 will only unlock the latching assembly 710 and allow the piston 150 , 550 to move downwardly to extend the tool arms 160 , 300 if the drill string (not shown) that connects to the upper section 110 is rotated from the surface before starting the surface pump. In normal drilling practices, the surface pump is started before the drill string is rotated. Thus, if the surface pumps are turned on first, the centrifugal activation mechanism 700 will remain locked as depicted in FIG. 16 , and the expandable tool 100 , 500 will remain locked in the retracted position.
To unlock the latching assembly 710 as depicted in FIG. 17 , the drill string must be rotated before turning on the surface pump. By spinning the drill string at an adequate speed, the centrifugal force acting on the T-shaped member 730 will cause it to slide radially outwardly against the radial spring 745 and along the guideposts 722 , 724 aided by the linear bearings 726 , 728 . It is expected that 120 - 125 revolutions per minute (RPM) of the drill string will be sufficient to cause the T-shaped member 730 to move radially outwardly and disengage from the sliding sleeve 750 . Once the locking portion 734 of the T-shaped member 730 has disengaged from the side-notch 754 of the sliding sleeve 750 , then the surface pump can be turned on while continuing to rotate the drill string. Then the sliding sleeve 750 is free to move axially downwardly against the axial spring 740 in response to the drilling fluid pressure acting on the upper surface 715 of the sliding sleeve 750 . The sliding sleeve 750 will stop moving downwardly when the lower end of the sleeve body 756 engages the shoulder 117 within the recess 115 in the tool piston 150 , 550 . The downward movement of the sliding sleeve 750 to the position shown in FIG. 17 open the fluid ports 644 to allow flow therethrough.
FIG. 18 depicts the latching assembly 710 in the unlocked position, with the sliding sleeve 750 moved downwardly to compress the axial spring 740 . Fluid is flowing through the ports 644 in the wall 112 of the upper section 110 to engage the upper surface 605 of the piston 150 , 550 , thereby causing it to move downwardly away from the upper section 110 , creating a gap 205 . The downward movement of the piston 150 , 550 causes the tool arms 160 , 300 to extend. Thus, the centrifugal activation mechanism 700 eliminates the need for shear pins 107 because the piston 150 , 550 will not actuate until the latching assembly 710 is disengaged from the sliding sleeve 750 by rotating the drill string before operating the surface pumps.
While preferred embodiments of the concentric expandable tool have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims which follow, the scope of which shall include all equivalents of the subject matter of the claims.
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An expandable downhole tool comprises a tubular body, at least one moveable arm disposed within the tubular body and being radially translatable between a retracted position and a wellbore engaging position, and at least one piston operable to mechanically support the at least one moveable arm in the wellbore engaging position when an opposing force is exerted. A method of reaming a formation to form an enlarged borehole in a wellbore comprising disposing an expandable reamer in a retracted position in the wellbore, expanding at least one movable arm of the expandable reamer radially outwardly into engagement with the formation, reaming the formation with the at least one moveable arm to form the enlarged borehole; and mechanically supporting the at least one moveable arm in the radially outward direction during reaming.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to visual bore hole logging. The visual examination of the bore hole for casing damage and/or fracturing and sediment stratification may be made with a video camera lowered throughout the bore hole and a video monitor in conjunction with a video cassette recorder for visualizing and recording the wall of the bore hole.
2. Description of the Prior Art
A well or bore hole is an artificial excavation made to extract water, oil, gas, and other substances from the earth. There is also the boring and drilling of holes for exploraton. Exploration holes are drilled to locate mineral deposits such as oil and gas, ground water, geothermal supplies, to check for the integrity for nuclear waste depositories, and also to deterine potential landslides in an unstable environment. Close circuit TV camera systems are known in the art for visually examining the walls to a given bore hole. Additionally, in large diameter bore holes, a trained geologist can be physically lowered into the hole with a light source to visually examine the stratification, fracturing and layering of the various geological formations down to which the bore hole penetrates. In small diameter holes, this type examination is impossible. Accordingly, in smaller holes visual wall examination must be made with a moving picture bore hole camera or with a closed circuit television video camera.
Additionally, the bore shaft itself made by the bore hole is often not in a vertical orientation and has a drift or deviation in azimuth from its true vertical. There are drift recorders which monitor and log the slanting or drifting of the bore hole from its true azimuth. Inclinometers are known which determine deviation as well as drift, for exmaple, by phographing from a plumb bob position against a compass background.
Additionally, while in the process of drilling a well and/or installing the steel tubing or casing to reinforce the wall of the bore hole, occasionally because of cave-ins, sedimentation and the like, the equipment in the hole becomes lodged and stuck therein. It then becomes a matter of locating the stuck pipe or other equipment in the wells, U.S. Pat. No. 2,817,808 to Giske, describes a method and apparatus for locating stuck pipe in wells.
After the steel casing or tubing has been in place for sometime in a well such as a ground water well, rusting and other shifts in the earth occasionally will cause rupturing or uncoupling of the steel casing. In this event, visual examination of the casing is necessary to see the extent of the break or leak and the feasibility of repairs.
Accordingly, the visual examination of the walls of a well are frequently needed when applied to the above problems. cl SUMMARY AND OPERATION OF THE INVENTION
An apparatus and method of visually examining the sidewalls of a bore hole include a down hole video tool lowered into the bore hole by means of a cable and winch on the surface. The apparatus includes a wide angle video camera enclosed in its lower section. An upper section houses a power supply/triplexer, a telemetry board, an FM modulator video amplifier transmission board, gyro data interface board and a gyroscope for showing the directional orientation of the camera and apparatus in the bore hole. The gyroscope orientation and the visual image of the portion of the sidewall viewed is transmitted to a video display monitor in an equipment van on the surface. The image on the screen includes a directional reference point so that the direction of a portion of the sidewall being viewed can be ascertained. The camera images are recorded by a video cassette recorder for a permanent record of the visualization of the entire length of the bore hole. Various geological data can be extrapolated by this visualization by means of the observed fracturing and stratification which may be observed in a given bore hole. Additionally, the probe can be used to inspect bore holes previously encased by steel tubing to detect any leaks or other deterioration in the tubing system.
The present invention consists of a down hole video tool which includes an elongate, two-section cylindrical housing which is lowered into the bore hole. The lower end of the tool holds a video camera, a wide angle video camera lens and a light source extending a few feet in front of the lens or around the lens to illuminate the dark interior of the bore hole. There is supportive equipment above ground which includes a winch having a cable attached to the upper end of the tool to lower and retrieve the tool in the well bore. The cable includes a bidirectional data transmitting cable and also an electric cable for providing a power supply to the tool itself. Typically, the winch is installed in a large equipment van used to transport the down hole video tool. Inside the van is a variety of support equipment including a television video monitor, a video cassette recorder, a video printer, telemetry equipment and a computer. A depth measuring device to indicate the position of the tool in the ground, and a temperature sensor to measure the ambient temperature at the location of the tool are also part of the equipment.
The down hole video tool has a pressure resistant housing which houses a video camera, a light source, bidirectional telemetry circuit board for handling and processing the signals for transmittal up to the television/video monitor above ground, video amplification means of the signals, a power supply/triplexer, and a gyro and/or inclinometer.
As the down hole video tool is lowered into the bore hole, it is impossible to keep the camera and tool oriented in one direction. There will always be a twisting or rotational effect by the down hole video tool as it twists on the supporting cable to some extent. As a result, the operator does not know the direction of a side of the wall being visualized on the video monitor by means of the images telemetered from the video camera in the hole. He is unable to tell the orientation or directional bearing of the camera in the hole, i.e., the operator cannot determine the north, south, east or west side of the bore hole displayed on the video monitor.
The present invention incorporates a built-in free gyroscope in the housing which is about one and one-half inches in diameter and is arbitrarily selected to point north and then is "locked in" to always point north. The probe and camera (down hole video tool) can rotate on the cable but the spin axis of the gyro remains fixed in space. A reference point generated by the free gyro is displayed on the video screen to always indicate the directional orientation of the sides of the wall of the hole. The visual display on the video monitor screen will probably show the directional reference point drifting or floating around on the screen as the video camera in the housing rotates back and forth in the bore hole. The camera is stationary in the tool. Directional orientation of the camera is indicated by the signal generated by the built-in gyro. The gyro generates a real time image dot displayed on the video screen above ground. The image dot is self correcting to constantly show target heading of the camera, for directional reference of fractures, bed dip, casing damage or other objects being viewed.
Video logs for the bore hole video examination are visually recorded on three-quarter inch video cassettes for a permanent record. These may then be copied onto VHF, Beta, or other formats for convenience. Also available in the equipment van are hard copies of video images produced by a video printer for immediate presentation, and a video typewriter for recorded commentary. The commentary is recorded on the videotape. The orientation has applications to show hard rock fracture sizing and orientation. For example, the layer of the fracturing can be visually observed and measured by the image on the video screen. If the fracture is inclined, then the angle of inclination can also be extrapolated by a standard trigonometric function by knowing the diameter of the bore, and the difference in height between the top of the fracture at one side of the bore hole and the top of the fracture at the opposite side of the bore hole. The difference in height would form the vertical leg of a right triangle and the diameter would be the horizontal leg of the right triangle. These two numbers could be used to calculate the tangent to find the angle of inclination of the fracture at that particular depth. The reference point showing the true north on the video display monitor would also show the direction of the slope of the fracture line, or bed dip.
The above ground winch which lowers the cable into the well bore hole has an optical encoder and a calibrated wheel on the winch. This measuring equipment displays on the video monitor the depth of the probe within a tenth of a foot. For example, in an average 8 inch diameter hole, the difference in height in the top of the fracture on opposite sides of the hole is three to eight inches. This can easily be determined by looking at the depth reading presented on the video screen at the top of the fracture while the tool is being lowered to the top of the fracture on the other side of the hole and noting or reading the difference in the depth, usually in inches, as shown on the visual display. The acetate overlay showing the compass readings can be overlaid on the screen by placing the center of the graphic compass with the depth reading dot and aligning the north direction point on the screen with the North arrow of the graphic compass and then determining the sloping direction of the fracture and the bed depth. The sloping direction requires two compass readings; one at the top of the fracture having the shallower depth, and the other at the top of the same fracture having the deeper depth.
One could drill an array of exploration bore holes in a given surface area and then map the fractures and stratifications of the underground formations to determine the geological makeup of that given area. In the event where the bore holes are slightly inclined, then the readings from a previously inserted inclinometer could be used as a factor to determine the true angle of inclination of the layers. Or an inclinometer could be used by attaching it to the tool so that all readings could be taken simultaneously.
Accordingly, it is an object of this invention to have a down hole video tool for passing through the length of a drilled bore hole, and having a video camera for visually observing the walls of the bore hole, and in conjunction with a gyroscope in the tool so that the orientation of the camera lens will be known when the data is telemetered up to the video screen monitor in the equipment van so that one will be able to have a directional reference point on the video monitor screen to known the directional orientation shown of the bore hole walls when viewed on the video monitor. The directional reference point provides further data so that one can observe and calculate the rising or dropping angle of any fragmentation of layered rock in the bore hole. The directional indicator also informs one of the direction of leakage in a cased bore hole.
In is an additional object of this invention to provide a video camera and wide angled camera lens attached to the lower end of a down hole video tool and having a light source attached adjacent to the video camera so that the wall of the bore hole can be visually observed and recorded on video tape by means of transmitting the image received by the camera lens and visually displaying it on a video screen while simultaneously recording the visualization of the walls of the bore hole. The video screen also displays data such as the temperature gradient at the video camera and also the depth at the camera so that one can match the visualizations and the layering found in the bore hole with the depth of the camera lens at a particular location.
It is a further object of this invention to provide a down hole video tool having two sections and which is lowered into the bore hole. The tool includes a video camera with wide angle lens in a cylindrical housing forming the lower head section, and an upper section including a cylindrical housing for a power supply/triplexer to power the components, a free gyroscope to indicate the designated reference point of the camera lens, a means for video transmission of the data up to the video display monitor and a telemetry board for handling all of the data inputs and power sources to bidirectionally transmit the data to the surface. These are part of the second section of the tool.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the schematic figure of the equipment van stationed above ground and feeding the down hole video tool into the bore hole by means of a winch. The bore hole is schematically shown in cross-section with the layering effects which would commonly be found to indicate the stratification of the subsurface area to be examined.
FIG. 2 is an enlarged fragmentary vertical cross section of the subsurface as shown in FIG. 1 wherein the light source is shown ahead of the wide angle video camera lens and in turn, the wall of the bore is being visually examined by means of viewing it on the display screen of the monitor in the equipment van. The video camera picks up the light reflections and transmits them via coaxial cable for display on the video screen monitor.
FIG. 3 shows the video tool in various stages of dismantlement. The upper section which is attached to the cable head is the housing which houses the gyroscope, gyro-data interface, power supply/triplexer, telemetry board, and video amplfier transmission board. The wide angle video camera is in the lower section of the housing with the light source in a caged environment attached adjacent to the camera lens.
FIG. 4 illustrates a typical example of what is seen on the video screen of the monitor in the equipment van. There is shown visually the horizontal section of the wall of the bore hole at a particular location, the temperature at that particular location and the depth of the tool at that particular location. There is also shown the "floating" directional reference point showing the north direction of the wall at that location.
FIG. 5 is a acetate overlay which can be placed on the screen of the video monitor to find the direction of a section of the visualized wall relative to the directional reference dot shown on the video display.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is disclosed in phantom lines the equipment van 2 which is used to store and transport the equipment to the job site. The van equipment includes a winch 4 which has a cable 6 attached to the down hole video tool 8 which is shown inside the bore hole 10. The bore hole to be visually monitored can be any hole previously excavated or drilled. The instrumentation inside the equipment van includes a video monitor 12 having a rectangular display screen 14, a video cassette recorder 16, a video printer 18 and a telemetry key board video typewriter 20. The cable 4 and cable head 3 serve several purposes: for example, (1) to raise and lower the video tool 8; and (2) to connect the tool 8 with the instrument panel 5 to bidirectionally relay the video transmissions by means of a coaxial cable and (3) to provide a cable to supply electricity to the tool. The down hole video tool generally has two sections, a first housing and a second housing. The upper section 30 the second housing houses the gyroscope 32, the gyroscope data interface 34, the power supply/triplexer board 36, the telemetry board 38, and the FM modulation amplifier video transmission board 40. The lower section 50, the first housing, houses the video camera 52, the light source 60 and various connecting cables 48.
The primary power supply is designed to accept side ranging incoming DC voltage anywhere from 40 to 150 volts. It takes the incoming variable DC to the tool light source. The lamp is capable of receiving 40 to 150 volts. There are also several regulated DC voltages to run the camera; perhaps 20 volts to the camera. The DC voltages also run the gyro, the camera, VC handling, telemetry coordination and the plotting to the gyro. The camera itself has a reliable bidirectional telemetry system. It is a microprocessor controlled system.
Attached to the head of the tool where the video camera is located is a light source 60 which shines and illuminates the sidewalls so that the video camera can pick up the light reflections from the sidewall as it is being passed through the bore hole. The light source, if desired, could be circular and concentric with the camera lens. The images picked up by the video camera are processed and fed through the electrical components inside the housing of the tool. The signal is passed to the surface by a conductor coaxial cable which carries video and sub-carrier frequencies bidirectionally. It is also called a coaxial data transmission line. The electronic components in the second housing 32 process and transmit bidirectionally a variety of electronic data.
The gyroscope directional orientation is also incorporated in the signal which is transmitted to the equipment inside the equipment van. The end result is a video display 14 as illustrated in FIG. 4. FIG. 4 shows what a typical visual display looks like in actual operation. One sees the three prongs 62 and the backside ring 64 supporting the light source 60 positioned in front of the video camera 52 and camera wide angle lens 54. The lithography of the sidewalls of the bore 10 are readily apparent because the light source reflects light off the sidewalls which in turn is picked up by the camera. The video camera shows a rectangular screen display as shown in FIG. 4 having a conventional scanning capability of approximately 270 horizontal lines on the screen. The video camera 52 remains stationary with the tool, i.e., if the entire video tool and housing rotates or twists back and forth as it is being lowered into the bore hole, then the camera will rotate a like amount. It is impossible to prevent any twisting movement of the camera in this type of operation. As a result of the twisting and turning on the cable 6, the orientation of the camera and lens 54 relative to the sidewall of the bore hole cannot be ascertained unless a directional reference point is created relative to the camera. This is accomplished by having a guilt-in gyroscope 32 inside the second housing comprising the upper section 30 of the tool so that even if the housing tool rotates by twisting on the cable, the spin axis of the gyroscope will still be aligned to a certain reference point which is usually arbitrarily selected as the true north. The north reference point can be seen in FIG. 4 as an off center dot 66. One can determine where the south side of the sidewall is by going 180 degrees from the true north reference point 66 displayed on the monitor. As the tool turns on the cable while it is being lowered in the hole, the reference point will move about or float on the video screen. However, everything is still relative to the reference point to the true north such that one can always determine the direction of a particular portion of the sidewall of the bore hole by means of the directional reference dot. The directional orientation is important in several matters especially when observing the fracturing and layering of the soils through which the bore hole is drilled. For example, FIG. 2 shows an enlarged cross sectional view of a typical layered stratigraphic formation in the subsurface area. As can be seen in FIG. 2, there are some fracturing 70 and layering 90 and they are inclined to indicate that the layering is not always horizontal but is quite often inclined or slanted as a bed or layering in the subsurface. The angle and direction of this angled fracturing or stratification can be calculated by taking data from the video screen as shown in FIG. 4. For example, the difference in the height of the fracturing can be observed on the display which reads the depth of the light source 60 in tenths of feet, and also how the orientation of the fracturing is slanted for example from north to sourth, or east to west. The difference in the height between the top 80 and 82 of a layer of opposite sides of the bore hole can be measured by taking the difference in the two depth readings on the display as the light source passes 80 and 82. The diameter of the holes and the difference in the height allows one to calculate the slope created by the hypotenuse of the right triangle to determine the inclination of that particular fault line. This can easily be calculated by using basic trigonometry or algebra to arrive at the angle of inclination or declination of that particular fault. By means of mapping vertically the series of layers and other geologic formation which are frequently encountered through a bore hole, one can create a geological profile of the type of rock formations in that particular area and at that particular hole. One can then drill an array of similar holes in that area and then by mapping the layering effects in the various holes one could arrive at a geological profile of that given area by means of visualizing the various rock and sedimentary layers and also their inclination points. This is extremely useful in oil and gas exploration where the geologists are looking for synclines and anticlines, or dome shaped underground impermeable rock formations which are generally required in order to trap any possible oil and gas deposits to that they could be drilled at the apex of the dome of the anticline.
The visualization of the bore hole is quite useful when looking for geothermal deposits in the sense that the camera can visually observe the hole itself to see the type of layered rock formations and to observe the other sought after information visually shown on the screen as shown in FIG. 4. In the upper left hand corner of the video display is displayed the degrees in Fahrenheit reading 63 where the tool is located. The tool has two built-in thermal sensors for continuous surface readout of tool and hole temperature. The pressure and temperature resistant housing comprising the tool has the ability to withstand heat up to 200 degrees Fahrenheit. However, when viewing a bore hole for potential geothermal use, the heat could damage the instrumentation in the housing and accordingly the temperature is used mainly as a safety factor to prevent damage to the video tool. As previously stated, the other set of numbers 67 shown on the video display screen indicates the depth in feet of the video tool.
FIG. 2 shows in highly exaggerated fashion a well bore 8 or a bore hole which is not truly vertical. It is nearly impossible to drill a perfectly vertical hole because of the diverse geologic formations encountered by the drill bit. Occasionally the drill hole or the bore hole is intentionally slanted in a given direction to reach a proposed source of oil and the like. However, the slanting of the bore hole can be readily determined by instruments already known in the art. A typical instrument is known as an inclinometer (not shown) which indicates and records the orientation of the tool or drill away from the vertical. In one type of inclinometer this can be done by sequentially taking photographs of a plumb bob in conjunction with a compass. In that way, the angle of inclination and the direction of the deviation of the bore hole can be extrapolated in conjunction with the video display to accurately describe the deviation from vertical and the condition of the sidewall of the bore hole at any given location. However, the depth reading 67 is a function of the amount of cable let out from the surface. The deviations from the true vertical would create a longer length of cable than the true depth because of the deviation from the true vertical. This could be factored to subtract the reading of the depth of the tool to arrive at the depth of the tool in the true vertical should that number be required.
FIG. 4 shows a situation where the bore hole is not truly vertical and this is evidenced by the center of the ring 64 for the light source not being in the center of the hole. This is only illustrated as an example of what is occasionally encountered in actual field conditions. One can quickly make a printed record at any given location of the tool by means of the video printer 18 connected to the video display monitor 12. Immediately, one can have a record of the bore hole at that particular location displayed on the screen 14. The master video log which is a video tape of the sidewalls along the entire length of the well bore hole examined, can be duplicated to have several copies made from the master video log for distribution to interested personnel for their evaluation and for their use of the data found by the video tool. One can take the acetate compass overlay 100 as shown in FIG. 5 and overlay it on the video display screen to quickly determine the true orientation of a particular section of the sidewall image shown on the video screen.
The center of the compass 102 (acetate overlay) is matched up with the dot 67 for the depth. The north arrow 104 is aligned with the north gyroscope dot 66 on the display 14. Now the directional bearings of the entire wall can readily be determined.
The two sections comprising the video tool; the second housing having the electronic components and gyroscope, and the camera (first) housing are coupled sections having interlocking pin 51 and hole 31 so that when they are connected together, the gyroscope will always be in the same orientation as the camera is. The cable head 3 which connects to the upper section of the tool also has an interlocking pin 5 with the upper section hole 29, so that all three parts can only be assembled or coupled in a preset configuration. When a job is initially begun, the gyroscope must be "zeroed" in to a fixed directional reference which is normally the true north. This is accomplished by having as assistant standing several hundred feet away with a survey sight line pointing to the true north and by means of a tripod or transit the true north is accurately determined. In turn, the gyroscope 32 which is caged in the housing 30 is adjusted so that its reference point 66 is set to the true north. The gyroscope in its uncaged position will always point to the true north even when the earth is rotating. It is a well known scientific principle that the axis of a free gyroscope will remain fixed with respect to space. When doing a well logging operation of a few hours the degree of offsetting of the true north from the gyroscope image on the video display is not important because of the minor change in orientation caused by the rotation of the Earth. However, where the operation takes several hours to do, the reference point 66 indicated as north on the video screen must be adjusted to compensate for the rotation of the earth. This has to be taken into consideration when the accuracy of the true north bearing is very important on a particular job.
When the tool is placed in the bore hole to be mapped or surveyed, the gyroscope 32 must first be zeroed in to the true or magnetic north. This is accomplished by performing the following sequential steps.
The gyroscope is energized for 5-10 minutes to allow it to come up to its operating speed of 40,000-50,000 RPM. The gyroscope is in a caged position, i.e., it is not free to float independently of the housing 30 in which it is contained. After the gyroscope has come up to operating speed, the down hole video tool 8 is placed in the bore hole 10. A surveyor's tripod or transit with a sight marker is placed as far away as possible, but at least 100 feet away from the bore hole and without any magnetic interferences. A sighting telescope (not shown) is demountably attached to the top of the end of the cable head 3. The telescope is sighted in with the sight marker and tripod or transit previously placed some distance away from the gyroscope. Usually, north will be the arbitrary directional reference point. However, east, west, south, or any direction could be used as a reference point if so desired. In this configuration there is a mark 7 or reference point on the outside cable head 3 indicating the north position for the gyroscope. The down hole video tool while hanging pendulant in the bore hole to be surveyed, is rotated until the north marker 7 on the outside of the housing comprising the cable head 3 aligns with the true north as sighted in with the sight marker. This can be accomplished by physically rotating the cable head which is interlocked with the attached tool so that the marker 7 aligns with the north according to the sighting with the tripod. When the mark 7 is aligned with the true north, there is a switch in the telemetry equipment 20 inside the equipment van which is switched on. This telemetry switch will uncage the gyroscope and allow it to float in a free position. The spin axis of the free gyroscope then will always point to the north direction. When the gyroscope is in the free-floating position it will always point towards north regardless of the rotation of the earth. This information is processed and displayed on the video display and the "floating" north directional reference dot 66.
During the switching on of the telemetry machine 20 to uncage the gyroscope to the free-floating position, the time is also entered into the telemetry equipment by means of the video keyboard. After the bore hole surveying has been completed, the tool is again pulled to the surface and the true north position of the marker on the housing indicating the direction of the gyroscope is again set and again entered into the telemetry equipment. The time of the day is also entered. In a surveying operation taking an hour or so, the drift caused by the rotation of the earth is negligible. However, in a more extended surveying operation extending over 3 - 4 hours, the drift could comprise 33-4 degrees drift. This drift caused by the earth's rotation will then be entered into the telemetry and processing equipment. The reference point displayed on the screen is corrected based upon the time vs. drift parameters.
The video system enclosed in the first housing 50 is a especially designed high resolution black and white or color video system for down hole use. The tool's depth capacity is 10,000 feet with a 2.150 inch outer-diameter for black and white and a 3.5 inch outer diameter for color. The array of cables exposed at the end of the housing 50 are coaxial cables for the camera, and also a power supply cord for the camera and light source 60. These cables 48 connect with the electronic components enclosed in the second housing 32. The spacers 9 slip over the tool and center the tool in large diameter bore holes.
A flux gate north directional seeker could be substituted for the gyroscope. An inclinometer could be attached to the tool to get directional slope of the bore hole. Usually, however, the bore hole to be video logged, has already been logged with an inclinometer, and the data is used in conjunction with the video logging.
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An apparatus and method of visually examining the sidewalls of a bore hole include a down hole video tool lowered into the bore hole by means of a cable and winch on the surface. The apparatus includes a wide angle video camera at its lower section. An upper section houses a power supply/triplexer, a telemetry board, an FM modulator video amplifier transmission board, gyroscope data interface board, and a gyroscope for showing the directional orientation of the camera and apparatus in the bore hole. The gyroscope orientation and the visual image of the portion of the sidewall viewed is transmitted to a video display monitor in an equipment van on the surface. The image on the screen includes a directional reference point so that the direction of a portion of the sidewall being viewed can be ascertained. The camera images are recorded by a video cassette recorder for a permanent record of the visualization of the entire length of the bore hole. Various geological data can be extrapolated by this visualization by means of the observed fracturing and stratification which may be observed in a given bore hole. Additionally, the probe can be used to inspect bore holes previously encased by steel tubing to detect any leaks or other deterioration in the tubing system.
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CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority to U.S. Provisional Patent Application No. 61/149,692, filed on Feb. 2, 2009, which is hereby incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is relates to an irrigation interrupter for controlling a scheduled irrigation of a land area based on real-time monitoring of the soil, and in particular real-time monitoring of the moisture content of the soil.
2. Description of the Related Art
The prior art discusses other irrigation systems and methods.
Closing an underground to above ground RF communication link is a challenging task. The challenge is typically due to difficult propagation conditions perpetrated by high water content as well as high conductivity in the soil.
The moisture and conductivity vary over time depending on environmental stimulus. High water content increases the rate of absorption of RF energy. Salinity and moisture both change the die-electric constant of the soil, effectively detuning the antenna element as water content changes over time.
In instances, it is possible to adaptively modify the antenna tuning elements, to attempt to tune the antenna to the current state of the soil.
However, in some instances it may not be possible to overcome the adverse effects of moisture in the ground by direct tuning of the RF and antenna components on board the underground wireless sensor. In other instances, certain wireless sensing devices may not be able to adapt their tuning in close to real time to match the soil conditions.
The Present Invention seeks to resolve the problems of the prior art.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a solution to the problems of the prior art.
In such conditions, where information about soil moisture and salinity conditions at the time of attempted transmission is available to the wireless sensor, for example when there are on board moisture and conductivity sensor present, the wireless transmitter will perform a simple computation to determine whether its transmission will be successful given the network activity history and the soil moisture and conductivity levels. The wireless sensor will track the moisture and conductivity levels, and based on those levels will adjust its transmission attempts. The impact of this decision making is that it will predict when the transmission will fail, and thus refrain from transmitting. This adaptive adjustment of the transmission schedule will help conservation battery life for battery operated sensor nodes. This adaptive schedule will be effective for one way as well as two way communication links. However its impact will be most evident for two-way over the air protocols.
It is an object of the present invention to provide a proprietary wireless root zone intelligence system that measures real time soil moisture, temperature and salinity. It is an object of the present invention to provide an advanced wireless sensor and analytical, intuitive, fully interactive software. It is an object of the present invention to optimize turf health and playability, improve product quality, optimize resource utilization.
It is an object of the present invention to provide a state-of-the-art wireless mesh network, coupled with comprehensive software monitoring, eliminates guesswork. It is an object of the present invention to provide real-time trending and predictive modeling accessible via software at your fingertips. It is an object of the present invention to provide world-class, web-enabled agronomy services. It is an object of the present invention to provide help users best manage greens, fairways and rough. It is an object of the present invention to provide sensor collection data on root zone moisture, salinity and temperature. It is an object of the present invention to provide monitor healthy thresholds.
It is an object of the present invention to provide a cost saving benefits. It is an object of the present invention to provide efficiencies in water, energy and fertilizer usage. It is an object of the present invention to provide added salinity controls. It is an object of the present invention to provide decreased labor inputs. It is an object of the present invention to provide increased turf quality and crop yields. It is an object of the present invention to provide agronomic benefits. It is an object of the present invention to provide efficient salinity management and irrigation uniformity. It is an object of the present invention to provide deeper rooting for more oxygen. It is an object of the present invention to provide predictive disease control. It is an object of the present invention to provide environmental benefits. It is an object of the present invention to provide water conservation of 25% or more. It is an object of the present invention to provide reduced phosphates, nitrates and pesticides. It is an object of the present invention to provide a reduced carbon footprint. It is an object of the present invention to provide regulatory benefits. It is an object of the present invention to provide water-mandate friendly, measurable compliance. It is an object of the present invention to promote green activity.
One aspect of the present invention is full control of irrigation without user intervention.
Another aspect is an adaptive irrigation interrupter which learns the watering patterns established by an irrigation controller and takes action to intelligently limit watering based on knowledge of time, temperature and soil moisture.
Ten sets, or profiles, of moisture levels and behaviors are defined for soils ranging from maximum moisture retention/need such as clay soils to minimal moisture retention such as sandy soils. Each profile has a minimum moisture level (where the device will not suppress any watering), a max moisture level (where the device will entirely suppress watering), and a mechanism for mid-flow cutoff so that for a watering cycle of a predetermined length the device controls how long to allow irrigation.
The interrupter learns the watering pattern of the controller by monitoring behavior over a set period (two weeks), and mapping the start and duration of each zone's irrigation. A default profile is preferably set to enable users to ignore a setting and only adjust it after observing overall plant results.
Web-site interaction preferably provides greater information.
The interrupter also preferably monitors sensor soil temperatures and its own to enable cold weather control, which may be set to trigger at 40 F and 33 F, where reduced watering is set.
Another aspect of the present invention is a method for adaptive irrigation control. The method includes obtaining a plurality of real-time soil measurements. The method also includes adjusting a scheduled irrigation based on the plurality of real-time soil measurements.
Obtaining a plurality of real-time soil measurements preferably includes obtaining real-time soil moisture, soil temperature and soil salinity values and obtaining a real-time moisture percolation value. The method also can further include determining watering schedules based on the values without end-user intervention and adapting watering schedules to at least one of seasonal, weather, climate and soil conditions.
Another aspect of the present invention is an adaptive irrigation interrupter. The adaptive irrigation interrupter preferably comprises a housing and a processor. The processor is preferably configured to create a plurality of profiles of moisture levels and behaviors. Each profile has a minimum moisture level, a maximum moisture level, and a mechanism for mid-flow cutoff for a watering cycle of a predetermined length to control the irrigation.
Yet another aspect of the present invention is a system for adaptive irrigation control. The system preferably comprises wireless soil sensors, a receiver and an interrupter. The sensors are preferably positioned below a surface of the land area. The receiver is in wireless communication with each of the wireless soil sensors to receive data from each of the wireless soil sensors and to transmit them to the interrupter. The interrupter preferably comprises a user interface and a processor. The processor is configured to generate a plurality of profiles of moisture levels and behaviors, each profile having a minimum moisture level, a maximum moisture level, and a mechanism for mid-flow cutoff for a watering cycle of a predetermined length to control the irrigation. The user interface communicates to an operator of the land area.
Yet another aspect of the present invention is a method for controlling irrigation. The method includes irrigating a soil area with water during an irrigation event utilizing a plurality of valves, each of the plurality of valves in flow communication with a water source and a sprinkler. The method also includes monitoring a moisture content of the soil area utilizing a wireless sensor for each of the plurality of valves, the wireless sensor in wireless communication with a wireless controller. The method also includes determining if the soil moisture content value exceeds a predetermined threshold. The method also includes limiting the irrigation event if the soil moisture content value exceeds the predetermined threshold.
Yet another aspect of the present invention is a method for controlling irrigation. The method also includes irrigating a soil area with water during an irrigation event utilizing a plurality of valves. Each of the plurality of valves is in flow communication with a water source and a sprinkler. Each of the plurality of valves corresponds to a wireless sensor. The wireless sensor comprises a probe conducting structure to be placed in the soil to form a capacitor, a circuit comprising a high frequency oscillator for applying an electrical stimulus to the probe structure, a reference capacitor connected in series to the high frequency oscillator, and a voltage meter located between the high frequency oscillator and the reference capacitor. The method also includes measuring an output voltage from a voltage meter when the high frequency oscillator is active. The method also includes calculating a capacitance of the soil as a function of voltage to obtain a soil moisture content value. The method also includes determining if the soil moisture content value exceeds a predetermined threshold. The method also includes transmitting a wireless signal from the wireless sensor to a wireless controller, the wireless signal indicating that the soil moisture content value exceeds a predetermined threshold. The method also includes limiting the irrigation event if the soil moisture content value exceeds the predetermined threshold.
Yet another aspect of the present invention is a system for controlling irrigation. The system includes a water source, a plurality of valves, a plurality of wireless sub-surface sensors, and a wireless controller. Each of the plurality of valves is in flow communication with the water source and a sprinkler. Each of the plurality of valves corresponds to a sub-area of a plurality of sub-areas of a soil area. Each of the plurality of wireless sub-surface sensors corresponds to a sub-area of a plurality of sub-areas of a soil area. Each of the plurality of wireless sub-surface sensors corresponds to a valve of the plurality of valves. Each of the plurality of wireless sub-surface sensors has a power source and a probe structure for measuring a moisture content of the corresponding sub-area of the plurality of sub-areas. The wireless controller is in wireless communication with each of the plurality of sub-surface wireless sensors and wherein a signal indicating a moisture value for a sub-area monitored by a sub-surface wireless sensor is sent to the wireless controller for controlling an irrigation event.
Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a top perspective view of a wireless soil sensor of the present invention with a sleeve attached over a portion of the wireless soil sensor.
FIG. 2 is a first side view of the wireless soil sensor of FIG. 1 .
FIG. 3 is an opposing side view of the wireless soil sensor of FIG. 1 .
FIG. 4 is top plan view of the wireless soil sensor of FIG. 1 .
FIG. 5 is a top perspective view of a wireless soil sensor of the present invention without a sleeve attached over a portion of the wireless soil sensor.
FIG. 6 is a first side view of the wireless soil sensor of FIG. 5 .
FIG. 7 is top plan view of the wireless soil sensor of FIG. 5 .
FIG. 8 is a rear plan view of the wireless soil sensor of FIG. 5 .
FIG. 9 is a front view of an interrupter with a front panel open.
FIG. 10 is a front view of an interrupter with a door closed.
FIG. 11 is a top perspective view of an interrupter with a front panel open to illustrate an interface.
FIG. 12 is a top perspective view of an interrupter with a front panel closed.
FIG. 13 is an isolated view of an interface of an interrupter.
FIG. 14 is a flow chart of a general method of an end-to-end system of the present invention.
FIG. 15 is a schematic diagram of a prior art irrigation control system.
FIG. 16 is a schematic diagram of an irrigation control system with an irrigation interrupt.
FIG. 17 is a schematic diagram of an irrigation control system with a wireless irrigation controller.
FIG. 18 is a schematic diagram of a prior art irrigation control system.
FIG. 19 is a schematic diagram of an irrigation control system with a tethered sensor.
FIG. 20 is a schematic diagram of an irrigation control system with a wireless interrupt.
FIG. 21 is a schematic diagram of an irrigation control system with a wireless controller.
FIG. 22 is a block diagram of a preferred embodiment of an irrigation interrupter.
FIG. 23 a schematic diagram of an irrigation system employing an interrupter of the present invention.
FIG. 24 a schematic diagram of an irrigation system employing an interrupter of the present invention.
FIG. 25 is a block diagram of a preferred embodiment of a wireless sub-surface soil sensor.
DETAILED DESCRIPTION OF THE INVENTION
The present invention may be used with a system and method such as disclosed in Glancy, et al., U.S. Patent Publication Number 2006/0178847 for an Apparatus And Method For Wireless Real Time Measurement And Control Of Soil And Turf Conditions, which is hereby incorporated by reference in its entirety.
The present invention may be used with a system, sensor and method such as disclosed in Campbell, U.S. Pat. No. 7,482,820 for a Sensor For Measuring Moisture And Salinity, which is hereby incorporated by reference in its entirety. The present invention may use a chemical sensor probe such as disclose in U.S. Pat. No. 4,059,499 which is hereby incorporated by reference in its entirety. The present invention may use a chemical sensor probe such as disclose in U.S. Pat. No. 5,033,397 which is hereby incorporated by reference in its entirety. The present invention may utilize the systems and methods disclosed in Magro et al., U.S. patent application Ser. No. 12/697,226, filed on Jan. 30, 2010, for a Method And System For Monitoring Soil And Water Resources, which is hereby incorporated by reference in its entirety. The present invention may also utilize the systems and methods disclosed in Magro et al., U.S. Provisional Patent Application No. 61/255,073, filed on Oct. 23, 2009, for a Method For Soil Analysis, which is hereby incorporated by reference in its entirety. Systems, methods, sensors, controllers and interrupters for optimizing irrigation are disclosed in Campbell et al., U.S. patent application Ser. No. 12/697,258, filed on Jan. 31, 2010, for a Method And System For Improving A Communication Range And Reliability Of A Soil Sensor Antenna, which is hereby incorporated by reference in its entirety. Likewise, systems, methods, sensors, controllers and interrupters for optimizing irrigation are disclosed in Campbell et al., U.S. patent application Ser. No. 12/697,254, filed on Jan. 31, 2010, for a Method And System For Soil And Water Resources, which is hereby incorporated by reference in its entirety.
A wireless soil sensor 21 is shown in FIGS. 1-8 . The wireless soil sensor is placed in the soil below the surface to monitor various parameters of the soil such as moisture. Other parameters include salinity and temperature.
A wireless interrupter 12 is shown in FIGS. 9-12 and an interface 12 for the wireless interrupter 12 is shown in FIG. 13 . The wireless interrupter 12 has a main body 12 a and a front panel 12 b which allows for viewing of the interface 12 c.
As shown in FIGS. 23 and 24 , an irrigation system employing an interrupter 12 of the present invention is generally designated 20 . The system 20 preferably includes a plurality of wireless sub-surface sensors 21 (upper soil 21 a and lower soil 21 b ), a plurality of above-ground receivers 22 , an interrupter 12 located at an operations center, and a plurality of above-ground sensors 24 . The above ground sensors 24 preferably measures air temperature, wind speed, and relative humidity.
FIG. 22 illustrates a block diagram of the preferred components of an interrupter 12 . The interrupter 12 preferably has a housing 70 , a microcontroller 71 , a radiofrequency antenna 72 , a memory 79 , a display 73 and a power supply 74 .
FIG. 25 illustrates a wireless sub-surface sensor 21 alternatively utilized in the system 20 . The wireless sub-surface sensor 21 preferably has a housing 30 , a processor 31 with an integrated sensor 33 , a configuration switchable antenna 32 , and a power supply 34 .
A schematic diagram of a prior art irrigation control system is shown in FIG. 15 .
A wireless device (soil sensor 21 , interrupter 12 or controller 11 ) typically goes through a network entry process, in which it searches for and locks onto the signals of other members of the wireless network it is entering. After the signal lock, a handshake takes place, where the entering node transmits and expects to receive a sequence of well defined messages over the air. At the conclusion of this handshake, the entering node is considered a member of the network. It will be able to transmit and receive over the air messages using a well defined protocol. It will be considered a “Joined” member. A “joined” member may maintain a connection oriented or a connection less link with its radio neighbors. (Example of a connection oriented link is a time synchronized CDMA channel between a station and a cell tower. Example of a connection-less link is the Carrier Sense Medium Access (CSMA) link between a WiFi station and its Access Point).
Typically, if the “joined” member is not able to communicate with the other end of the link within a predefined window, it loses its “joined” status, and has to go through a network entry process again. At the least, it may have to perform a less complex re-synchronization task to re-establish its time synch with the network (if is uses a connection oriented link). The link establishment, re-synch, or network entry process will continue (typically with less and less frequency, upon failed attempts) until a) the node rejoins the network, b) the time interval between reentry attempts becomes so large that the node effectively becomes dormant, or c) until the node runs out of battery.
The wireless soil sensor 21 is required to transmit messages for all of the above transactions. If the cause of loss of “joined” status is dues to surrounding soil that is too moist or too saline then the rejoin attempts will also fail. If this condition is not detected, the wireless soil sensor 21 will continue wasting scarce battery reserves for transmissions. The adaptive transmission scheduling mechanism discussed here takes into account the moisture and conductivity of the soil that surrounds the wireless soil sensor 21 . It will stop transmissions until the moisture levels of the soil surrounding the node have dropped to manageable levels that will allow successful transmissions.
An example of a preferred method of adaptive transmission for wireless soil sensor 21 is as follows. A preferred method for an adaptive transmission aspect of the present invention begins with determining if (x) number of consecutive connection attempts (or transmission) have failed. Next, the method includes determining if the measured moisture level (or a composite metric that includes moisture and conductivity levels) is at some threshold (y) or above. Next, the method includes assuming the surrounding soil is too wet. Next, the method includes suspending the timers that control the transmission activity of the node. Next, the method includes, continuing to sample the moisture levels, and as long as the moisture levels are above threshold (z), attempting to connect once every predetermined time period, T (T time units only, where T is larger than typical inter-transmission intervals). Next, the method includes determining when the moisture levels have dropped below a threshold (w), then un-suspending the timers and a state machine that controls transmissions. Next, the method includes, allowing the normal protocol to resume for the system.
One can manage what one can measure. And, one can do it all on a real time basis. Soil intelligence equals savings and health. The present invention is preferably a complete package of advanced software, agronomic services and wireless sensor system that helps take the guesswork out of turf management. A flow chart of an overall method is shown in FIG. 14 . On aspect of the present invention turns raw data into useful operating thresholds which help maintain and optimize plant health and performance. One aspect of the present invention provides the necessary formula that automatically alerts when and where a facility might be experiencing stress and what the treatment options are.
One aspect of the present invention has a data collection component of the software, which allows for monitoring in real time, from an office or from on-site or remote locations, the key variables of moisture, salinity and temperature from each sensor site. The graphic displays are user-friendly and the present invention helps set high-low threshold ranges for each sensor location so that one instantly knows whether the soil is in or out of the optimal range for growth conditions and playability. By continuously analyzing the recorded data and thresholds for each location, this component visually alerts one to conditions at each sensor location and suggests what actions are needed to be more efficient and effective.
One aspect of the present invention optimizes turf and crop health and playability by measuring root zone moisture, salinity and temperature and applying best practices to your turf management. Once the wireless soil sensors 21 are in the ground sending raw data, an optimal zone is devised by analyzing accumulated sensor data, putting decades of agronomic experience to use and applying tested scientific principles. The Zone defines the upper and lower operating thresholds to ensure plant health. This helps with: course evaluation; soil and water analyses; review of existing practices including irrigation, nutritional inputs and maintenance; threshold determinations; sensor placement and more. On a real-time basis, one can manage greens, tees, fairways and rough to keep a facility in prime condition.
The wireless soil sensor 21 provides wireless interface between the sensing elements and the Communication Control Nodes (CCNs) that preferably form a mesh network. The key features include the shape: 8×4 inches. Buried with a Standard Cup Cutter. Supports sensors: analog or digital. 3 “D” Cell batteries: 4+ years life, field replaceable. 1 Watt FHSS radio board supports approximately 400 ft. range 4 in. in ground. Sensor interface and antenna for over air programming for product upgrades.
The key functionalities of the wireless soil sensor 21 are as follows: provide accurate, real-time data on soil moisture, temperature and salinity. Key Features: Pre calibrated for sand, silt and clay. Moisture measurement. Accuracy: +/−0.02 WFV from 0 to saturation at <2.5 dS/m conductivity. +/−0.04 WFV from 0 to saturation at 2.5-5 dS/m conductivity. Repeatability: +/−0.001 WFV. WFV is the fraction of soil occupied by water, a soil at 10% soil moisture has a WFV of 0.10. Conductivity measurement: Accuracy: +/−2% or 0.02 dS/m, whichever is greater, 0-2.5 dS/m. +/−5%, 2.5-5 dS/m. Repeatability: +/−1% or 0.1 dS/m whichever is greater, 0-2.5 dS/m. +/−4%, 2.5-5 dS/m. Temperature measurement: Accuracy: +/−0.5° C. from −10 to +50° C., +/−1° F. from 14 to 122° F. Repeatability: 0.05° C., 0.1° F. Benefits: Dual sensors allow gradients of soil moisture, conductivity, and temperature to be monitored. High accuracy and repeatability. No individual sensor calibration required.
Above-Ground Wireless Mesh Network: Communication Control Nodes. Key Functionality: CCNs are the interface to the Sensor Nodes. Each is a radio node that automatically joins and forms the mesh network on power up. Key Features: Range of ˜1 mile above ground unobstructed. Requires 1 Amp while transmitting. 12-24 Volt AC or DC power. Can be attached via 110/220 Volt power adapter. Weather proof enclosure. Benefits: Self forming, self healing, multihop mesh network; No special wiring required; Two way communications with link quality statistics; Control of buried nodes; The multihop mesh allows extension of the wireless coverage area far beyond the nominal range of the radios.
Agronomy. Soil health impacts everything grown above. What is agronomy? It is the study of plant and soil sciences and how they impact crop and plant production, performance and yield. Every plant has specific tolerances to environmental variables like moisture, temperature and salinity which impact the ability to grow, flourish, proliferate and perform to expectations. Just as a doctor can help monitor and advise to keep you in peak physical condition, agronomists can help keep your facility in peak condition. Agronomists using the present invention help define those optimal threshold levels as well as their impacts on root, leaf and lateral growth, responses to man-made or natural environmental stress, and resistance to disease and insect pressure. As a result, in this case water usage was reduced by nearly 30% while playability was enhanced uniformly. The indicator of the present invention predicts the likelihood for disease outbreaks before they happen.
The software package utilized feeds off data provided by the wireless soil sensors 21 and wireless communications system. It displays real time conditions and provides comprehensive intelligence and predictive actions. The system helps establish health- and performance-optimizing operating threshold ranges, evaluate your data and current practices, and refine existing programs. The results, optimal turf conditions and real savings, will generate a strong and lasting return on investment. The agronomic benefits include more efficient salinity management, uniform irrigation, deeper rooting, predictive disease control and healthier, more stable conditions. There are environmental benefits as well like water conservation, reduced use of phosphates, nitrates and pesticides, a reduced carbon/water footprint and regulatory compliance.
Real time sensor measurements can include soil oxygen, pH, concentrations of specific ion species- (Na+ has a very detrimental effect compared to the same concentration of Ca+2). Pollutant measurements include both hydrocarbons (oils, gasoline, etc.) and metals (chromium, lead, etc.).
As to the wireless transmission network, an alternative process of an adaptive model may be utilized with the present invention. An antenna, designed for efficient RF communication in air is relatively straightforward because the key electrical properties of the transmission medium (air) are well known and essentially constant. In below ground RF transmission, the key properties of the soils will very greatly with moisture content and salinity hence it is a much more difficult problem to design an efficient antenna. In addition, the best antenna design is influenced by how deeply buried the antenna is. The present invention includes elements to the antenna circuit that, under control of microcontroller, allow for varying the properties of the antenna to more closely match the conditions and improve range and reliability of communication. The sensor of the present invention measures both the dielectric constant of the soil (moisture) and conductivity (salinity) directly. Hence, the sensor measures precisely the two most important factors affecting antenna efficiency.
In a predictive model, the method includes activating a sensor and measuring soil electrical properties. The method also includes, based on the soil properties, activating antenna elements to give an effective transmission. The method also includes transmitting sensor data.
In an adaptive model, the method includes activating a sensor and measuring soil electrical properties. The method also includes transmitting data repeatedly until all switchable antenna configurations have been attempted. The method also includes monitoring signal strength for each transmission. The method also includes repeat this process possibly every 60 sensor transmissions.
As time progress, a receiver can put together a two dimensional map (soil dielectric constant on one axis, soil conductivity on the other) with received power for all antenna configurations. The map is downloaded on some regular schedule to the buried sensor node. When the sensor makes a measurement, the sensor reviews the map for the antenna configuration that gives the highest receive power at the receiver for the current conditions. A node configures an antenna and sends a packet of data. Even after the map is downloaded, every 60 sensor readings will have all the different antenna configurations attempted which will allow the map evolve.
The advantage of this adaptive process is that it can make an allowance for the actual depth of burial as well as the relative antenna locations and orientations. This is important because different antenna configurations have different radiation patterns. Hence, it is possible that a less than ideal antenna configuration works best in that it has the highest radiated power in the particular direction and polarization that the receiver antenna lies in.
As shown in FIG. 15 , an irrigation system 10 ′ includes a 24 VAC power supply, a controller 11 , and a valve box 13 with valves 123 a and 13 b . These irrigation systems 10 ′ work by using a 24 volt alternating current source to open valves 13 a and 13 b . When no current flows (open switch 51 ), the valves 13 a and 13 b are closed and no water flows. A controller/timer 11 is used to turn on the current to the separate valves 13 a and 13 b . Usually there is a “common” wire 53 that returns the current from all valves 13 a and 13 b . Separate “hot” wires 52 a and 52 b are used for each of the valves 13 a and 13 b . As shown in FIG. 18 , the irrigation controller 11 controls the valve box 13 through wires 17 a and 17 b to provide water form source pipe 16 b to sprinkler pipe 16 a for dispersion on a soil 15 through sprinkler 14 .
As shown in FIG. 19 , the prior art is improved upon by a system 10 with a tethered sensor 21 ′ in which is a sensor coupled to an interrupter 12 wired into the wiring 17 a , 17 b , 17 c and 17 d of the valve box 13 . The interrupter 12 acts to turn off a scheduled irrigation if the moisture exceeds a predetermined threshold established by a user. The interrupter 12 acts as an in-line switch that closes (allowing current to flow and the valve 13 to open) only if the controller 11 starts a scheduled irrigation and the soil moisture is below a predetermined threshold established by a user). In the system 10 of FIG. 19 , the interrupter 12 can only interrupt a scheduled irrigation, not initiate an irrigation. The system 10 has a sensor 21 which is cabled (no wireless communication). The system 10 of FIG. 19 has the advantage of being very simple, it is capable of being easily installed into virtually all existing irrigation systems, and it requires no independent power (the system 10 draws power off the 24 VAC irrigation line).
As shown in FIG. 20 , a wireless interrupt approach is similar to the “Tethered Sensor” system 10 of FIG. 19 , except that wireless communication is used between a wireless soil sensor 21 and an interrupter 12 . The wireless soil sensor 21 requires battery power and the interrupter 12 requires a battery to accommodate flexible wireless reporting. The principle advantage of the system 10 of FIG. 20 is that no cabling is needed, and installation is simpler than the tethered system 10 of FIG. 19 . As shown in FIG. 20 , the wireless soil sensor 21 transmits a wireless signal 18 a to the interrupter 12 pertaining to the moisture levels of the soil in a particular soil area.
A wireless controller system 10 is shown in FIG. 21 . The wireless controller system 10 uses a wireless link back to a wireless irrigation controller 11 (there is no “interrupter”) The principle advantage of the wireless controller system 10 of FIG. 21 is that the wireless soil sensors 21 preferably initiate irrigation if needed (allowing for the user to set scheduled irrigation times as well if desired). A user also may allow the wireless controller 11 to look at more than one wireless soil sensor 21 for each irrigation zone (area irrigated by one valve 13 ) taking an average, use the lowest value, etc. One can also allow for simpler level adjusting, including such features as a “hot day” button nudging the target water levels up a notch and many others.
The goal of one aspect of the present invention is to develop an inexpensive and easy to install system compatible with existing irrigation systems that can be quickly configured by homeowners/landscapers of limited technical sophistication. An objective of the present invention is an overall lower cost, a system that is easy to install in existing and new irrigation systems, setup that is as easy to use as a traditional irrigation controller, and careful design of setup features, default modes, user input device and display to give a superior customer interface.
Irrigation interrupt of the system interfaces simply with existing irrigation control systems to over-ride scheduled irrigation when moisture levels hit user settable thresholds. When operating in this manner, the system is incapable of initiating an irrigation event and needs to be used with a conventional irrigation controller. An irrigation controller 11 of the system 10 can initiate and stop irrigation events and replaces existing installation irrigation controllers or is suitable for complete control of new installations through both timing of irrigation to certain times of the day as well as based on near real-time soil moisture data.
As mentioned above, a typical irrigation controller system 10 ′ is shown in FIG. 15 . The system 10 ′ includes a 24 VAC power supply connected to 120 VAC and an irrigation controller 11 . Wiring 52 a and 52 b leads from the controller 11 to one or more valve boxes 13 . When the current loop is closed, the valves 13 a and 13 b open and a zone is watered. Typically, the controller 11 is set to turn on and off valves at predetermined times for a set time.
In the irrigation interrupt system 10 , as shown in FIG. 16 , the interrupter 12 is positioned between the standard irrigation controller 11 and the valves 13 a and 13 b . A wireless soil sensor 21 is placed in each irrigation zone and the wireless soil sensor 21 is in periodic communication with the irrigation controller 12 . In this system, watering only occurs when both the standard irrigation controller 11 indicates that it is time to water and the irrigation interrupter 12 indicates that soil moisture is below a predetermined threshold. The interrupter 12 opens switch 54 a and 54 b to terminate the current flow through lines 52 a ′ and 52 b ′ and close the valves 13 a and 13 b . Line 55 provides power to the interrupter 12 , especially when the switch 51 of the controller 11 is open.
In the wireless irrigation controller system 10 of FIG. 17 , the same interrupter hardware is used but the inputs to the irrigation interrupter 12 are always on, i.e. the irrigation interrupt 12 is now in control and irrigation will occur under the direct control of the wireless interrupter 12 based on soil moisture data. Different firmware is necessary, but the hardware is identical with only minimal changes in the wiring.
In both systems, power for the irrigation interrupter 12 is drawn directly off the 24 VAC eliminating the need for a separate power supply.
The system 10 is capable of operating with soil moisture only wireless soil sensors 21 with integrated two-way wireless telemetry, sensor firmware, an irrigation interrupter/controller (Controller) and controller firmware. The wireless soil sensors consist of a soil moisture only sensor, wireless two-way telemetry, microcontroller, and at least some non-volatile memory, and are preferably battery powered. These components are integrated into one physical package (no cabling) and the wireless soil sensor 21 is buried in strategic locations to monitor soil moisture conditions. The sensor firmware manages making sensor measurements, transmitting them to the controller, receiving controller commands, and power-management (putting system to sleep). The controller 11 preferably consists of two-way wireless telemetry compatible with the wireless soil sensors 21 , a microcontroller, non-volatile memory, a user input (preferably a four or five way wheel), display (preferably 36 character two line LCD), and circuitry for opening or closing switches for irrigation zones (switch in an open position is over-riding irrigation). In existing irrigation systems and for use with an already installed controller, the wireless controller 11 is spliced into existing wiring close to an existing irrigation controller. In replacing an existing irrigation controller or in new installations, the wireless controller 11 is directly connected to irrigation zone wiring. The controller firmware allows collection of wireless telemetry of soil moisture data, “commissioning” of new wireless soil sensors 21 , i.e. associating a wireless soil sensor 21 with an irrigation zone and an installation, setting irrigation thresholds, etc.
All of the components preferably operate over a temperature range of −20 to 70° C. (with the exception of the display which is operable over 0 to 50° C.) and are capable of storage over-20 to 70° C. All components preferably are Human Body Model ESD resistant but not lightning resistant. Wireless soil sensors 21 are preferably fully waterproof while the interrupters 12 preferably only have a low level of “splashproofing”. For the purposes of determining battery shelf life in the wireless soil sensors 21 , a temperature under 40 C is assumed (temperature, depending on battery technology, can greatly impact self discharge rates).
Wireless telemetry range of approximately 100-200 feet is preferred. The range is achieved at depths of up to 12 inches and in moderate clutter (vegetation, slight topography, through garage wall, etc.). A wireless soil sensor 21 is preferably installed at least as close as 3 inches from soil surface for monitoring soil moisture in shallow rooting turf. The package of the wireless soil sensor is preferably no larger than 2″×2″×8″ (ideally 1.5″×1.5″×6″). A bulky package is difficult to install (particularly at shallow depths), disrupt soil environment, and a turn-off to consumers. A non-volatile memory is preferred. Timekeeping is accurate to within +/−2% which allows the wireless soil sensors 21 to wakeup at on a regular schedule, timing for I2C commands, as well as scheduling sensor “listen” windows for wireless receive modes.
The wireless soil sensor 21 is capable of receiving simple operational parameters wirelessly from a controller 11 or an interrupter 12 , which allows the controller 11 or the interrupter 12 to set reporting interval, selection of adaptive algorithms, etc.
A procedure for re-programming the wireless soil sensors 21 after production is included in order to allow for changes encountered in debugging or upgrades. Alternatively, it can be through a programming header in the battery or by some other wireless programming option.
The wireless soil sensor 21 is preferably able to detect imminent battery, to prevent the wireless soil sensors 21 from failing suddenly with no warning or begin to operate intermittently reflecting battery temperature and other variable as well as possibly giving corrupted data that may result in incorrect irrigation decisions.
The sensor firmware is capable of executing and reading I2C commands. Analog sensor requires I2C commands to control oscillator and make A/D measurements. I2C commands need to be executed sequentially according to a sloppy timing of about +/−3 mS over 100 mS. I2C can operate anywhere from 20 to 200 KHz. The sensor firmware is able to perform simple calculations like conversion of raw A/D values into soil moisture which requires simple functions-addition, subtraction, division, polynomials but no log, trig, etc. functions. The sensor firmware is capable of going into a very low power mode between set measurement interval with routines to wake up at end of interval which may range from 1-100 min. which is set in a non-volatile configuration file which can be modified by interrupt controller. After measurement is complete, soil moisture data needs to be sent to interrupt controller 11 .
The sensor firmware preferably has a static soil moisture mode. An operational mode that allows the wireless soil sensor 21 to wake up, measure soil moisture, and if a change in soil moisture from the last wirelessly reported measurement does not exceed a settable threshold, return to a sleep mode without sending data. This threshold value, as well as whether this feature is enabled, preferably resides in a non-volatile configuration file which can be modified by the interrupt controller 11 . The wireless soil sensor 21 preferably transmits a new reading once every six hours regardless of soil moisture changes to confirm operation.
The wireless soil sensor 21 preferably has a default mode firmware upon power restart for the sensor firmware, which allows a wireless soil sensor 21 to be commissioned, i.e. assigned to a specific irrigation interrupter to allow for resolving sensors from a close neighbors residence. In addition, commissioning must be flexible to allow for a change in assigned interrupt controller 11 in the future or if commissioning is lost.
A wireless soil sensor 21 is preferably capable of a listening mode in a power efficient manner for receiving changes to the configuration file wirelessly from the interrupt controller 11 with a maximum file size of 100 bytes at least once a month without degrading three year sensor battery life. The wireless soil sensor 21 preferably has the ability to download full operating firmware.
On a regular schedule (about once every six hours) the wireless soil sensor 21 preferably provides in addition to the soil moisture value, diagnostics such as battery voltage, and raw measured values not to exceed an additional 25 bytes. This data is used to assess performance and for diagnosis of bugs or sensor failure.
If the raw A/D values used to determine soil moisture data are out of normal ranges, the wireless soil sensor 21 preferably sends a “Bad Data” even if the computed soil moisture value appears reasonable. This helps detect failed wireless soil sensors 21 and prevent bad control actions.
The irrigation interrupter 12 is capable of turning on and off AC current up to 700 mA continuously at 70 C for each irrigation zone from an AC voltage range of 16 to 34 volts with no more that 1V in drop across switching circuitry. Switching circuitry is not damaged by inductive transients generated by the turn off of valve solenoids.
Regardless of whether the interrupt controller 11 is allowing or blocking irrigation, the interrupt controller 11 can detect the presence of an AC voltage (generated by irrigation controller 11 to initiate an irrigation). This feature allows for calculations of savings such as % of scheduled irrigation events that were canceled by system.
The hardware for the irrigation interrupter 12 is preferably resistant to moderate ESD and transients that may enter system through 24 VAC transformer in order to be reliable.
The interrupt controller 11 draws power directly from nominal 24 VAC transformer to avoid having to use a separate power supply with a maximum current draw of 100 mA. The interrupt controller 11 operates correctly with an AC input varying from 16 to 34 VAC to account for AC mains voltage of 84 to 130 VAC (typical specified level of AC power seen in a household) and variation in transformer output with load.
The interrupt controller 11 is capable of operating in typical residential systems which have between four and eight zones. More sophisticated systems could be addressed by using multiple units.
The interrupt controller 11 is preferably capable of a log for the last 30 days of soil moisture readings for eight zones at 10 minute interval as well as whether an irrigation event is occurring, and whether it has been interrupted at 1 minute intervals in non-volatile memory. The log is preferably structured so accurate date and time is available for data record. This feature is good for both debugging purposes but also in allowing the system to display to the user the amount of water saved thus justifying the product.
Firmware responds as gracefully as possible to problems. For instance, if soil moisture data is out of range or uC lockup (possibly detected by watchdog circuit) irrigation proceeds according to the irrigation controller 11 (i.e. no interrupt). If an irrigation interrupter 12 is operating as a wireless irrigation controller (no standard irrigation controller), the system 10 should default to no irrigation. Failure modes give obvious indication of problems.
Ample code space is preferably reserved to allow for extensive additional features in the future. All user settable configurations are preferably stored in non-volatile memory so as to allow for seamless recovery from lockup or loss of power. Preferably, a real time clock has the ability to keep time after power loss for up to 1 month.
The interrupter firmware is capable of generating a user water savings report for the last day, week, and month (i.e. percent of scheduled irrigation that was interrupted) by zone and as a whole for all eight zones as well as total run time per zone.
A process is developed to allow sensors upon installation or system expansion to be assigned to a particular irrigation zone for a particular irrigation interrupter. The process needs to be flexible enough to allow for replacement of failed wireless soil sensors 21 as well. This allows the system 10 to be used with neighboring installations without confusion as well as assigning the right sensor to the right zone.
A user sets, for each zone, the maximum soil moisture level that will terminate an irrigation event. There is also a settable hysteresis, Y, i.e. if during a single scheduled irrigation event the soil moisture rises about the threshold X and irrigation is stopped, it would not begin again until level fell to X-Y. This prevents valves from turning on and off rapidly when approaching the threshold. When new irrigation event occurs, the threshold defaults back to X.
A hold feature allows a user to hold current conditions going forward (i.e. take last soil moisture readings and apply as thresholds).
A show current status mode for the interrupt controller 11 defaults to when no keypad entry has occurred for a minute or so and shows zone by zone-threshold, last soil moisture data, irrigation is being attempted, and if irrigation is being interrupted.
The save configuration allows up to six configurations to be saved, named, and recalled (for all zones thresholds, hysteresis, adaptive algorithms on or off, etc.). This allows for summer and winter settings, etc.
A disable setting is where all zones are enabled and the system is under control of the irrigation controller 11 solely, i.e the interrupter 12 allows valves 13 a and 13 b to be on at all times when the standard irrigation controller 11 schedules irrigation regardless of the soil moisture data. This is a “safety mode” so that if there are critical problems, the user is not forced to reconfigure things to keep the grass from dying.
A bump feature allows a user to “bump” up or down all thresholds equally at an approximately 0.5% water by volume increment (allows for quick adjustment for hot weather or other reasons), which revert to previous settings after 1 days unless user selects to apply them permanently.
The firmware is preferably capable of detecting missing or out of range soil moisture and low battery conditions and display warning.
A wireless irrigation controller mode allows the irrigation interrupter 12 to function as full soil moisture data driven irrigation controller 11 without the use of a standard irrigation controller 11 . Essentially all of the features of a standard irrigation controller 11 are implemented such as scheduling irrigation times, valve run-times, etc. These scheduled events are subjected to the same “interrupt” schemes as the irrigation interrupter 12 based on soil moisture data.
When water is applied to the soil the wireless soil sensors 21 report the increase in moisture content but also look at the tail off in moisture levels when irrigation ceases. In cases of significant overwatering, there is a sharp spike in moisture levels followed by a sharp fall after irrigation ceases. This is due to the soil essentially being so wet it “free drains” below the root zone (thus wasting the water). The present invention implements algorithms to monitor this and adjust irrigation events to eliminate this wasteful practice allowing the system to essentially configure itself over time. The wireless soil sensor 21 is preferably directly integrated with a radio and microcontroller. It also preferably has a sleeve that fits over the sensor that the user removes to turn it on. It also preferably has an optional microcontroller generated clock signal to avoid having to use a separate oscillator for the conductivity measurement. It also preferably has the same RF frequency the radio uses to eliminate having to use a separate oscillator for the soil moisture measurement. It also preferably uses “spread spectrum oscillators” to achieve FCC compliance. It also preferably has sensor components that are currently PCB may be made out of conducting plastic formulations simplifying assembly, improving aesthetics, and reducing costs.
From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes modification and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claim. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.
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A irrigation interrupter is disclosed herein. The irrigation interrupter learns the watering patterns established by an irrigation controller and takes action to intelligently limit watering based on knowledge of time, temperature and soil moisture. The interrupter learns the watering pattern of the controller by monitoring behavior over a set period (two weeks), and mapping the start and duration of each zone's irrigation. A default profile is preferably set to enable users to ignore a setting and only adjust it after observing overall plant results.
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BACKGROUND OF THE INVENTION
This invention relates generally to an endless track structure to replace wheels of a light, as well as other recreational vehicles, and more particularly to such a track structure that has a quick attachment method, a non-rigid movable frame and support method for both edges of an endless track.
The background of track structures for various wheeled vehicles have heretofore become known to adapt those vehicles for use on unstable and irregular surfaces, such as snow, sand, mud and irregular rocky terrain. Through the course of their development, many such devices have become known and their structures have become quite sophisticated to particularly adapt them to use under specialized conditions and with particular vehicles. In general such known track structures have been particularly designed for use with heavy massive vehicles of the automotive and truck type or two wheeled vehicles of the motorcycle type, undoubtedly because of the prevalence of such vehicles in commerce during the developmental period of track devices. Because most of such track devices have been specifically designed for use with a particular vehicle, this rather essentially has limited the use of these devices to those particular vehicles with which they were associated.
In the present day, three and four wheel recreational vehicles characterized by a small size and light weight, both substantially less than similar characteristics of an ordinary automobile, have become popular. Such vehicles normally are not designed for roadway use, but have traditionally been provided with pneumatic tires, commonly of a type to allow use of the vehicle on somewhat unstable and irregular natural surfaces, at least insofar as such use can be had with pneumatic tired vehicles. Pneumatic tires, however, or in fact any rotary type of wheels, do not allow effective use of such vehicles upon various unstable surfaces, such as loose snow of any substantial depth, unconsolidated earth, sand, mud, random spaced rocks and the like, which may be traversed readily by a track type vehicle. My current invention seeks to provide an improved track structure particularly adapted to replace wheels of such light wheeled recreational vehicles to allow vehicle use on unstable and irregular surfaces not adapted to traverse by pneumatic tires. The track structures heretofore used by heavy vehicles of an automotive or truck type have generally provided a rigid frame, bearing mounted drive cogs and idler wheels to define a course about which an endless track moves to support a vehicle on a surface for travel thereon. This type of rigid frame track structure has proven usable in heavier vehicles, especially when operated at low speed with a vehicle having a sophisticated suspension system to absorb shock. Such rigid frame track structures, however, are neither necessary nor desirable for use in track structures for light recreational vehicles and is not effectively usable with such vehicles. My invention provides a nonrigid movable frame that mounts spaced pairs of drive and idler wheels to define the course of an endless track. A primary feature of my invention provides a frame containing interconnected elastically deformable leaf spring elements. Either form of a movable frame allows relative motion between the driving self-cleaning cog wheels and various pairs of idler wheels supporting the endless track to absorb shock and maintain tension upon the track to keep it in its normal course and prevent accidental dislodgement, all to distinguish this frame from rigid frame structures which accomplish neither of these features. For a track structure that replaces pneumatic tires on a lightweight recreational vehicle to be practical, it must provide connecting methods that allow simple and easy installation or mounting on a carrying vehicle in a short time period by unskilled persons.
Previously known track structures have provided methods for releasable attachment to the existing hub structure of a vehicle that releasably mounts a wheel carrying a pneumatic tire. Most of those prior mounting methods have included an integral part of a track structure that either is not or cannot be easily removed to accommodate the mounting process, but rather the entire track structure has had to be mounted on the vehicle hub as a single unit. Some prior track structures have even had multiple support from the vehicle frame as well as a drive shaft. By reason of this, it has been commonly difficult to mount such track structures on a wheel hub because the track structure itself is large and heavy making it hard to position and to make access to the hub area difficult and inconvenient when the track structure is in position for mounting on a hub. Because of the difficulties in mounting, most prior track structures have usually been designed to be mounted for use for longer periods of time which is not desirable for light recreational vehicles as they are more desirable to change back and forth from wheels to tracks as the seasons or conditions would dictate. My invention solves this problem by providing a releasably interconnected shaft that is easily and simply removable from the track structure to allow the shaft to be separately mounted on a wheel hub with simple and easy access to the hub during mounting, and the endless track structure then reinstalled on the shaft after the shafts mounting on the hub. This feature distinguishes my invention from the prior art devices requiring mounting of an entire endless track device on a wheel hub as a single entity. Many prior track devices have provided particular driving cogs associated with particular endless tracks to drive those tracks from a medial position. This type of track structure has proven usable with heavier automotive type vehicles because of the weight of the vehicle, and especially when the vehicle has sophisticated suspension methods and is operated at relatively low speeds, but such structures are not well adapted for use with light recreational vehicles commonly without sophisticated suspension means and operated at higher speeds. The endless tracks used in all track structures have significant width and when they are driven from a medial position, especially at higher rates of speed, where is a substantial tendency, probably because of leveraged forces caused at the track edges, for the track to become dislodged from its normal course and eventually become separated from its support structure. My invention solves this problem by providing two spaced opposed driving cog wheels, with self-cleaning cogs on their interior peripheral surfaces facing each other, to provide simultaneous synchronous driving support for a track simultaneous at each of its side edges. This feature provides substantially more stability to maintain a track in its normal course and prevent accidentally loosening even at relatively high speeds. This structure also provides an additional benefit in allowing the use of track material that is presently available in commerce for use with ordinary snowmobiles, as such material commonly provides lug structures at its two side edges for driving support of the type required by my invention. Thusly existing endless track material and driving lugs presently commercially available, incorporating the latest state-of-the-art technology and lower cost in my invention.
Prior endless track structures generally have not been particularly concerned with the lower support course of the track because with heavier vehicles operating at relatively low speeds, the configuration did not cause any particular problem so long as there was sufficient track area to support the vehicle upon the surface over which it traversed. In this track structure, which is designed for use on light vehicles at relatively high speeds, it has been found desirable that the forward portion of the track course must be raised somewhat above the rearward flat portion, to help transfer the flexibility of the front portion of the track frame to the terrain and obstacles being traversed and also prevent the problem that the track will tend to accumulate and move snow, mud or debris in front of the track and the entire track structure will tend to move somewhat downwardly into a supporting surface. Either of such happenings will restrict motion of the track structure and tend to increase the probability of track dislodgement. Therefore the forward most pairs of idler wheels on the frame are at a spaced distance above the rearward pair of idler wheels defining the flat course of the track structure in its rearward part, and provide means to guide the track in a regular angulated course from the forward idler wheels to the rearward flat portion. Prior track structures generally have not provided any articulating or elastically resilient frame linkage between wheels defining the endless track course to aid in maintaining the track in a taut condition about its course. In general, this is not practical with heavier vehicles as the weight of the vehicles themselves would create too great a tension on the endless track to allow its effective operation. This invention, however, which operates on lighter recreational vehicles, does provide such linkage and in so doing is more efficient in maintaining the endless track in its normal course without dislodgement, especially at high speeds, than is the nonmovable frame structure of prior art devices. The particular type of movable frame structure of this invention also allows inclusion of traditional and special mechanical tension adjusting mechanisms to accommodate both a long term and short term changes or variations in belt length and tension. This invention resides not in any one of these individual features, but rather in the overall combination of all of the particular structures and functions necessarily included as herein set forth and claimed.
BRIEF SUMMARY OF INVENTION
My invention provides an endless track structure to replace wheels of light three or four wheeled recreational vehicles for travel on irregular and unstable surfaces. A mounting shaft defines in its inner end a hub for releasable mounting on the studs of a wheel hub of a vehicle. The hexagon mounting shaft irrotatably carries two driving cog wheels, spaced by two hexagon bore antifriction bearings therebetween, and are mounted on a hexagon thin wall sleeve so as this sub assembly can be mounted to the rigid fame beam and then with all the parts assembled are releasably maintained on the hexagon mounting shaft by a threadedly engaged slotted nut and cotterpin at the outer end of the mounting shaft. The rigid frame beam, with the hexagon bore antifriction bearings mounted in its medial portion, supports a forward idler shaft with antifriction bearing mounted spaced apart idler wheels in its lateral portions. The rigid frame beam, in a medial position has mounted in its forward end and in its rearward end, pivotally mounted spaced apart rub bar struts, which in their lower portions pivotally support similar spaced elongated rub bars having upturned forward portions, with a mounting shaft between each strut structure and with the mounting shafts positioning the rub bars in a downward and rearward position beneath the rigid frame beam mount. The rearward parts of each rub bar with adjustable slots carry a rearward idler shaft with mounted spaced apart rear antifriction mounted idler wheels to support the lower rearward course of an endless track. An endless track having friction devices on its outer surface and driving lugs on its inner surface, in spaced relationship along each of its side edges, is carried about the course defined by the driving cogs, idler wheels, and rub bars to form a somewhat triangular configuration with a raised lower forward apex. The rub bars may optionally be replaced with four idler wheels to support the lower intermediate portion of the endless track with less friction in dry conditions than would be caused by the rub bars which work best in snow. A species of flexible frame provides a central beam of adjustable length formed by two leaf spring elements interconnected by a medial rigid frame beam structure projecting upwardly therefrom for rotary support on the medial bearing shaft. The shafts carrying the opposed paired forward and rearward idler wheels are carried, respectively, by the forward and rearward ends of this central spring beam. This optional species of this invention has no rub bars, but downwardly secondary springs depend angularly and inwardly from each end of the central rigid frame beam to support shafts paired opposed medial forward and rearward idler wheels positioned between the front and rear idler wheels to define the endless track course therebetween. In creating such a device, it is: A principal object to provide an endless track structure to replace pneumatically tired wheels on three or four wheeled light recreational vehicles to allow use of such vehicles on unstable and irregular surfaces.
A further object of this invention is to provide such a structure that has a mounting shaft, to be releasably carried by the wheel hub of a vehicle to be serviced, that is readily removable from the endless track structure to allow quick and easy mounting on a vehicular hub and subsequent mounting of the track structure on the mounting shaft without the need of shear keys and keyways.
A further object of this invention is to provide such a device that has paired spaced driving cogs and idler wheels to drive and support an endless track structure simultaneously at each of its side edges.
A still further object of this invention is to provide such a device that has a movable frame structure interconnecting the drive wheel shaft and idler wheel shafts so that all of these shafts may move relative to each other with a bias to tension a track thereabout with the tensioning and length adjustment being made possible from either the front or the rear and to absorb shock.
A further object of this invention is to provide such an endless track structure that maintains an elevated forward portion of the track above an underlying surface supporting the rearward portion of the lower track course to aid passage of the track over soft, unstable surfaces to be traversed.
A still further object of this invention is to provide such a structure that is operative with existing drive cogs and elastomeric snowmobile tracks that drive from the side edges.
A further object of this invention is to provide a species of such device wherein the frame beam is formed of elastically resilient leaf spring material and the main beam carries at least two supports one at the front and one at the rear, for a pair of rub bars to aid in defining the lower course of an endless track between the front and rear idler wheels without the use of intermediate idler wheels.
A further object of this invention is to provide a species of such device wherein the frame beam is formed of elastically resilient leaf spring material and the main beam carries at least two depending, angularly and inwardly extending sets of intermediate idler wheels to aid in defining the lower course of an endless track between the front and rear idler wheels without use of rub bars.
A still further object of this invention is to provide new and novel design to make the track to be adjustable both at the front and at the rear for both length and endless track tension adjustment with the same length endless track.
A still further object of this invention is to provide such a track structure that is of new and novel design, of rugged and durable nature, of simple and economic manufacture and otherwise well suited to the uses and purposes for which it is intended.
Other and further objects of this invention will appear from the following specification and accompanying drawings which form a part thereof. In carrying out the objects of my invention, however, it is to be understood that its essential features are susceptible to change in design and structural arrangement with only one preferred embodiment and one alternate embodiment being illustrated in the accompanying drawings as is required.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1a is a pictorial view of a four wheeled and FIG 1b a three wheeled All Terrain Vehicle both of which are equipped with a preferred embodiment of the invention showing slider rub bars supporting the medial lower portion of the endless track.
FIG. 2 is a pictorial view of the preferred embodiment as shown in FIG. 1a and FIG. 1b.
FIG. 3 is a side view of an All Terrain Vehicle factory equipped with tires.
FIG. 4 is a sectional view of the wheel hub and removed wheel taken along line 4--4 as shown in FIG. 3.
FIG. 5 is a side view of the wheel hub with the hexagonal mounting shaft installed.
FIG. 6 is a side elevational section of the preferred embodiments taken along line 6--6 as shown in FIG. 2.
FIG. 7a is a side view of a front track assembly showing the slider rub bars and the adjustability of the frame to allow the same endless track to be used for the front location.
FIG. 7b is a side view of a rear track assembly showing the slider rub bars and the adjustability of the frame to allow the same endless track to be used for the rear location.
FIG. 8 is a partial view of the driving cog wheel showing the engagement of the driving cog wheel cogs and the endless track lugs, showing the relief incorporated in the shape of the cogs to extrude unwanted material buildup in the contact areas.
FIG. 9 is a sectional plan view of the preferred embodiment as taken along the line 9--9 in FIG. 2.
FIG. 10 is a vertical sectional view of the preferred embodiment as taken along the line 10--10 in FIG. 2.
FIG. 11 is an exploded pictorial view of the preferred embodiment of the track assembly showing the slider rub bars but does not show the endless track for clarity.
FIG. 12 is a side elevation of the spring beam assembly which accommodates the slider rub bars for the support of the lower intermediate course of the endless track.
FIG. 13 is a side elevation of the spring beam assembly which accommodates the optional intermediate idler wheels for the support of the lower intermediate course of the endless track.
FIG. 14a is a pictorial view of a four wheeled and FIG. 14b of a three wheeled All Terrain Vehicle equipped with an optional embodiment of the invention showing intermediate idler wheels in place of the rub bars for support and defining the lower path of the endless track.
FIG. 15 is a pictorial view of the optional embodiment shown in FIG. 14a and FIG. 14b.
FIG. 16 is a side elevational section of the optional embodiment as taken along line 16--16 as shown in FIG. 15.
FIG. 17a is a side view of a front track assembly showing the optional bottom intermediate idler wheels and the adjustability of the frame to allow the same endless track to be used for the front locations.
FIG. 17b is a side view of a rear track assembly showing the optional bottom intermediate idler wheels and the adjustability of the frame to allow the same endless track to be used for the rear locations.
FIG. 18 is a sectional plan view of the optional embodiment as taken along the line 18--18 in FIG. 15.
FIG. 19 is a vertical sectional view of the optional embodiment using intermediate idler wheels, as taken along the line 19--19 in FIG. 15.
FIG. 20 is an exploded pictorial view of the optional embodiment using intermediate idler wheels, in the track assembly but does not show the endless track for clarity.
DETAILED DESCRIPTION OF THE INVENTION
The drawings show the preferred embodiment of the track laying attachment 30 that are constructed according to the invention and that constitutes the best methods of the invention currently known to the applicant. The attachment 30 includes a mounting shaft 31 showing the preferred form of the shaft being hexagonal in shape and has a mounting flange 32 at its inner end adapted to be secured to a wheel hub of a vehicle, such as the All Terrain Vehicle (ATV) 33 shown in FIG. 3. With the wheels removed from the ATV's wheel hub as shown in FIG. 4. When it is so secured, the mounting shaft 31 rotates with the wheel hub as shown in FIG. 5. FIG. 3 also shows an embodiment in which the mounting flange 32 extends radially outwardly from the inner end of the mounting shaft 31. A portion of a typical ATV wheel hub 34 is shown in FIG. 4, FIG. 5, FIG. 9 and FIG. 10. The wheel hub 34 has projecting studs 35 onto which a wheel would be mounted and secured by nuts 36. The preferred mounting shaft 31 is mounted in the same manner. To accomplish this, the studs 35 are placed through holes provided in the mounting flange 32 so that they protrude from the outer surface of the flange 32. The mounting shaft 31 is then tightly secured to the hub 34 by placing the nut's 36 on the protruding ends of the studs 35 and tightening them against the outer face of the flange 32. In FIG. 10 a driving cog wheel 37a is longitudinally slid onto a hexagon shaped thin wall sleeve 38 which has a tab on three alternating facets and at both ends, then the two hexagon bore antifriction bearings 39 are slid onto the hexagon shaped thin wall sleeve 38 followed by the second driving cog wheel 37b. This sub assembly 40 as shown in FIG. 11 is then placed onto the track supporting rigid frame beam 41 with the two hexagon bore antifriction bearings 39 setting into tight fitting recesses that are cast into the top of the track supporting rigid frame beam 41. The two hexagon bore antifriction bearings 39 are then capped with a cast light weight metal cover 42 and secured with bolts 43, lock washers 44 and hex nuts 45. After the drive cog wheel assembly 40 is secured the three tabs, which are located on both ends of the hexagon shaped thin wall sleeve 38, are bent over against the face of the driving cog wheel hubs 46. In FIG. 11 the driving cog wheel 37 is cast in one piece of a light weight metal with a hexagon bored hub 46, a solid dished web 47 with evenly spaced stiffening ribs 48 for handling the torsion and bending forces that are generated from the driving torque and the terrain being traversed. These stiffening ribs 48 face inwardly giving a smooth surface facing to the outside of the solid dished web, featuring a safe snag free surface. The driving cog wheel 37 also includes an annular stiffening rim 49 centrally located on the extreme outside of the dished web 47 to which the cog projections 50 are attached to the inside, facing to the same side as the projecting side of the driving cog wheel hub 46.
The driving cog wheel 37 has evenly spaced apart, endless track lugs 120 receiving projections or cogs 50 at its periphery. These cog projections 50 as shown in FIG. 8 have a bearing surface 51, each of which is rounded at its periphery to guide the endless track drive lugs 120 of the endless track 99 into the space between the cog projections 50 with suitable relief to cause any snow or other compressible material to be squeezed out and fall through the space and down onto the endless track 99 area below and inhibiting the buildup of snow or other compressible material on the cog projections 50.
The rigid frame beam 41 then has attached to the bottom of it leaf spring mounts 55 and 56 with a clamp plate 57 secured with bolts 58, lock washers 59 and hex nuts 60 as shown in FIG. 6, FIG. 10 and FIG. 11. The rigid frame beam 41 has a block out at the front and rear of it to receive a square nut 52, then rear leaf spring 55 with its front end passed through a slotted hole in the front end of leaf spring 56 are then set into a tight fitting longitudinal slot in the bottom side of the rigid frame beam 41 with the clamp plate 57 secured over them and bolted to the rigid frame beam 41 with bolts 58. Through a hole in the rear end of the rear leaf spring 55, an endless track 99 tension adjusting bolt 53 with a hex jamb nut 54 is threaded and the adjusting bolt 53 passes through a hole in the rear end of the rigid frame beam 41 and is threaded into the square nut 52. Through a hole in the front of the leaf spring 56, an endless track 99 tension adjusting bolt 53 with a hex jamb nut 54 is threaded and then the adjusting bolt 53 passes through a cast hole in the front end of the rigid frame beam 41 and is threaded into the square nut 52. To the front end of the leaf spring 55 a connecting leaf spring 61 in combination with the front idler wheels 62 and mounting shaft 63 with mounting plate 64 are connected using the bolts' 65, lock washers 66 and hex nuts 67. The front idler wheels 62 with antifriction bearings 68, snap rings 69, inner spacer 70 and outer spacer 71 are secured to the ends of the front idler mounting shaft 63 using the bolt's 72 and flat washers 73 that are threaded into drilled and tapped holes in the ends of the front idler mounting shaft 63.
As the preferred embodiment for the bottom intermediate support of the endless track 99 we have attached to the rear of connecting leaf spring 61 strut shaft 74 and mounting plate 75 that connects to the front end of the slider rub bars 81 by means of bolts 76, lock washers 77 and hex nuts 78. The slider rub bar 81 connects to the ends of the strut shaft 74 using bolts 79 and flat washers 80 by threading into tapped holes in the ends of the strut shaft 74. The slider rub bars 81 are cast from light weight metal with a machined polymer plastic rub surface 82 slid onto receiving ribs on the slider rub bars 81 as shown in FIG. 10 and FIG. 11.
The rear leaf spring mount 56 has attached to its rearward end by means of bolts 87, lock washers 85 and hex nuts 86, a rear idler shaft 83 with mounting plate 84. The ends of the rear idler shaft 83 connects to the rear of the slider rub bars 81 by passing through longitudinally elongated slots. The rear idler shaft 83 passing through the elongated slot and having the rear idler wheels 94 with antifriction bearings 89, snap rings 89, inner spacer 90 and outer spacer 91 are secured to the ends of the rear idler shaft 83 using the bolt's 92 and flat washers 93 that are threaded into drilled and tapped holes in the ends of mounting shaft 83.
With the endless track 99 tension take up in there total retracted positions that is the adjusting bolts 53 in there fullest extended out positions the endless track 99 can now be installed onto the track frame assembly by sliding the endless track 99 over the driving cog wheels 37, front idler wheels 62, rear idler wheels 94 and the slider rub bars 81 simultaneously.
As shown in FIG. 14 and FIG. 15 the All Terrain Vehicles show the track unit 30 with an optional embodiment for the bottom intermediate support of the endless track 99 that replaces the slider rub bars. To the rear of connecting leaf spring 61 is attached the front intermediate idler wheels 113, front intermediate idler mounting shaft 74 with mounting plate 75 and bolted by means of bolts 76, lock washers 77 and hex nuts 78. The front intermediate idler wheels 113 connect to the ends of the front intermediate idler wheel shaft 74 with antifriction bearings 114, snap rings 115, inner spacer 116 and outer spacer 117 which are secured to the front intermediate idler shaft 74 using the bolt's 119 and flat washers 117 that are threaded into drilled and tapped holes in the ends of idler shaft 74. To the rear of leaf spring 56 is attached the rear idler wheels 94 mounting shaft 83 with mounting plates 84 and 100 by means of bolts 87, lock washers 85 and hex nuts 86. The rear idler wheels 94 connect to the ends of the rear idler wheel mounting shaft 83 with antifriction bearings 88, snap rings 89, inner spacer 90 and outer spacer 91 are secured to the mounting shaft 94 using the bolt's 92 and flat washers 93 that are threaded into drilled and tapped holes in the ends of the rear idler wheel mounting shaft 83. To the front of mounting plate 100 which is attached to the front of mounting plate 84 is attached the rear intermediate idler wheels 106 mounting shaft 101 with mounting plate 102 by means of bolts 103, lock washers 104 and hex nuts 105. The rear intermediate idler wheels 106 connect to the ends of the rear intermediate idler mounting shaft 101 with antifriction bearings 107, snap rings 108, inner spacer 109 and outer spacer 110, which are secured to the mounting shaft 101 using the bolt's 112 and flat washers 111 that are threaded into drilled and tapped holes in the ends of rear intermediate idler mounting shaft 101.
The endless track 99 tension take-up feature is accomplished by the leaf spring mount 55 for the front and leaf spring 56 for the rear, by tightening the adjusting bolts 53 which pass through the cast holes in the ends of rigid frame beam 41 and are threaded into the square nuts 52 which are mounted in cast block outs located in the front and rear of the rigid frame beam 41 and are locked from unwanted loosening with the hex locking jamb nuts 54. The two extra mounting holes in the front end of the leaf spring 55 are to allow the front idler wheel 62 with its mounting shaft 63 to move forward and bolt into the front two mounting holes for maximum track length positioning to the front and having more stability for a front track assembly as shown in FIG. 7, and FIG. 17. The two extra holes in the rear end of the leaf spring 56 are to allow the rear idler wheel 94 with its mounting shaft 83 to move back into the rear two mounting holes for maximum track length positioning to the rear and having more stability for a rear mounted track assembly as shown in FIG. 7, and FIG. 17.
As a total track assembly the driving cog wheel 37 is slipped onto the mounting shaft 31 by means of having a hexagon shape bore through its middle at its center hub 46. The same six sided hexagon shape of the mounting shaft 31 the thin wall hexagon sleeve 38 and the driving cog wheel 37 bore at hub 36 allows synchronized rotational movement between the hexagon shaft 31 and the driving cog wheels 37 without the need for a shear key and keyway. Longitudinal movement is prevented by the hexagon bore antifriction bearings 39 as they are set into cast tight fitting recesses in the top of the rigid frame beam 41 and the cast bearing cover 42. The mounting shaft 31 is attached through the hexagon shaped thin wall sleeve 38 and through the hexagon bore antifriction bearings 39 to the upper portion of the track supporting rigid frame beam 41.
FIG. 12 shows the preferred flexible frame assembly 123, incorporating the centrally located rigid frame beam 41 with leaf spring extension 55 extending out to the bottom front and leaf spring 56 extending to the bottom rear for the flexible support of the slider rub bars 81 that maintains the downward orientation of the endless track 99. FIG. 13 shows the optional flexible frame assembly 124, incorporating the centrally located rigid frame beam 41 with leaf spring extension 55 extending out to the bottom front and leaf spring 56 extending to the bottom rear for the flexible support of the front intermediate idler wheels 113 and the rear intermediate idler wheels 106 that maintains the downward orientation of the endless track 99.
The endless track 99 is restrained from unwanted dismounting when making turns or lateral applied forces such as side hill traversing by the feature of the driving cog wheels 37 having the annular rim 49 making contact and supporting the top intermediate portion of the endless track 99 and the annular rim 49 running at the outward edge of the endless track 99, and restraining the endless tracks lugs 120 from lateral movement as shown in FIG. 10 and FIG. 19. The front idler wheels 62, optional intermediate idler wheels 106 and 113 and rear idler wheels 94 run in the same path as does the driving cog wheels annular rim 49 on the endless track 99. The slider rub bars run on the inside face of the endless track 99s lugs 120 as shown in FIG. 10 affording the same lateral restraint of the endless track from unwanted dismounting.
The endless track 99 is a standard length snowmobile endless track with diving lugs 120 located near its outer edges, multiple longitudinal continuous bands 122 and connecting transverse bands at spaced intervals as shown in FIG. 9, FIG. 10, FIG. 18 and FIG. 19.
The driving cog wheel sub assembly 40 is held onto the mounting shaft 31 by a hex slotted nut 96 threaded onto the end of the mounting shaft 31 with a cotter pin 97 inserted through a slot in the hex slotted nut 96, through the hole in the outboard end of the mounting shaft 31 for preventing unwanted loosening of the hex slotted nut 96. The hex slotted nut 96 has a soft elastomer molded snap-on cover 98 that gives a smooth snag free surface over the hex slotted nut 96 when installed on the mounting shaft 31. The track can be installed onto or removed from the mounting shaft 31 as an assembly with a minimum amount of tools and of time.
______________________________________DRAWING REFERENCE NUMERALS WORKSHEETPART NAME______________________________________30 Track Laying Attachment31 Mounting Shaft32 Mounting Flange33 All-Terrain Recreational Vehicle34 Wheel Hub35 Projecting Studs36 Hex Nuts37 Driving Cog Wheel38 Thin Wall Sleeve39 Hexagon Bore Antifriction Bearing40 Sub Assembly of 37, 38 and 3941 Rigid Frame Beam42 Top Cap43 Bolts44 Lock Washers45 Hex Nuts46 Driving Cog Wheel Hub47 Solid Dished Web48 Stiffening Ribs49 Annular Stiffening Rim50 Cog Projections51 Bearing Surface52 Square Nuts53 Tension Adjusting Bolt54 Hexagon Jamb Nut55 Front Leaf Spring56 Rear Leaf Spring57 Clamp plate58 Bolts59 Lock Washers60 Hex Nuts61 Connecting Leaf Spring62 Front Idler Wheels63 Front Idler Shaft64 Front Idler Shaft Mounting Plate65 Bolts66 Lock Washers67 Hex Nuts68 Antifriction Bearings69 Snap Rings70 Inner Spacer71 Outer Spacer72 Bolts73 Flat Washers74 Front Strut Shaft75 Front Strut Shaft Mounting Plate76 Bolts77 Lock Washers78 Hex Nuts79 Bolts80 Flat Washers81 Slider Rub Bar82 Polymer Plastic Slider Rub Surface83 Rearward Idler Shaft84 Rearward Idler Shaft Mounting Plate85 Lock Washers86 Hex Nuts87 Bolts88 Antifriction Bearings89 Snap Rings90 Inner Spacers91 Outer Spacers92 Bolts93 Flat Washers94 Rear Idler Wheels95 Leaf Washer96 Hexagon Slotted Nut97 Cotter Pin98 Molded Snap On Cover99 Endless Track100 Rear Intermediate Idler Extension Plate101 Rear Intermediate Idler Shaft102 Rear Intermediate Idler Mounting Plate103 Bolts104 Lock Washers105 Hex Nuts106 Rear Intermediate Idler Wheel107 Antifriction Bearings108 Snap Rings109 Inner Spacers110 Outer Spacers111 Leaf Washers112 Bolts113 Front Intermediate Idler Wheel114 Antifriction Bearings115 Snap Rings116 Inner Spacers117 Outer Spacers118 Flat Washers119 Bolts120 Lugs121 Endless Belt Band Openings122 Endless Belt Bands123 Flexible Frame124 Optional Flexible Frame______________________________________
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An endless track structure to replace the wheels of an all-terrain vehicle, that is adequately attached to the existing wheel hub by a removable mounting shaft. This provides a non-rigid frame that supports spaced apart synchronized driving cog wheels. This frame has mounted within its upper portion, two hexagon bore anti-friction bearings that slide onto a hexagon shaped thin wall sleeve, allowing the assembled track structure to be installed as a unit. There are spaced idler wheels in front and rear portions of the non rigid frame that support the track. They form a triangular configuration with raised front portion and flat rear portion. A non rigid frame provides interconnected resilient leaf spring supports located in the front and rear of the track.
An endless track maintains its appropriate configuration over the driving cog wheels by the front and rear idler wheels, and under the lower course by spaced apart slider rub bars supported by a flexible frame. An optional intermediate suspension may be substituted for the slider with a pair of spaced apart front and rear intermediate idler wheels at the frame portion.
The ability to adjust the position of the front and rear idler wheels in relation to the bearing support is accomplished by multiple mounting holes in the front and rear leaf spring. This allows the track to be lengthened to the front or rear, and still use the same length endless track.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is broadly concerned with an improved golf glove which provides convenient, compact, and readily-accessible storage for golf tees and a ball marker. More particularly, it is concerned with a golf glove having a hand-receiving glove portion, a tee holder of elastic or any other suitable material, and a retainer into which a ball marker may be easily inserted and removed using one hand.
2. Description of the Related Art
Golf is a popular sport enjoyed around the world by millions of people of all ages. Players use clubs to sink a ball with as few strokes as possible into each of the nine or eighteen successive holes on a course. Players commonly wear spiked shoes to avoid damaging the greens and to maintain stance, as well as a golf glove on one hand to facilitate gripping the club. The game is normally played by groups of one to four golfers, who commence play towards each of the holes by driving the ball from a tee. Since golf courses schedule tee off times closely, to permit as many groups as possible to play in a day, it is desirable to play as expeditiously as possible.
Golfers have long been faced with the difficulties of transporting tees and ball markers around the links and keeping them conveniently at hand while leaving their hands free to play the game.
Although the golf bag generally used to transport the clubs includes pockets in which a supply of tees and markers may be stored and transported, such pockets are not well suited for providing easy access to small items. Even if a player were willing to walk to the bag and rummage through the pockets to obtain a tee, the process might have to be repeated if the tee were damaged while driving the ball, as it is sometimes necessary for a player to use more than one ball at a tee. In such cases repeated rummaging through the bag for additional tees would be required, thus slowing the game. While a golfer could retrieve several tees from the bag before teeing up, a storage problem would arise at the tee, since the hands must be kept free to grip the club during the drive.
Use of pockets in the golfer's clothing is similarly unsatisfactory. Items stored in the shirt pockets may fall out and be lost when the player bends to tee up or place a marker. Tees and markers are too sharp to be suitable for comfortable trouser pocket storage.
Previous devices have attempted to provide storage containers for tees, markers, and golf tools but do not provide a golf glove including accessible open holders for individual tees and markers of conventional construction which permit easy one-handed removal and replacement. U.S. Pat. Nos. 4,993,613 issued to Frisbie and 4,736,877 issued to Clark require attachment to a player's golf bag or belt. U.S. Pat. No. 5,003,637 issued to Lonon describes a closed, relatively bulky utility container for attachment to a golf glove. U.S. Pat. No. 3,847,110 issued to Inoue describes a golf score indicator for attachment to a golf glove. U.S. Pat. Nos. 4,639,947 and 4,489,444 issued to Lanscioni and Graham respectively, disclose a golf glove having an apertured flap which may be opened for access to a ball marker. U.S. Pat. No. 3,588,917 discloses a golf glove having hook-and-loop material for holding a marker fitted with complementary material. Heretofore there has not been available a golf glove having a holder for tees and a ball marker with the advantages of the present invention.
SUMMARY OF THE INVENTION
The present invention overcomes the problems previously outlined and provides a greatly improved golf glove having holders for tees and a ball marker. Broadly speaking, the glove includes a series of channels for securing tees to the glove in side-by-side relationship, and a retainer into which a ball marker may be easily inserted by sliding.
In particularly preferred forms, the golf glove includes an overlapping flap type closure and the tee-holder is mounted atop the flap. In still other preferred forms, the marker retainer is coupled with the tee-holder and includes a slot for holding the marker base overlying the tee-holder with the tang projecting outwardly.
OBJECTS AND ADVANTAGES OF THE INVENTION
The principal objects and advantages of the present invention include: providing golf tee and ball marker storage which is open and readily accessible to a golfer; providing such storage in which each item is separately secured; providing such storage which is compact and light weight; providing a golf glove which provides such storage; providing such a golf glove which permits easy, one-handed access to tees and markers for removal and replacement; providing such a golf glove which includes tee-holding channels of elastic or other suitable material; providing such a golf glove which includes a pocket for receiving a ball marker; providing such a golf glove which includes a pocket having a slot for slidably receiving a ball marker and for holding the marker in the pocket with the tang projecting outwardly from the slot; providing such a golf glove having a pocket with an opening oriented to permit the centrifugal force of the swing to force the marker inwardly into the holder; and providing a golf glove which can be easily modified to provide such storage.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of the golf glove of the present invention showing golf tees and a ball marker in place in respective holders;
FIG. 2 is an enlarged, fragmentary plan view of the glove of FIG. 1, with parts broken away for clarity;
FIG. 3 is a cross section taken generally along line 3--3 of FIG. 1; and
FIG. 4 is a cross section taken generally along line 4--4 of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
I. Introduction and Environment
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, the words "upwardly", "downwardly", "rightwardly" and "leftwardly" will refer to directions in the drawings to which reference is made. The words "inwardly" and "outwardly" will refer to directions toward and away from, respectively, the geometric center of the embodiment being described and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof and words of a similar import.
Referring now to the drawing, a golf glove with tee holder 10 in accordance with the invention includes a glove 12, having fingers 14, a thumb 15, a body 16, and closure assembly 18. A tee holder 20 is attached to closure assembly 18 and a ball marker holder 22 is disposed above tee holder 20.
In more detail, glove 12 is of flexible construction, preferably of leather and is perforated with ventilation holes 24 on the dorsal surface of fingers 14. In preferred embodiments, both dorsal and ventral finger surfaces are perforated. In certain embodiments the dorsal thumb surface may be perforated as well. Glove body 16 includes a ventral, palmar surface 26, and a dorsal, back surface 28 which is divided by an opening 30 into a lateral portion 32 adjacent the thumb 15 and a medial portion 34. Opening 30 is reinforced with piping 36 at the margins.
Glove closure assembly 18 includes a generally rectangular area of fabric loop fastener material 38, attached to lateral back surface 32 by a row of marginal stitching 40. A generally rectangular flap 42 is coupled with medial portion 34 so as to overlie fastener material 38 in mating engagement when in the closed position. Flap 42 includes an inner surface 44 of fabric loop fastener material and an outer surface 46 joined by a row of marginal stitching 48. In other embodiments, snaps, buttons, or any other suitable closure devices may be substituted for fabric loop fastener material or hook and loop fasteners in closure assembly 18.
Tee holder 20 includes a band 50 mounted atop flap 42 by spaced rows of stitching 52 which form tee-receiving channels 54, presenting a pair of open ends 55. In other preferred embodiments, band 50 may be mounted on glove 12 at any suitable location. Band 50 may be constructed of elastic or any other suitable material, such as, for example, woven synthetic fabric having a warp of rubberized filaments. Tees 56 each include a head 58, shaft, 60, and tapered end 62 and may be of wood, plastic, metal, or any other suitable material. An outer covering 64 is secured over band 50 by a row of marginal stitching 66.
Ball marker holder 22 includes a generally circular pocket 68 secured to tee holder outer covering 64 by a row of marginal stitching 70. In other embodiments, pocket 68 may be mounted directly to glove 12 at any suitable location and may be of any geometric configuration suitable to accommodate a ball marker. In still other embodiments, more than one pocket may be employed.
Pocket 68 is notched to present a slot 72 presenting proximally oriented converging curved edges 74 and distally oriented curvate end 76 to accommodate a marker 78 having a generally disk shaped base 80 coupled with a tang 82. In other embodiments, marker 78 may be of any suitable geometric configuration. Pocket 68 may be constructed of leather, synthetic resin, non woven synthetic fabric, cotton, or any other flexible material and may be imprinted, embroidered, or otherwise marked with a logo or design.
In other preferred embodiments, glove 12 includes tee holder 20, but not marker holder 22. Rows of stitching 40, 48, 52, 66, and 70 may be single or multiple, and gluing may be substituted for stitching where suitable. Where the components to be joined are of synthetic resinous material, fusion welding may be employed.
In use, a tee 56 is inserted into open end 55 of golf glove channel 54 by introducing tapered end 62 under band 50 and sliding shaft 60 into channel 54. Additional tees are inserted in side-by-side relationship in the adjacent channels 54. Tees may be inserted from either end of channels 54, according to user preference, or they may be alternated head-to-end in order to facilitate access to the heads for removal. As best shown in FIG. 4, band 50 urges channel ends 55 downwardly against outer flap surface 46 until a tee 56 is inserted into channel 54.
Tees 56 can be oriented with heads 58 facing the proximal side of the band and with ends 62 facing the distal side to permit the centrifugal force of the swing to force the tees distally into channels 54, with heads 58 serving as stops. However, band 50 secures the tees in place regardless of their orientation.
As tee 56 is introduced, band 50 stretches, tightly engaging the tee against flap surface 46 and securing it against loss. In preferred embodiments, channel 54 will stretch to accommodate tees of varying dimensions. A tee is removed by grasping the head 58 and sliding outwardly.
A ball marker 78 is inserted into holder 22 by sliding the base 80 past converging slot edges 74, along slot 72, and into pocket 68 with the tang 72 projecting outwardly through the slot until it contacts distal end 76, which serves as a stop. Pocket 68 engages base 80 against flap covering 64 in supporting relationship. During the swing, centrifugal forces act to urge marker 74 into pocket 68 and tang 72 towards end 76. A marker is easily removed for use at the next hole by grasping the projecting tang 72, which serves as a handle, and sliding the base outwardly from the pocket 68 along slot 72.
Advantageously, a golf glove of conventional construction may be easily modified to include holders 20, 22. Moreover, the golf glove with tee holder of the present invention obviates the need for additional accessories for tee and marker storage, such as belt mounted carriers and the like. The convenient location of tees 56 and ball marker 78 permits frequent, easy one-handed removal and replacement in the respective holders, 20, 22 during the course of the game.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown.
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The improved golf glove of the present invention is constructed to provide convenient, compact, and readily-accessible storage for a golf tee and a ball marker. The glove includes a hand-receiving glove portion having an overlapping flap type closure, a tee holder mounted atop the flap and having a series of channels of elastic or any other suitable material for securing tees in side-by-side relationship, and a retainer into which a ball marker may be easily inserted and removed using one hand. The marker retainer is coupled with the tee-holder and includes a slot for holding the marker base overlying the tee-holder with the tang projecting outwardly.
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BACKGROUND
The present invention relates generally to ammunition storage and more particularly to a volumetrically efficient drum-type ammunition magazine amenable for installation on transport vehicles having a turret type gun.
It is to be appreciated that although the present invention has particular advantage for use in limited space and weight environments, such as aboard transport vehicles, ships and the like, the general principles taught by the invention may have use in other ammunition handling systems.
As to limited space/weight applications, it is desirable that an ammunition magazine be volumetrically efficient, that is, hold a large number of rounds per unit volume. A linkless feed system is desirable in this regard, because linked ammunition necessarily includes the "dead" weight associated with the links which support and help guide the individual ammunition rounds.
In addition, the rate of fire of modern guns may be hundreds or thousands of rounds per minute. This results in very high acceleration and deceleration in the ammunition supply system which make belts formed by cartridge carrying links unsatisfactory because of breakage or separation which may occur.
Further, modern larger caliber guns, such as 25mm, are capable of firing a variety of ammunition types such as high explosive, armour piercing, among others; hence, an ammunition magazine compatable with the weapon for utilizing this feature to its greatest advantage should be able to store more than one type of ammunition and be capable of feeding each type of ammunition to the weapon upon demand without significant interruption of the weapon firing rate.
It is also important that the ammunition magazine be structurally compatable with the turret mounted weapon so that the magazine does not interfere with the range of motion of the turret or otherwise limit the firing envelope of the weapon. In many cases this requires the ammunition magazine to be installed in a remote position from the gun.
Numerous other ammunition magazines that have a general DRUM-TYPE configuration have been invented in the past, and at least three types are known to be in current use. However, none are known that have the ability to independently feed two of more different types of ammunition.
One known type consists of a fixed continuous helical outer partition to guide and support the ammunition case, and a rotating "stave" inner drive means to drive the ammunition rounds, by interface with the projectile and shoulder position of the round, around the fixed helical outer portion. It is easily appreciated that such a continuous outer helical guide is both difficult and expensive to manufacture. Also, because the outer helical guide must be continuous, the inner stave guide means must stop well short of extending radially outward to the base of the round, which results in unfavorable efficiencies and subsequent higher loads and power requirements.
A second type consists of a rotating helical inner drive means (looking very much like a post-hole digging auger) which propells ammunition rounds axially, with the ammunition rounds being restrained and guided by fixed longitudinal tracks in the stationary outer drum. The apparent advantage of this type is that the multiple rows all progress very slowly toward the exit end of the drum. As the ammunition rounds move slowly, the inertia of the ammunition rounds is small which promotes the ability of the system to start very rapidly. Unfortunately, the speed and mass of the rotating center helix is quite large, which detracts from the apparent advantage obtained from low ammunition round velocity, and transmission of drive power to the ammunition round is poor due to high sliding velocities between the rotating center helix and the ammunition rounds. Further, the system is complicated because the ammunition rounds exits the drum at all radial positions, which requires an additional "Scoop Disc Assembly", or the like, to obtain a continuous single stream output at a fixed location. See U.S. Pat. No. 2,935,914, issued to B. Darsie ET AL.
A third type, which is in fact a variant of the second type, utilizes a fixed inner helix with a rotatable outer drum and longitudinal track assembly. This design eliminates the need of a Scoop Disc Assembly, but results in high round inertia.
The present invention provides a lightweight volumetric efficient ammunition magazine capable of storing a plurality of different types of ammunition within a single magazine and separately delivering such different types of ammunition upon demand without the need for expensive helical guides or drive means.
SUMMARY OF THE INVENTION
In accordance with the present invention an ammunition magazine includes a drum-type housing, means defining a plurality of bays concentrically disposed within the drum-type housing and means for supporting ammunition rounds within each of the concentrically disposed bays along directions defined by radii of the drum-type housing.
Further, ammunition carrier means, rotatably mounted within each concentrically disposed bay are provided for moving said ammunition rounds within the concentrically disposed bays and means are provided for rotating the ammunition carrier means within the concentrically disposed bays.
More particularly, a magazine is provided for the storage and dispensing of linkless ammunition in which the drum-type housing has a top and a bottom therein and means defining a plurality of ports in the top for passage of linkless ammunition rounds therethrough. The means defining a plurality of concentric bays defines both an inner bay and an outer bay and the means for supporting the ammunition includes a plurality of fixed tiered partitions for supporting linkless ammunition rounds therein along directions defined by radii of the drum-type housing.
Means are provided for separately rotating the ammunition carrier means within the inner and outer bays, and ramp means, interconnected between adjacent fixed tiered partitions, are provided for transferring linkless ammunition rounds from one fixed tiered partition to another and thereafter to the corresponding port as each ammunition carrier means is rotated.
Tab means disposed on said ammunition carrier means and between each linkless ammunition round drive the linkless ammunition rounds along the ramp means from one fixed tiered partition to another as the ammunition carrier is rotated.
Because the concentric bays are separately disposed in the drum-type housing and the ammunition carrier means may be operated separately from one another within each of the concentric bays, a different type of ammunition may be stored in each of the bays and separately withdrawn therefrom upon demand.
As a further advantage of the present invention, the carrier means is highly efficient in moving the ammunition rounds within the magazine because it drives the ammunition rounds over their entire length and thereby enables the ammunition rounds to roll, rather than slide, which reduces frictional loading.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will appear from the following description when considered in conjunction with the accompanying drawings, in which;
FIG. 1 is a perspective view of the ammunition magazine according to the present invention in an operative relationship with a turret mounted automatic rapid fire gun as it may be employed on a transport vehicle and showing the ammunition magazine being disposed directly under the turret;
FIG. 2 is a perspective view of the drum-type housing of ammunition magazine partially broken away to show ammunition rounds disposed therein supported by a plurality of fixed tiered partitions disposed in concentrically disposed inner and outer bays and an ammunition carrier rotatably mounted within each of the inner and outer bays for separately moving the ammunition rounds within the inner and outer bays, respectively, as well as means for rotating the ammunition carriers within the concentrically disposed inner and outer bays;
FIG. 3 is a partial cross-section taken along the line 3--3 in FIG. 2 showing in greater detail the fixed tiered partitions for supporting the ammunition rounds as well as ramps interconnected between adjacent fixed tiered partitions for transporting the ammunition rounds from one adjacent fixed tiered partition to another as the ammunition carrier is rotated;
FIG. 4 is a partial top view of the ammunition carrier showing the disposition of the ammunition rounds along directions defined by radii of the drum-type housing and between tabs disposed on the ammunition carriers for driving the ammunition rounds along the ramps (FIG. 3) from one tiered partition to another; &
FIG. 5 is a partial cross-section of the inner and outer bay more clearly showing the relationship between the fixed tiered partitions and the ammunition carriers.
DETAILED DESCRIPTION
Turning now to FIG. 1 there is shown in perspective view, an ammunition magazine 10 in accordance with the present invention showing the magazine 10 in an operative relationship with a gun 12 mounted on a turret 14, all of which may be disposed on a transport vehicle (not shown).
The magazine 10 communicates with the gun 12 via a pair of feed chutes 16, 18, extending from ports 24, 26, disposed in a top portion 28 of the drum-type housing 30. It should be appreciated that the feed chutes 16, 18, as well as the gun 12 and the turret 14, are not part of the present invention but are shown as a typical installation of the ammunition magazine 10.
An enlarged perspective view of the magazine 10, partially broken away, is shown in FIG. 2. In general, a center and an outside wall 38, 40, respectively, as well as the top 28 and a bottom 42 provides means defining an inner and an outer bay 46, 48, respectively, within the drum-type housing 30.
It should be appreciated that for illustrative purposes only two bays, an inner and an outer, are shown; however, depending on the requirements of the magazine 10, in accordance with the present invention, a greater number of bays may be employed.
In addition, in as much as the inner bay 46 and the outer bay 48 are similar except for size, the outer bay will be primarily described with all such description and comment applying to the inner bay except for specific differences as may be pointed out.
The illustrated configuration for the magazine of the present invention is for 25 mm caliber ammunition rounds 50 provides for the storage of 576 rounds of ammunition in the outer bay 48 which may be primary or high explosive ammunition, and 288 rounds of ammunition in the inner bay 46 which may be secondary or armour piercing ammunition. The outer bay 48 may have an outer radius of about 25 inches and the inner bay 46 may have an outer radius of about 14 inches with the height of the magazine being about 14 inches.
Seven fixed tiered circular partitions 52 are attached to the outer wall 40 for supporting the ammunition rounds 50, and as shown in FIG. 3, each of the fixed partitions 52 have a gap 54 therein to enable the ammunition rounds to transition from one fixed tiered partition to another as will be described hereinafter in greater detail. The fixed partitions 52 extend inwardly toward the center of the magazine to an extent necessary to support the approximately right cylindrical portion 56 of the ammunition round 50 (see FIG. 4).
The fixed partitions 52 are spaced apart a distance greater than the maximum diameter of the ammunition round 50 and support the rounds along direction defined by radii 58 of the drum-type housing.
As best shown in FIG. 5 the inner bay 46, the partitions 52 may have an upturned portion 60 for supporting the round 50. This latter feature promotes low friction rolling of the round 50 on the fixed partition 52 as the rounds are moved within the bays 46, 48.
Ammunition carriers 68, 70 concentrically and rotatably mounted within the inner and outer bays 46, 48, respectively provide means for moving the ammunition rounds 50 within the inner and outer bays, respectively, and between the fixed partitions 52.
Each ammunition carrier 68, 70 consists of eight carrier rings 76, attached to movable upright partitions 78, 80, respectively, having a series of cutouts 82 conforming to contour of an ammunition rounds 50. The ammunition rounds 50 ride, or roll, on the fixed partitions 52 within the confines of the cutouts 82 as the ammunition carrier is rotated by motors 84, 86, respectively.
Bearings 88, 90 support the movable partitions 78, 80 at the bottom 40 of the magazine and bearings 92, 94 support the movable partitions 78, 80 at the top 28 for rotation within the outer and inner bays 48, 46 respectively.
Attached to each of the movable partitions 78, 80 are ring gears 100, 102 disposed for engagement with drive gears 104, 106 attached to the motor 84, 86 respectively.
As will be hereinafter discussed in connection with the operation of the magazine 10, the carrier rings have inner and outer transfer tabs, 108, 110 attached thereto for guiding or driving the ammunition rounds 50 during transition of the rounds from one fixed partition to an adjacent fixed partition.
Structurally, the transfer tabs 108, 110 add strength to the carrier rings 76 and help support the carrier rings in a spaced-apart relationship. As best shown in FIG. 2, the inner transfer tabs 108 are connected together between the carrier rings where as the outer tabs 110 are shorter and do not connect as they have a small running clearance with the fixed partitions 52.
FIG. 3 shows in detail ramps 112 extending between adjacent fixed partitions 52 which provide a means for transferring, or transitioning ammunition rounds from one fixed tiered position to another and thereafter to the correspondent port 24, 26, as each ammunition carrier 68, 70 is rotated by the motors 84, 86. As shown in FIG. 3 a slot 114 is provided in each ramp 112 in order to enable the carrier rings 76 to pass therethrough.
It should be appreciated that the magazine 10 construction is amenable to modular construction, and although not shown in the FIGURES, it is apparent that the carriers 76 and the center and outer walls 38, 40 may be readily designed as "bolt-together" layers which enables the rapid assembly of a magazine 10 of any desired capacity by assembling together as many layers as needed.
In operation, the drive motors 84, 86 rotate the ammunition carriers via the drive gears 102, 104 and the ring gears 98, 100. As the ammunition carrier 84, 86 are moved in a direction shown by arrows 116 in FIG. 3 between the fixed partitions 52 they are driven upwardly from lower fixed partitions to higher fixed partitions along the ramps 112 by the transfer tabs 110 along the directions indicated by the arrow 118 until they reach the exit port 26 where they are taken from the part by handoff apparatus 120, the latter not being part of the present invention.
The reloading of the magazine 10 can is rapidly achieved by running the motors in reverse and feeding ammunition to the handoff apparatus 120.
Although there has been described hereinabove a particular arrangement of an ammunition magazine in accordance with the present invention for the purpose of illustrating the manner in which the invention may be used to advantage, it should be appreciated that the invention is not limited thereto. Accordingly, any and all modifications variations or equivalent arrangements which may occur to those skilled in the art, should be considered to be within the scope of the invention as defined in the appended claims.
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A drum-type ammunition magazine includes a plurality of concentric ammunition bays therein with each bay having disposed therein a plurality of fixed tiered partitions for supporting linkless ammunition and a rotatably mounted ammunition carrier for moving the linkless ammunition within the bays and between the fixed tiered partitions and toward a port communicating with each ammunition bay. The ammunition carriers may be operated independent of each other, enabling storage of a different type of ammunition in each of the ammunition bays.
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BACKGROUND OF THE INVENTION
This invention relates to medical-surgical devices for connecting intravenous tubing to a catheter and more particularly to a clamping device for ensuring against separation of the connection between intravenous tubing and a subclavian catheter implanted in a patient.
During certain medical procedures it may be necessary to insert a catheter into the subclavian vein in the chest cavity to supply large amounts of medication or for intravenous feeding. Recent practice uses a catheter needle assembly in which a long flexible catheter is telescopically received concentrically within the needle. The needle is inserted into the vein and the catheter is threaded through the needle, the needle thereafter being withdrawn and held in a clamp secured to the patient with the head of the needle positioned outside the clamp. An intravenous tube receiving socket or receptacle is formed on the end of the catheter and extends outside the needle head remote from the inserted portion for receiving a plug-like insert formed on the end of the intravenous tubing adjacent a bulbous portion, the socket and insert being connected by a friction fit. Although this connection serves its purpose when no separating force is applied to the catheter or tubing, separating difficulties are encountered when a patient in an unconscious or semiconscious condition flails about and pulls at the apparatus. Because a pressure change occurs in the subclavian vein during the breathing process, if a separation occurs between the catheter and the intravenous tubing, air can be sucked into the catheter resulting in an air embolus with grievous injury or death befalling the patient.
SUMMARY OF THE INVENTION
Consequently, it is a primary object of the present invention to provide a clamp for securing the intravenous tubing to the subclavian catheter to minimize the risk of air entering the catheter.
It is another object of the present invention to provide a clamping device for preventing separation of the connection between a subclavian catheter and intravenous tubing.
It is a further object of the present invention to provide a clamping member for positively gripping the adjoining ends of a subclavian catheter and the cooperatively connected intravenous tubing to ensure against separation thereof.
To attain these objectives the present invention provides a clamp for preventing relative axial movement of the subclavian catheter and the intravenous tubing to maintain the connection fast at the adjoining ends. The clamp comprises a tube-like member having internal ridges or ribs adjacent one end thereof and a plurality of radially moveable jaw members on the other end, the jaw members being moveable inwardly toward the axis of the tube from an inoperative position toward a clamping position and locked in the latter position by a lock ring which may act against cooperating camming members on the jaw members. The clamp is positioned about the intravenous tubing with the ridges in gripping engagement with a resilient bulbous portion of the tubing adjacent the terminal plug-like insert, the latter extending substantially axially toward the end of the clamp carrying the jaw members. Thereafter the clamp is positioned about the catheter needle head and socket, the latter being forced into connecting engagement with the plug-like insert, and the jaw members are closed about the needle head and secured by the lock ring. The jaws are formed with radial and circumferential portions, the radial portion being disposed to act against the catheter facing end of the needle head to prevent relative axial movement thereof while the circumferential portions act against the surface of the needle head to prevent relative radial movement thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is an isometric view illustrating a clamp constructed in accordance with the principles of the present invention in the operative position securing a subclavian catheter to intravenous tubing, the catheter being depicted diagrammatically as implanted within a patient;
FIG. 2 is a side elevational view illustrating the clamp shown in FIG. 1 in the inoperative or unlocked position;
FIG. 3 is a view similar to FIG. 2 but illustrating the operative locked position of the clamp with parts thereof broken away for purposes of illustration;
FIG. 4 is an end view of the clamp as viewed from the left end of FIG. 2 but in locked condition; and
FIG. 5 is a cross sectional view taken substantially along line 5--5 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings a clamp constructed in accordance with the principles of the present invention, illustrated generally at 10, is shown in the operative position in conjunction with a conventional subclavian catheter 12 implanted within the subclavian vein of a patient and with intravenous tubing 14 through which medication or nutritious feeding matter is fed to the catheter. The catheter is received telescopically within a needle having a metal cylindrical needle head 16 at the end remote from the catheter, the needle in the operative position being held stationary within a foldable clamping device 18 secured to the patient by stitches 20 passing through holes 22 in the clamping device. The needle head has a planar surface at the needle end and the needle extends axially therefrom. A plastic cylindrical socket member 24 extends from the needle head for frictionally receiving a plug-like insert 26 at the end of the intravenous tubing. Intermediate the plug-like insert and the tubing proper is a resilient bulbous member 28 conventionally formed integral with the tubing and the insert. The bulbous member 28 generally is formed from latex or other rubber-like material and may be readily compressed radially. Conventionally, the insert 26 is forced into the socket 24 and is held in place merely by frictional engagement of the plastic material from which they are formed. However, it has been found that separation can readily occur inadvertently when a patient flails about with the result that an air embolus can occur.
The clamp of the present invention prevents separation of the catheter assembly from the intravenous tubing by securely grasping the bulbous portion of the tubing and the needle head radially and by providing an axial engagement or stop against the needle head to prevent relative movement of the needle head and the tubing. To this end the clamp comprises a substantially tubular member 30 of a length substantially equal to the distance from the needle head adjacent the needle proper to the bulbous portion of the intravenous tubing preferably proximate the medial portion thereof. Formed on the interior wall of the clamp adjacent the opening receiving the intravenous tubing is at least one and preferably a plurality of ridges or ribs 37. Each of the ridges preferably has a sloped surface extending rearwardly from a maximum extention so as to form gripping teeth for engaging the bulbous portion of the intravenous tubing, the slope providing for ease of receiving the bulbous member while providing resistance against ready removal thereof from the clamp. As best illustrated in FIG. 5 the gripping ridges may extend completely about the circumference of the interior wall of the tubular clamp, but it should be understood that equivalent results would be attained if the ridges extended only partly about the circumference sufficient to provide gripping engagement with the bulbous portion.
At the forward end of the clamp, that end being the end that clamps the needle head, the tubular member has a plurality of longitudinally extending slits 32 at space locations about the periphery thereof so as to form a plurality of spaced flaps 34. The material from which the tubular member is constructed should be a readily bendable plastic such as polypropylene so that each of the flaps 34 will in effect be connected to the main body of the tubular member by a living hinge. Thus each flap can be bent outwardly away from the axis of the tubular member so that the needle head may be received within its annulus. At the free end of each of the flaps is a tab 36 having a substantially triangulated configuration such that it forms the sector of a circle. As best illustrated in FIG. 4 each of the tabs 36 has an arcuate surface 38 remote from the flaps so that when the flaps are bent equally toward the axis of the tubular member the arcuate surfaces 38 form a small circle, the radius of the circle being smaller than the radius of the needle head 16 such that the flaps can encapsulate the needle head with the tabs 36 engaging the planar surface of the needle head remote from the socket member 24. When so positioned about the connected catheter socket 24 and intravenous tubing insert 26 these members are prevented from separation by locking the flaps 34 against outward movement.
To lock the flaps once positioned about the needle head so that the tabs, which effectively act as jaws, retain the connection against axial movement the present invention proposes a lock ring 40 which is positioned about the tubular member intermediate the flaps and a plurality of annular manual gripping ribs 42 on the exterior of the tubular member at the intravenous tubing end. By providing a camming arrangement between the ring and the flaps the ring will force the flaps into locking engagement with the needle head. To this end the present invention proposes a protuberance 44 on the outer surface of each of the flaps, the protuberance of each flap being substantially equally spaced from the tabs so that the ring 40, which also is constructed of a plastic material, can be manually forced over the annular ridge provided by the totality of the protuberances and bend the flaps about the living hinges radially inwardly. Equivalent structure may be provided by providing a taper on the ring 40 or by flaring the flaps diametrically from the living hinge connection with the tubular member and the jaw end.
To use the clamping device the tubular member is placed about the insert end of the intravenous feeding while the flaps are in the open position and the ridges 37 are forced to bite into the bulbous portion of the intravenous tubing. The tube 30 is disposed about the needle head 16 and the plug-like insert 26 is inserted into the socket 24. The locking ring 40 is then pulled toward the catheter over the camming protuberances 44 forcing the jaws downwardly about the end of the head of the needle. The catheter assembly and the intravenous tubing are thusly secured and clamped together and substantially prevented from separation.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A clamp for preventing separation of a connected subclavian catheter and intravenous tubing has a tube-like member having internal ridges adjacent one end for gripping a resilient bulb portion of the tubing and has a series of radially moveable jaw members on the other end bendable inwardly to grasp the end of a needle head on the catheter. A lock ring positioned about the tube-like member is slideable into engagement with cam members on the jaw members to lock the latter position.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of and claims priority to U.S. patent application Ser. No. 10/925,355, filed Aug. 23, 2004 now U.S. Pat. No. 7,404,609 in the name of Andreas K. Nielsen, which is a divisional of and claims priority to U.S. patent application Ser. No. 10/198,204, filed Jul. 17, 2002 (now U.S. Pat. No. 6,796,622) also in the name of Andreas K. Nielsen, each of which are incorporated herein by reference.
FIELD OF THE INVENTION
Embodiments of the present invention relate to furniture such as an entertainment center.
BACKGROUND OF THE INVENTION
Component electronics for audiovisual applications conventionally include multiple, free-standing enclosures that receive power and signals from facility wiring and communicate with other components on wired cables or wireless links. Support for numerous components has conventionally been provided by furniture called an entertainment center. A conventional entertainment center may have open shelving and enclosed shelving for supporting and enclosing not only the components but also media used with the components. Such furniture also conventionally provides holes through the back and through the shelving for accommodating the signal cables and power cables associated with the components.
A conventional entertainment center is spaced away from a facility wall to allow cabling to be tucked behind the cabinetry of the entertainment center because provisions for cabling inside the cabinetry of the entertainment center are inadequate. The space between the entertainment center and the facility wall also supplies ventilation air for the components.
The conventional entertainment center provides movable shelving for accommodating consumer electronics assemblies of different vertical height; but, provides fixed horizontal dimensions designed for a maximum component width. Use of a conventional entertainment center is limited by the fixed horizontal width of its design. Users seeking, for example, to accommodate a larger home theater display (e.g., a big screen television set, a rear projection system, or a front illuminated screen) have little recourse but to purchase new furniture in the event the larger width display does not fit the fixed horizontal width provided by an existing entertainment center.
A large market exists for furniture to support consumer electronics. New products of various sizes are launched into this market annually. Without furniture capable of accommodating different horizontal widths, consumers may be reticent to purchase more expensive entertainment center furniture or may forego the acquisition of newer larger components. Consequently, without the present invention, both the consumer electronics and furniture industries face significant economic impairments to growth in sales.
SUMMARY OF THE INVENTION
A furniture system according to various aspects of the present invention includes an enclosure of a first space to be occupied by a home theater display wherein the enclosure, when placed against a facility wall provides a second space open to the top of the furniture system for ventilation of the home theater display.
When the enclosure includes shelving for consumer electronics assemblies, the shelving may be located between a first vertical side and a second vertical side. The first vertical side is adjacent to the display. The second vertical side has a depth greater than the depth of the first vertical side so that a portion of the second space is behind the shelving for ventilation of the consumer electronics assemblies.
Another furniture system according to various aspects of the present invention includes an enclosure of a space to be occupied by a home theater display and a base for transporting the display into and out from the space. The enclosure includes adjustable members that facilitate extending the enclosure to enclose the display at a width of a set of widths.
Another furniture system according to various aspects of the present invention includes an enclosure of a space to be occupied by a home theater display and a base for transporting the display into and out from the space. The base includes adjustable members that facilitate extending the base to support the display at a width of a set of widths.
Another furniture system according to various aspects of the present invention includes a pair of cabinets and a base for supporting a home theater display. The base includes wheels attached to a lower surface of the base to facilitate rolling the base between the cabinets. The base includes at least one section, mechanically coupled to the base that may be placed in one of a set of positions apart from a center of the base to give the base an apparent width that approximates a corresponding width of any of a set of home theater displays of various widths. The section includes a trim surface to block viewing of the wheels from the front of the entertainment furniture system when the section is placed in any position of the set.
The cabinets may include inner sides shorter in depth than outer sides, thereby forming a passage in the rear of the system for ventilation and cabling.
By including a multi-section base, the load weight of the display is efficiently coupled to the wheels for a variety of displays. By including trim pieces that overlap, the overall appearance of the base is improved. When the furniture system further includes a bridge, an overlapping aspect of the bridge relative to the cabinets is aesthetically similar to the overlapping appearance of the base for improved appearance of the furniture system as a whole.
A base, according to various aspects of the present invention, supports a home theater display and includes a stage and at least two sections. The stage and each section provide a respective front surface to block viewing of a space beneath the home theater display and to enhance the appearance of the base. The sections facilitate horizontal positioning relative to each other to establish a width of the base to approximate the width of any one of a set of home theater displays having differing respective widths. The base includes a plurality of wheels in the space that allow movement of the stage and display as a unit on a provided surface.
The stage and sections may be mechanically coupled by slides. Locks may be added to the slides to maintain the selected positioning.
According to various aspects of the present invention, a method is performed to mount a home theater display in a furniture system. The method includes, in any order: adjusting a horizontal width of a base for supporting the home theater display; placing a first cabinet against a facility wall; placing a second cabinet against the facility wall and spaced apart from the first cabinet a width sufficient for the base; and rolling the base between the first cabinet and the second cabinet. By supporting the display on a wheeled base and transporting the display on the base as a unit, access is facilitated to cabling for power and signals to the display. Cabling may be fully connected and routed prior to rolling the base between the cabinets.
BRIEF DESCRIPTION OF THE DRAWING
Embodiments of the present invention will now be further described with reference to the drawing, wherein like designations denote like elements, and:
FIG. 1 is a perspective view of a furniture system according to various aspects of the present invention wherein the doors of one of the cabinets are omitted for clarity of presentation;
FIG. 2 is a top view of the furniture system of FIG. 1 wherein the bridge and crown of one of the cabinets are omitted for clarity of presentation;
FIG. 3 is a perspective view of the underside of a base for use in the furniture system of FIG. 1 ; and
FIG. 4 is a top view of the bridge and a crown of the furniture system of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A furniture system according to various aspects of the present invention supports any of a variety of home theater displays of various widths. The furniture system generally encloses a space for locating the home theater display, the space being enclosed on several sides, for example, the left side, the right side, and the top. The furniture system may further enclose a portion of the rear of the space. Enclosing is typically for establishing, improving, or cooperating with the interior design of a room where the home theater display is to be used. The enclosure provides ventilation for the display according to various aspects of the present invention.
The display is supported on a base having wheels to transport the base and display as a unit separate from the enclosure portion of the furniture system. The furniture system is typically arranged to abut each vertical side of the home theater display and present to a front view a continuous series of trim surfaces that substantially hide the wheels from view. When the rear of the furniture system is placed against a facility wall, spaces defined by the enclosure accommodate wiring and ventilation and are easily accessible from the front of the furniture system. Conventional materials and techniques of furniture manufacture may be used in the design and construction of furniture systems of the present invention except as described below.
For example, furniture system 100 of FIGS. 1-4 includes cabinets 102 and 103 , back panel 101 , bridge 104 , and base 105 . Cabinets 102 (and 103 ) support component electronics and media (not shown). Each cabinet 102 ( 103 ) includes inner side 242 ( 244 ), outer side 250 ( 252 ), crown 132 ( 133 ), any number of suitable shelves 121 and 123 , and a cabinet back 246 ( 248 ) having holes 122 and 124 through which power and signal cables may be routed. Because outer side 250 ( 252 ) extends further to the rear than inner side 242 ( 244 ), cabinet 102 ( 103 ) defines a space 216 ( 218 ) for cabling and ventilation.
A back panel of the furniture system enhances the finished appearance and is retained in a vertical position while cabinets 102 and 103 are moved to establish a suitable width 110 for base 105 . For example, back panel 101 is mounted to allow cabinets 102 and 103 to be repositioned without access to the rear of the furniture system to effect a change in mounting of back panel 101 . Back panel 101 in one implementation rests on a hook 262 ( 264 ) on each cabinet 102 ( 103 ) and slides in groove 414 of bridge 104 . When cabinets 102 and 103 are positioned closer together or farther apart, back panel 101 slides on hooks 262 and 264 and is maintained in a vertical position by groove 414 . Back panel 101 does not obstruct cable passage holes (e.g., 122 and 124 ) or significantly block ventilation holes in cabinet backs 246 and 248 when cabinets 102 and 103 are positioned for a minimum width 110 . Back panel 101 includes stiffeners 210 , 212 , and 214 to reduce warping.
A bridge provides a visual connection between cabinets, usually at the top of a furniture system, by spanning the width between cabinets. While cabinets are moved to establish a suitable width, the bridge cooperates with the cabinets and the back panel to maintain its position on top of the cabinets. The horizontal position of the bridge can be adjusted (e.g., to center the bridge between the cabinets) without access to the top or rear of the furniture system. A bridge may be supported on the front of crowns of two cabinets and may also be supported via a back panel and hooks on which the back panel is supported. A bridge may have a depth when installed that is substantially equal to the depth of the inner sides of cabinets on which it rests.
For example, bridge 104 rests on the top of cabinet 102 and rests on the top of cabinet 103 . Bridge 104 nests with back panel 101 in groove 414 to prevent movement of bridge 104 toward the front of furniture system 100 . Preferably, back panel 101 bears no weight of bridge 104 so that back panel 101 slides easily when cabinets are moved. Bridge 104 nests with crowns 132 and 133 via slots 406 and 408 to prevent movement of bridge 104 toward the front or toward the rear of furniture system 100 . A front surface 422 of crown 132 (and a symmetric surface of crown 133 (not shown)) is overlapped by a portion 402 of bridge 104 . When surface 422 includes raised or recessed features, corresponding recesses or raised features may be added to surface 424 to provide an integral appearance when surfaces 422 and 424 are pressed against each other. When supported by cabinets 102 and 103 , bridge 104 covers a space 106 between cabinets 102 and 103 . Bridge 104 may include conventional lighting to illuminate space 106 . In one implementation, bridge 104 is not fastened to either cabinet 102 or 103 but slides on the crown portion 132 and 133 of each cabinet so that bridge 104 is aligned easily over the center of space 106 and flush against crowns 132 and 133 . Bridge 104 may further include U-shaped slots for avoiding interference between body 404 of bridge 104 and lighting in crowns 132 and 133 (e.g., installed in apertures 135 and 137 ).
A crown provides an aesthetically pleasing top to a cabinet and provides support for lighting and a bridge. A crown cooperates with a bridge according to various aspects of the present invention to support the bridge while the cabinet is being moved toward or away from the other cabinet on which the bridge is supported. For example, crowns 132 and 133 cooperate with bridge 104 as discussed above. Further, crowns cooperate with a bridge of the present invention to provide an aperture 430 for convection cooling of the home theater display and any entertainment equipment components located within cabinets 102 and 103 . Aperture 430 includes a portion 216 rear of cabinet back 246 , a portion 218 rear of cabinet back 248 , and a portion 430 above base 105 . Rear panels, crowns, and/or a bridge of furniture system 100 may include any conventional grills, hole patterns, slots, or voids to facilitate cooling.
A base, according to various aspects of the present invention provides an adjustable width so as to support one of various width home theater displays and provides a concealed mechanism for moving the base in and out of position between cabinets of the furniture system. Such a base includes sections mechanically coupled to each other and capable of being positioned with respect to each other to provide a base having one of various overall widths. Any mechanical coupling technique may be used to provide discrete or continuously variable positions. Concealment of wheels may be accomplished by expandable trim surfaces, where expansion is accomplished by overlapping, telescoping, deploying, or stretching trim surfaces. A deployed trim surface may be stored as rolled stock in the base. Stretching may include elastic, pleated, or accordioned material. For example, base 105 of FIGS. 1-4 includes stage 113 , section 112 attached to stage 113 by integral slides, and section 114 attached to stage 113 by integral slides. The stage provides wheels for movement of the base; and the sections and the stage provide cooperative overlapping trim surfaces to conceal the wheels. A trim surface of each section overlaps a portion of the nearest cabinet that abuts the base.
A stage provides support for at least one section and provides transportation for an object placed on the stage or on the section. For example, stage 113 includes platform 111 , casters 302 - 305 , studs 311 - 314 , and trim piece 108 . Section 112 ( 114 ) includes platform 322 ( 323 ), side 306 ( 308 ), and trim piece 107 ( 109 ). Platform 322 ( 323 ) includes a pair of slots 326 ( 327 ) and 328 ( 329 ) for attaching the section to the stage. The underside of section platforms 322 and 323 bears on the an upper side of stage platform 111 . Studs 311 - 314 pass through slots 326 - 329 to accept a stud termination (e.g., a fender washer and nut). Each slot, stud, and termination cooperate to form a slide for mechanically coupling a section to the stage. By loosening stud terminations, each section 112 and 114 may be moved along its respective slides (e.g., along axis 110 ) toward and away from the center of platform 111 . By moving each section a proportional distance from the center of platform 111 , base 113 is extended to any width (W) 110 within the range of the slides. After moving the sections, any suitable lock (e.g., a locking mechanism) may be employed to secure the position, fix the overall width of stage 113 , and more efficiently transfer load borne by base 105 to casters 302 - 305 . For example, stud terminations may be tightened to draw and bind the stage and section together.
Casters 302 - 305 are fixed to an underside surface of platform 111 and provide load bearing support. Each caster pivots around a vertical axis. Each caster provides a wheel that rotates on a horizontal axis. Any conventional caster may be used. A home theater display placed onto base 113 may rest in part against an upper surface of platform 111 and/or on an upper surface of section platforms 322 and 323 . Weight of the display is communicated via slides to stage 113 and through casters 302 - 305 to the facility surface on which furniture system 100 is placed. In operation, casters 302 - 305 facilitate movement of stage 113 (and a display placed on stage 113 ) along an axis of width 110 so to align stage 113 between cabinets 102 and 103 , and along an axis of depth 120 so to move stage 113 into space 106 . A home theater display atop stage 113 may completely fill the width 110 and depth 120 of space 106 .
The space directly below stage platform 111 is substantially hidden from view by the cooperation of trim pieces 107 - 109 . Trim piece 107 ( 109 ) extends away from the center of platform 111 and beyond the extremity of platform 322 ( 323 ) to overlap a portion of cabinet 102 ( 103 ) and consequently to cover any portion of space 106 that might remain between base 113 and cabinet 102 ( 103 ). Trim piece 107 ( 109 ) also extends toward the center of platform 111 to overlap a portion of trim piece 108 . When section 112 ( 113 ) is slid toward or away from stage 111 , trim piece 107 ( 109 ) slides in front of trim piece 108 to continue to perform the hiding function.
Each section 112 and 114 may further include a railing on one or more edges of the section to reduce the risk that an object placed on the base will unexpectedly slide off the base. For example, section 112 ( 114 ) may further include side 306 ( 308 ) that extends above platform 322 ( 323 ) to form a lip 202 ( 206 ). Railings may be added to the upper surfaces of any platform 111 , 322 , and/or 323 . For example, railing 204 ( 208 ) is added on the top rear edge of platform 322 ( 323 ).
Movement of base 105 is facilitated in any conventional manner. According to various aspects of the present invention, base 105 provides at least one handle or hand-hold to move base 105 . For example, trim piece 108 extends downward yet leaves space for a user to place his or her hand or hands under trim piece 108 and pull on trim piece 108 to move base 105 on depth axis 120 out from between cabinets 102 and 103 . In an alternate implementation, platform 111 is formed with a hand access hole through platform 111 to facilitate pulling base 105 on depth axis 120 out from between cabinets 102 and 103 .
Assembly of an entertainment system with an entertainment furniture system as discussed above may proceed according to a method performed in any order as follows. Measure the width of the home theater display to be positioned in space 106 . Determine whether it is desired to abut both cabinets 102 and 103 to the sides of the home theater display, and if not add a suitable amount to the width. Assemble sections 112 and 114 to stage 113 . Before tightening stud terminations, extend each section 112 and 114 symmetrically from the center of stage 113 an amount equal to about half the desired width, then lock the sections to the stage (e.g., by tightening the stud terminations). Place back panel 101 against a facility wall. Place cabinet 102 within a few inches of the facility wall as desired, allowing for access to cable TV, power, telephone, Internet, and other facility wiring connections for use by the entertainment system. Place cabinet 103 roughly the desired width from cabinet 102 . Lift back panel 101 onto hooks 162 and 164 . Place bridge 104 on top of the crown portions of cabinets 102 and 103 , centering bridge 104 over space 106 , and fitting bridge 104 onto back panel 101 for maintaining back panel 101 in a vertical position. Move cabinets 102 and/or 103 to obtain the desired width of space 106 . While cabinets 102 and 103 are being moved apart (or together), back panel 101 is confined to slide on axis 120 while being maintained in a vertical position; and, bridge 104 is confined to slide only on axis 120 while being maintained square to the top of cabinets 102 and 103 . If cabinet lighting is provided in bridge 104 or crown portions of cabinets 102 and 103 , connect power wiring. Place a home theater display on base 105 and transport the base and display as a unit to a position in front of space 106 . Place all other entertainment system components (e.g., tuner, amplifier, audio media player, speakers) in cabinets 102 and 103 . Route all cables and wiring from the display to the components. Reach around cabinet inner side 242 ( 244 ) to access cables passing through holes 122 and 124 (and suitable holes in cabinet back 248 (not shown)). Transport the base and display as a unit into space 106 until the trim pieces 107 and 109 meet and overlap a portion of the front trim pieces 142 and 144 of cabinets 102 and 103 .
Another furniture system according to various aspects of the present invention may include a base as discussed above and an enclosure. The enclosure may include: (a) shelving to one side of a space to be occupied by the base; and (b) a vertical panel on the opposite side of the space. The enclosure may include a bridge and/or a back panel that spans the top and/or rear sides of the space. For example, such a furniture system may include all of the structures discussed above with reference to system 100 , except that: (a) cabinet 102 is replaced by a panel similar to side 250 (e.g., omitting crown, doors, drawer, shelves, as well as front, inside, and rear structures) and supported by being attached to either a back panel similar to 101 and/or to a bridge similar to 104 ; and (b) bridge 104 is replaced with a bridge modified to attach to or cooperate with side 250 (e.g., omitting all of the structure associated with resting on top of and cooperating with a full size cabinet 102 ). The structures and cooperation of the bridge and cabinet 103 would be included in this alternate furniture system. The asymmetric implementation discussed here (cabinet to the right of display) may be implemented as a mirror image (cabinet on left of display) in an alternate implementation.
In alternative implementations of the furniture systems discussed above, cabinet doors and drawers are partially or entirely omitted. In still further alternate implementations, any arrangement of shelving, doors, and/or drawers may be located between sides 244 and 252 (and/or sides 250 and 242 if implemented).
Another alternate furniture system according to various aspects of the present invention includes merely a base as discussed above (cabinets 102 and 103 , bridge 104 , and back panel 101 are omitted).
The foregoing description discusses preferred embodiments of the present invention which may be changed or modified without departing from the scope of the present invention as defined in the claims. While for the sake of clarity of description, several specific embodiments of the invention have been described, the scope of the invention is intended to be measured by the claims as set forth below.
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An entertainment center includes a base that expands horizontally to accommodate different width home theater displays; and, a light bridge that rests on top of one or more cabinets placed on either side of the base. The side cabinets provide a vertical column of open space for accommodating wiring among the entertainment system components and ventilation for heat generated by those components. The base includes casters to facilitate moving the base in and out from between the side cabinets. Sliding portions of the base extend horizontally yet continue to transfer all load weight onto the casters. The front woodwork of the base presents a pleasing seamless appearance as a consequence of overlapping trim pieces.
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BACKGROUND
[0001] The present invention relates to a method to mitigate and reduce the volatile compound emissions (Volatile Organic Compounds (VOC) and other volatile compounds) of a Steam Methane Reformer (SMR) plant by routing the contaminated streams to the furnace and by using the heat of the furnace to destroy the organic compounds. Steam Methane Reformers are used to produce Synthesis Gas (syngas) from Methane and Steam and can be adjusted to produce pure hydrogen, methanol or other products. These endothermic reactions occur at high pressure and temperature releasing a lot of heat. Part of this heat is used to produce steam required by the process in one or more boilers.
[0002] To produce steam, the boiler will need high quality water which is usually mixed with condensates from the process and sent to a deaerator to remove oxygen, dissolved CO2 and other impurities. The process condensates will sometimes contain volatile organic and volatile inorganic compounds coming from the plant process, which might have been absorbed by the water during condensing. Typically those volatile compounds such as, but not limited to, methanol or ammonia would be stripped from the water and vented to the atmosphere by the deaerator. Other vent streams containing volatile compounds (e.g. vent stream from boiler blowdown drum, process condensate stripper) can be treated similarly.
[0003] In order to protect our environment, more and more states and countries have new legislation limiting and reducing atmospheric rejects by industrial plants. The first regulations were focusing on sulfuric acid or nitric oxides but today regulations are now implemented on volatile compound emissions (VOC & Other). The proposed invention describes how the heat from the furnace of an SMR could be used to destroy those pollutants and reduce the environmental impact of the plant.
SUMMARY
[0004] The present invention is a method for Volatile Compound (VC, which includes VOC and other volatile compounds) mitigation in a syngas production process. This method includes providing a hydrocarbon reforming syngas production plant, this plant includes a reformer system comprising a primary fuel and oxidant stream, where part of this system is at low pressure, a steam inlet stream, and a primary combustion system for providing heat to said reformer system and producing a reformer flue gas stream, and a gaseous vent stream mainly composed of water and containing VC. This method also includes introducing at least a portion of said vent stream into one or more of the following: said primary fuel or oxidant stream; said steam inlet stream; said reformer box; said reformer flue gas stream.
BRIEF DESCRIPTION OF THE FIGURES
[0005] FIG. 1 is a schematic representation of one embodiment of the present invention, indicating the VC containing stream being injected into the convective section of the heat recovery device.
[0006] FIG. 2 is a schematic representation of one embodiment of the present invention, indicating the VC containing stream being injected into the radiant section of the reformer unit.
[0007] FIG. 3 is a schematic representation of one embodiment of the present invention, indicating the VC containing stream is combined with an ambient air stream, introduced into convection section where it is preheated, then combined with a fuel stream, and then introduced into the reformer through burners, where it is combusted.
[0008] FIG. 4 is a schematic representation indicating a vertical VC containing stream injection manifold, in accordance with one embodiment of the present invention.
[0009] FIG. 5 is a schematic representation indicating a horizontal VC containing stream injection manifold, in accordance with one embodiment of the present invention.
[0010] FIG. 6 is a schematic representation indicating the blow down from the heat recovery device, in accordance with one embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0011] The invention provides a number of technical solutions for using the heat of the reformer to destroy the volatile compounds (VC), which can be implemented in order to destroy the volatile compounds without a dedicated thermal or catalytic oxidizer.
[0012] As defined in this document, volatile compounds (VC), includes, but is not limited to, regulated volatile organic compounds, and other volatile compounds both organic and inorganic. This also includes, but is not limited to, ammonia and amines.
[0013] One solution is to route the VC-containing stream, composed mostly of water and VC, to the convection section (also called waste heat recovery section) of the plant. In order to ensure the full destruction of the VC, the higher the flue gas temperature at the injection point, the better. A preferred embodiment of this solution would be to inject the contaminated stream into the flue gas duct between the exit of the furnace and the first coil of the waste heat recovery section. In order to ensure high destruction efficiency the flue gas temperature should be above 750° C. and preferably above 850° C. The injection system could be designed with an injection grid located horizontally or vertically, co-current or counter current of the flue gas flow. The preferred solution would be to have a counter flow injection to minimize the impact on the downstream coils in the waste heat section. Additionally the invention could include the mixing of the vent with steam to avoid any condensation in the lines prior to and at the injection point.
[0014] In another embodiment of the solution, the contaminated stream would be injected in the bottom of the furnace in one or more places in the flue gas tunnels. Temperature at the injection point should be in the range of 1000° C. to 1060° C. In order to ensure the full destruction of the VC, beside the high temperature a sufficient residence time is important. The preferred distance to allow the maximum destruction of the VC would be ⅔ rd of the furnace length away from the flue gas exit. This would provide enough residence time to ensure destruction efficiency over 99%. The injection point should be carefully designed to avoid any impact on the refractory bricks of the flue gas tunnel and should ensure no liquid carry-over into the firebox.
[0015] In another embodiment, the contaminated stream may be injected on one or several side of the furnace at one or several locations. In the preferred solution the vent would be injected low enough not to disturb the burners flames but high enough to allow enough residency in the box and destruction of the VC. Tube protections would have to be engineered to avoid spraying the vent directly on the tubes and therefore cooling down the tubes, reducing the efficiency of the process reactions and leading to potential tube damage due to the water.
[0016] In another embodiment, the contaminated stream could be injected from the top of the furnace either in the fuel system of the burners or in a separate injection point. If injected in the fuel system a protection system would have to be put in place to ensure that no liquid water is sent to the burners.
[0017] The invention provides a number of technical solutions that could be implemented in order to destroy the volatile compounds without a dedicated thermal or catalytic oxidizer.
[0018] Turning now to FIG. 1 , hydrocarbon reforming syngas production plant 100 is presented. Reformer feed stream 101 and steam stream (steam inlet stream) 103 are introduced into the catalyst tubes of reformer unit 104 . Reformer unit 104 may be a Steam Methane Reformer (SMR) or an Autothermal Reformer (ATR). Hydrocarbon fuel (primary fuel) and oxidant stream 102 is introduced into the primary combustion system 114 in the shell side of reformer 104 , where they are combusted thereby providing the temperature and heat required for the reforming process. The products of this combustion exit the shell side of reformer 104 as SMR flue gas stream 106 .
[0019] Reformer feed stream 101 and steam stream (steam inlet stream) 103 are converted into syngas stream 105 , which exits reformer 104 and proceeds to downstream cleanup, cooling and utilization (not shown). The SMR flue gas stream 106 then enters heat recovery device 107 , where it indirectly exchanges heat with boiler feed water stream 112 , thereby producing steam stream 103 , and with the SMR flue gas stream exiting as cool flue gas stream 110 . The two major sections of system 100 comprise a radiant section 108 , and a convection section 109 , with the convection section primarily comprised of heat exchange tubes.
[0020] Most of the dissolved oxygen, as well as other non-condensable gases, in boiler feed water stream 112 are removed in deaerator 111 . The dissolved oxygen stream also contains volatile compounds (VC) which exit deaerator 111 in VC containing stream (gaseous vent stream) 113 . In one embodiment, VC containing stream 113 is introduced into convective section 109 of heat recovery section 107 . The idea would be to introduce the VCs into a section of the system wherein the pressure is relatively low and wherein the temperature and residence time are sufficiently high to destroy the VCs. By relatively low, it is understood that the pressure should be less than 2 bar, preferably less than 1.5 bar and could even be below atmospheric pressure.
[0021] Turning now to FIG. 2 , hydrocarbon reforming syngas production plant 200 is presented. Reformer feed stream 201 and steam stream (steam inlet stream) 203 are introduced into the catalyst tubes of reformer unit 204 . Reformer unit 204 may be a Steam Methane Reformer (SMR) or an Autothermal Reformer (ATR). Hydrocarbon (primary fuel) fuel and oxidant stream 202 is introduced into the primary combustion system 214 in the shell side of reformer 204 , where they are combusted thereby providing the temperature and heat required for the reforming process. The products of this combustion exit the shell side of reformer 204 as SMR flue gas stream 206 .
[0022] Reformer feed stream 201 and steam stream (steam inlet stream) 203 are converted into syngas stream 205 , which exits reformer 204 and proceeds to downstream cleanup, cooling and utilization. The SMR flue gas stream 206 then enters heat recovery device 207 , where it indirectly exchanges heat with boiler feed water stream 212 , thereby producing steam stream 203 , and with the SMR flue gas stream exiting as cool flue gas stream 210 . The two major sections of system 200 comprise a radiant section 208 , and a convection section 209 , with the convection section primarily comprised of heat exchange tubes.
[0023] Most of the dissolved oxygen, as well as other non-condensable gases, in boiler feed water stream 212 are removed in deaerator 211 . The dissolved oxygen stream also contains volatile compounds (VC) which exit deaerator 211 in VC containing stream 213 . In one embodiment, VC containing stream 213 is introduced into the radiant section of reformer unit 204 . The idea would be to introduce the VCs into a section of the system wherein the pressure is relatively low and wherein the temperature and residence time are sufficiently high to destroy the VCs. By relatively low, it is understood that the pressure should be less than 2 bar, preferably less than 1.5 bar and could even be below atmospheric pressure.
[0024] Turning now to FIG. 3 , hydrocarbon reforming syngas production plant 300 is presented. Reformer feed stream 301 and steam stream (steam inlet stream) 303 are introduced into the catalyst tubes of reformer unit 304 . Reformer unit 304 may be a Steam Methane Reformer (SMR) or an Autothermal Reformer (ATR).
[0025] Reformer feed stream 301 and steam stream (steam inlet stream) 303 are converted into syngas stream 305 , which exits reformer 304 and proceeds to downstream cleanup, cooling and utilization. The SMR flue gas stream 306 then enters heat recovery device 307 . The two major sections of system 300 comprise a radiant section 308 , and a convection section 309 , with the convection section primarily comprised of heat exchange tubes. Within heat recovery device 307 , the combined stream indirectly exchanges heat the above combined ambient air stream 302 A and VC containing stream 313 , and with boiler feed water stream 312 , thereby producing steam stream 303 , and with the SMR flue gas stream exiting as cool flue gas stream 310 .
[0026] Most of the dissolved oxygen, as well as other non-condensable gases, in boiler feed water stream 312 are removed in deaerator 311 . The dissolved oxygen stream also contains volatile compounds (VC) which exit deaerator 311 in VC containing stream 313 . A deaerator will typically operate at between 0.4 bar and 0.7 bar, so stream 313 will be at an equivalent low pressure. VC containing stream 313 is combined with ambient air stream 302 A, and the combined stream is introduced into radiant section 308 . In radiant section 308 , the combined stream is in indirect heat exchange with hot flue gas stream 306 , thereby producing preheated oxidant stream 302 A. Preheated oxidant stream 302 A is combined with fuel stream 302 C, which are then introduced into the shell side of reformer 304 , where they are combusted thereby providing the temperature and heat required for the reforming process. The products of this combustion exit the shell side of reformer 304 as SMR flue gas stream 306 .
[0027] The idea would be to introduce the VCs into a section of the system wherein the pressure is relatively low and wherein the temperature and residence time are sufficiently high to destroy the VCs. By relatively low, it is understood that the pressure should be less than 2 bar, preferably less than 1.5 bar and could even be below atmospheric pressure.
[0028] FIGS. 4 and 5 are illustrative embodiments of two possible ways in which VC containing stream 113 may be introduced into convective section 109 of heat recovery section 107 . FIG. 4 illustrates a vertical injection manifold, and FIG. 5 illustrates a horizontal injection manifold. Additional embodiments are envisioned, and are within the ability of one of ordinary skill in the art to develop and implement without undue experimentation.
[0029] As indicated in FIG. 4 , VC containing stream 113 is introduced into convective section 109 in a vertical injection manifold. This vertical manifold may have forward facing injection ports (A) or rearward facing injection ports (B). These ports may inject VC containing stream 113 at a positive or negative angle to the horizontal, as required for optimum distribution and mixing in SMR flue gas stream 106 .
[0030] VC containing stream 113 may be injected on one or several sides of convective section 109 , at one or several locations. Special care should be taken to protect heat exchangers close to the injection ports to avoid spraying the vent directly on the exchanger tubes and therefore cooling down the tubes, reducing the efficiency and leading to potential tube damage due to the water.
[0031] As indicated in FIG. 5 , VC containing stream 113 is introduced into convective section 109 in a horizontal injection manifold. This horizontal manifold may have forward facing injection ports (A) or rearward facing injection ports (B). These ports may inject VC containing stream 113 at a positive or negative angle to the vertical as required for optimum distribution and mixing in SMR flue gas stream 106 . Special care should be taken to protect heat exchangers close to the injection ports to avoid spraying the vent directly on the exchanger tubes and therefore cooling down the tubes, reducing the efficiency and leading to potential tube damage due to the water.
[0032] VC containing stream 113 may be injected from near the top of convective section 109 , or at any point above the horizontal midpoint of convective section 109 .
[0033] Turning now to FIG. 6 , hydrocarbon reforming syngas production plant 600 is presented. Reformer feed stream 601 and steam stream (steam inlet stream) 603 are introduced into the catalyst tubes of reformer unit 604 . Reformer unit 604 may be a Steam Methane Reformer (SMR) or an Autothermal Reformer (ATR). Hydrocarbon (primary fuel) fuel and oxidant stream 602 is introduced into the primary combustion system 614 in the shell side of reformer 604 , where they are combusted thereby providing the temperature and heat required for the reforming process. The products of this combustion exit the shell side of reformer 604 as SMR flue gas stream 606 .
[0034] Reformer feed stream 601 and steam stream (steam inlet stream) 603 are converted into syngas stream 605 , which exits reformer 604 and proceeds to downstream cleanup, cooling and utilization. The SMR flue gas stream 606 then enters heat recovery device 607 , where it indirectly exchanges heat with boiler feed water stream 612 , thereby producing steam stream 603 , and with the SMR flue gas stream exiting as cool flue gas stream 610 . The two major sections of system 600 comprise a radiant section 608 , and a convection section 609 , with the convection section primarily comprised of heat exchange tubes.
[0035] Most of the dissolved oxygen, as well as other non-condensable gases, in boiler feed water stream 612 are removed in deaerator 611 . The dissolved oxygen stream also contains volatile compounds (VC) which exit deaerator 611 in VC containing stream 613 . In one embodiment, the blow down stream 614 from heat recovery device 607 is introduced into a phase separation device 615 , where it is separated into a high solids content waste stream 616 and a vapor stream 617 which may contain VCs. Vapor stream 617 may then be introduced into deaerator 611 , after which VC containing stream 613 is introduced into either the radiant section 608 or the convective section 609 of reformer unit 604 . In one embodiment, VC containing stream 613 is introduced into both the radiant section 608 and the convective section 609 of reformer unit 604 . Vapor stream 617 may then be introduced directly into either the radiant section 608 or the convective section 609 of reformer unit 604 . In one embodiment, vapor stream 617 is introduced into both the radiant section 608 and the convective section 609 of reformer unit 604 .
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A method for volatile compound (VC) mitigation in a syngas production process is provided. This method includes providing a hydrocarbon reforming syngas production plant, this plant includes a reformer system comprising a primary fuel and oxidant stream, where part of this system is at low pressure, a steam inlet stream, and a primary combustion system for providing heat to the reformer system and producing a reformer flue gas stream, and a gaseous vent stream mainly composed of water and containing VC. This method also includes introducing at least a portion of the vent stream into one or more of the following: the primary fuel and oxidant stream; the steam inlet stream; the reformer flue gas stream.
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BACKGROUND OF THE INVENTION
It is well known that many substances, whether gaseous, liquid or solid, tend to expand when heated. Although there are exceptions, most gases and liquids (under constant pressure) tend to expand when heated. Most metals also tend to expand when heated. This tendency of liquids and gases to expand when heated is utilized in producing power from heat. One common example is the steam engine. Also, it has been proposed to produce power from differentials in temperature by the tendency of some solids to increase in size when heated or cooled. The invention disclosed and claimed herein relates to power produced by the application of differentials in temperature to metal belts.
This invention relates to the art of heat engines and particularly to one of a type utilizing thermal expansion and contraction of metal belts to effectuate its actuation.
It is an object of this invention to provide a relatively simple heat engine which has a minimum of moving parts and which operates directly upon the application of heat to portions of one or more continuous metal belts so that such portions of each belt lengthen due to thermal expansion; while other portions of each belt are cooled to cause such portions to shorten due to thermal contraction. The belt or belts are passed around pulleys which are caused to be rotated by the action of the belts as different portions of such belts lengthen and shorten.
It is another object of the invention to provide an improved heat engine of the type mentioned whereby only a temperature differential is required without requiring a high combustion temperature as in a gasoline or other fuel type engine, although devices of my invention are also operative with such high temperatures.
It is another object to provide such a heat engine wherein each continuous belt which is lengthened and shortened in different portions by thermal means is wrapped around a pair of oppositely positioned pulleys of different diameters, one pulley being of slightly smaller diameter than the other. The pulley shaft of each pulley is connected to a pulley shaft of the pulley of another pair to assure the same angular velocity of the pulleys, although the linear velocities of the belts change throughout their lengths due to their lengthening and shortening.
Other objects and advantages of the invention should become apparatus upon reference to this description and claims and to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a simplified representation of features of an engine to illustrate the principles of operation of my engine;
FIG. 2 shows another diagrammatic representation of the engine illustrating especially the piping by which heat and cooling is directed to various segments of the engine;
FIG. 3 shows in detail a side elevation of a complete heat engine embodying the invention;
FIG. 4 shows a top plan view of the heat engine of FIG. 3;
FIG. 5 shows an enlarged sectional view of a portion of the engine of FIGS. 3 and 4 as viewed along the line 5--5 of FIG. 4;
FIG. 6 shows an enlarged sectional view of a portion of the engine of FIGS. 4 and 5 as viewed along the line 6--6 of FIG. 4;
FIG. 7 shows a simplified perspective representation of an alternative construction of the engine;
FIG. 8 shows a fragmentary sectional view of a portion of an alternative construction of the engine;
FIG. 9 illustrates another embodiment of my invention;
FIG. 10 shows a fragmentary portion of the structure of FIG. 9 on an enlarged scale; and
FIG. 11 illustrates the resolution of forces acting on the belt at the upper and lower parts of FIG. 10.
DESCRIPTION OF SIMPLIFIED REPRESENTATIONS
As shown in FIG. 1, there are provided two metal belts 1 and 2 and five pulleys 3, 4, 5, 6 and 7. Shafts 8 and 9 are provided. Pulleys 3, 5, and 7 are mounted on shaft 9 and are keyed thereto so that the pulleys 3, 5 and 7 and the shaft 9 rotate as a unit. Pulleys 4 and 6 are mounted on and keyed to shaft 8 so that the pulleys 4 and 6 and shaft 8 rotate as a unit. Pulleys 3 and 6 are larger than pulleys 4 and 5. Pulley 3 preferably but not necessarily has a diameter equal to the diameter of pulley 6. Pulley 4 preferably but not necessarily has a diameter equal to the diameter of pulley 5. Metal belt 1 follows a continuous path around pulleys 3 and 4. Metal belt 2 follows a continuous path around pulleys 5 and 6. Pulley 7 on the end of shaft 9 provides means of taking power off from the engine. This pulley is used as a driving pulley for some externally driven device requiring a motor driven away from pulley 3.
The rotation of the pulleys is accomplished by heating and cooling of selected portions of the belts 1 and 2. Belt 1 causes rotation of pulleys 3 and 4 as heat is applied to region 1a and extracted from region 1b of the belt. Movement of the belt is in the direction of the arrow 30. Belt 2 causes rotation of the pulleys 5 and 6 as heat is applied to region 2a and extracted from region 2b. Its direction of movement is in the direction of arrow 31 which is the same direction of movement as for belt 1. The rotation of the pulleys 3 and 5 causes shaft 9 and the pulley 7 to be rotated to thereby transmit motion to an external object required to be driven.
As will be explained later, the force acting on shaft 9 through pulley 3 as a result of the fact that the force of the contraction of segment 1b of belt 1 is greater than the force acting on shaft 9 through the segment 1a. The segment 1a is expanded due to heat thus reducing the tension in segment 1a on shaft 9. Also, the force acting on pulley 5 as a result of the contraction of segment 2b is greater than the force acting on pulley 5 through the segment 2a because the tension of segment of 2a is reduced by its expansion due to heat applied thereto. However, the force acting on shaft 9 through pulley 5 is less than the force acting on pulley 3 because of the shorter radius of pulley 5. This causes pulleys 3 and 5 and axle 9 to turn counter clockwise as viewed in FIG. 1.
The expansion of segment 1a and contraction of segment 1b also exerts force to tend to turn pulley 4 clockwise. The expansion of segment 2a and contraction of segment 2b exerts force to tend to turn pulley 6 counter clockwise. However, because of the greater diameter of pulley 6, the net effect is to turn pulley 4 and pulley 6 and shaft 8 counter clockwise.
In FIG. 2 there is illustrated the piping used in heating segments 1a and 2a and used in cooling segments 1b and 2b. A heater 24 delivers heated fluid through pipes 26 and 26a to segment 2a and delivers heated fluid through pipes 26 and 26b to segment 1a. A cooler 25 delivers cooled fluid through pipes 28 and 28a to segment 2b and through pipes 28 and 28b to segment 1b. Heating fluid may be recirculated back to the heater through pipes 27a, 27b and 27 and cooling fluid recirculated back to the cooler through pipes 29a, 29b and 29 although if desired such spent fluid may be exhausted to the atmosphere.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The belts 1, 2, the pulleys 3, 4, 5, 6 and 7, and the shafts 8 and 9 are shown at least diagrammatically in FIG. 1. However, some of these elements are not shown in the drawings of FIGS. 3 and 4 which show the actual structure as it appears with the belts hidden by the housings 10 and 11. In FIGS. 2, 3 and 4 the belts 1 and 2 are hidden by being enclosed within the housings 11 and 10 respectively. The pulleys 3, 4, 5 and 6 are also hidden in these Figures by the housings 10 and 11. The shafts 8 and 9 and the pulley 7 are indicated in FIGS. 3 and 4. The belts 1 and 2 and the pulleys 3 and 5 as well as pulley 7 are shown in FIG. 6.
Both of the housings 10 and 11 (FIG. 4) are secured on their right ends, as viewed in FIG. 3, by means of brackets 12 in a stationary position to the floor or other support 13 by means of suitable fasteners 14. The left ends of these housings 10 and 11 are provided with other brackets 15. The brackets 15 are secured to the housings 10 and 11 by suitable means such as the fasteners 16 shown in FIG. 5. These brackets 15 are positioned on the support 13 without being fastened thereto so that they are free to shift and slide longitudinally with the housings 10 and 11.
Each of the housings 10 and 11 is divided into two parts. The housing 10 is provided with a left portion 10a and a right portion 10b while housing 11 is provided with a left portion 11a and a right portion 11b. Considering housing 11, for example, its left portion 11a is sufficiently large to encircle the pulley 3 and extend beyond the pulley 3 with two hollow tubular arms 11c and 11d. Arm 11c is longer than arm 11d. Arm 11c extends to an expandable tubular bellows 11e which connects the arms 11c to the short arm 11f of the right housing portion 11b. The short tubular arm 11d of the left housing portion 11a is connected at its end to another flexible expandable tubular bellows 11g which connects to a long tubular arm 11h of the right housing portion 11b. The two bellows 11e and 11g allow relative movement between the left and right portions 11a and 11b of the housing 11 twoard and away from each other.
In addition, the arm 11h is provided (See FIGS. 3 and 5) with an upwardly extending arm 17 having a circular hole in it through which a rod 18 freely passes. The rod 18 supports a coiled compression spring 19 which reacts between the arm 17 and the left housing portion 11a to urge the two housing portions 11a and 11b away from each other. Another downwardly projecting arm 20 (FIG. 3) extends from the tubular arm 11c and this slidably supports, in a similar manner, another rod 21 which carries another coiled compression spring 22 which reacts between the arm 20 and the right housing portion 11b to likewise urge the housing portions 11a and 11b away from each other. The reason for the two sets of arms and compression springs 19 and 22 is to provide symmetry and minimize any binding condition which might otherwise arise by the transom-latch action.
It is apparent that the belt 1 is housed to pass through the tubular arms 11c, 11f, 11d and 11h in its path around the two pulleys 3 and 4. In this manner, the housing 11 completely encircles the belt 1 and the two pulleys 3 and 4.
In a similar manner, the housing 10 is provided with identical structure to that of housing 11. It has four tubular arms corresponding to arms 11c, 11f, 11d and 11h, the two arms; 10c, and 10f being shown in FIG. 4. It also has corresponding bellows 10e and 10g and springs and related members such as springs 19 and 22. Their functions are all identical. In this same manner, this housing 10 completely houses the pulleys 5 and 6 and the belt 2 in its path around the pulleys.
As shown particularly in FIG. 5, the tubular arm 11d is provided with a restricted opening 23 in the region of the bellows 11g. The arm 11d is also telescoped into the arm 11h so that each arm acts as a longitudinal guide for the other. Likewise, although not shown, the structure in the region of the other three bellows 11e, 10g and 10e is identical. The arms telescope within each other and are provided with restricted passages such as passage 23. The purpose of the restricted passages corresponding to passage 23 is to minimize heat transfer through these passages 23 in order to maintain as high a temperature differential as possible between opposite sides of the passages.
Beyond the left end of the housings 10 and 11 is a heat generator 24 which is intended to supply heat to various portions of the device. Beyond the right end of the housings 10 and 11 is a cooling unit 25 intended to cool other portions of the device. Suitable piping is provided from these units 24 and 25 to direct a consistent flow of hot and cold fluid, which may probably be air, to the regions of the device selected for heating and cooling as already indicated in FIG. 2. To restate, the belt regions 1b and 2b are cooled while the regions 1a and 2a are heated. The piping is intended to convey the heat or cooling so that this condition occurs.
A pipe 26 (FIGS. 3 and 4) is used to supply heat from the heat unit 24 by way of branch pipes 26a and 26b to the inside of housing arms 11c and 10h, respectively. The fluid supplied through these pipes is intended to pass around the belt portions 1a and 2a and then be exhausted through branch pipes 27a and 27b to return pipe 27 feeding back into the heater unit 24.
Cooling is accomplished by feeding cold fluid from pipe 28 through two branch pipes 28a and 28b to the inside of housing arms 11h and 10c, respectively. The cold fluid entering into tubular arms 11h and 10c passes cool around appropriate belt portions 1b and 2b. The cool fluid exhausted from the housings by means of branch pipes 29a and 29b is returned by pipe 29 to the cooling unit 25. The pipe arrangement, for facilitating its understanding with relationship to the various portions of the housings 10 and 11, is shown in simplified form in FIG. 2. From the piping there shown, it should be apparent, upon careful study, that the heat is directed through the pipes from the heat unit 24 to provide heat at the regions 1a and 2a of the belts and cool fluid is supplied from the cooling unit 24 to the regions 1b and 2b.
With the arrangement and structure as shown, and with the suggested application of the correct amounts of heat and cold, the belts 1 and 2 rotate in the direction of the arrows 30 and 31 (FIG. 1) to drive the pulleys each in the same direction so that the unit acts as a prime mover.
The purpose of the springs 19 and 22 is to maintain the belts 1 and 2 under consistent tension.
In order to understand the operation of the device and how it is caused to rotate in a given direction, it is helpful to show the forces on a single set of pulleys, such as 3 and 4, for example. Referring to FIG. 1, if F3 and f3 are considered to be the forces exerted on the pulley 3 by the belt 1, and pulley 3 has a radius of R, which is larger than the radius r of the smaller pulley 4, and F4 and f4 represent the forces on the pulley 4 by the belt 1, initially (before heating and/or cooling) F3 equals F4 equals f3 equals f4 because the only forces acting on the pulleys are the forces of the compression springs 19 and 22. As region 1a is heated and region 1b is cooled, assuming that shafts 8 and 9 are prevented from opposite rotation and there is no slippage of the belt 1 on the pulleys 3 and 4, F3 and F4 (equal and opposite) increase and f3 and f4 (equal and opposite) decrease due to contraction in region 1b and expansion in region 1a of the belt 1. As this occurs, F3 times R minus f3 times R becomes greater than F4 times r minus f4 times r. This creates an unbalanced force condition which urges movement of the belt in the direction of the arrow 30.
The forces and effects of heating and cooling on the other pulleys 5 and 6 and belt 2 are substantially the same, except the same pulley 5 is on the same shaft 9 as the large pulley 3, and the large pulley 6 is on the same shaft as the small pulley 4. Therefore, the lower portion 2a is heated and the upper portion 2b is cooled. Physically, these are the differences. However, by applying the same reasoning as for the pulleys 3 and 4 and the belt 1, it can be determined that the belt 2 moves in the direction of the arrow 31 which is the same direction as the movement of the belt 1, indicated by arrow 30.
Because the shafts 8 and 9 connect the pulleys 3, 5 and 4, 6 together, aside from any allowable deflection, the angular velocities of the shafts 8 and 9 and the pulleys 3, 4, 5 and 6 are always the same for each. The movement of the pulleys and the belts is achieved by changes in linear velocities of the peripheries of the pulleys and the belts because of the thermal expansion and contraction of the belts due to heating and cooling. In addition, the connecting together of the two sets of pulleys by the shafts 8 and 9 prevents reverse rotation of the pulleys with respect to each other which would otherwise balance out the forces and prevent actual continuous rotation in a given direction. With the present system, the unbalance of forces is relieved dynamically by rotation of the belts and the pulleys in a single direction at a time.
After heating and cooling is arrested, the forces causing rotation are relieved and the force system is balanced so that rotation is arrested as equilibrium results.
With the system described, in order to prevent slippage of the belts, they are maintained under tension as previously described by means of the springs 19 and 22. It should be evident that the expansion and contraction of the belts causes shifting of the support brackets 15 along the support 13. This is the reason that the brackets are allowed to slide freely. Although there is no specific structure shown to permit flexing of the piping system relating to the pipes 26, 27, 28 and 29, and the related branch pipes, as long as the amount of movement is small, the pipes will probably have sufficient deflection within themselves to compensate for the elongation and contraction of the belts. Otherwise, the pipes can be made of more flexible materials or provided with expansion joints.
In order to minimize heat transfer through the walls of the housings 10 and 11 and to maintain a high efficiency as possible, the interior walls of the housings can be provided with insulation 32, as indicated in FIGS. 5 and 6.
An alternate structure is shown in FIG. 7 and provides another form of the prime mover. One set of pulleys, such as 33 and 34, is secured to the shafts 38 and 39 and provided with a driven pulley 45 just as before, but the opposite ends of the shafts 38 and 39 are secured to bevel gears 43 and 44 which are engaged respectively with other bevel gears 46 and 46a maintained on shaft 47 which extends at right angles to the shafts 38 and 39. The shaft 47 is journalled on suitable means not shown. The purpose of the bevel gears and the shaft is to prevent relative angular rotation between the shafts 38 and 39 so that the pulleys 33 and 34 of the belt 41 will rotate properly upon the application of heat and cold in the same manner as applied for the structure shown in FIG. 1. The pulleys 33 and 34 and the belt 41 are preferably contained in a housing such as housing 11 and the hot air and cold air are sent respectively to its regions 41a and 41b similarly as previously described from the heat unit 24 and the cooling unit 25.
Because the belt is preferably made of metal, the thicker the metal the stiffer it becomes and the less is its facility to bend around pulleys. Therefore, in order to increase the power of the unit by increasing the thickness of the belt, it can be made up of a plurality of belts 58, as shown in FIG. 8, where the plurality of belts are sandwiched against each other and are shown bent around a pulley 49. As is explained hereinafter, the horsepower output of the unit is related to the size of the belt used.
The devices indicated in FIGS. 1, 7 and 8 can also be used as refrigerators. Instead of utilizing the forces provided by heating and cooling to drive a pulley 7 or other device, the pulley 7 or the pulley 45 can be driven to drive the other pulleys such as 3, 4, 5, 6, 33, 34, and 49 and create a cooling condition. If the unit shown in FIG. 1 is driven in the direction of the arrows 30 and 31, regions 1b and 2b contract while regions 1a and 2a stretch. When 1b and 2b contract, 1b and 2b heat up to radiate heat to their surroundings. When 1a and 2a stretch, they cool off to cause absorption of heat from their surroundings which can be the region or regions to be cooled. The amount of stretch allowed is controlled by controlling the relative diameters of the pulleys so that stretching or contracting never occurs above the elastic limit of the belts. If so, the device does not operate properly.
The refrigeration cycle is possible on the assumption that the cooling and heating occurs because of a change in volume of the metal as the metal is stretched and contracted. Poisson's ratio is related to the fact that the volume of a metal increases as it is stretched. If so, cooling occurs because the same amount of metal in the larger volume (like expansion of gas) contains the same total amount of heat. It is merely distributed over a larger volume which then has a lower temperature. Then, after absorbing heat, the metal is contracted to the original volume, it necessarily becomes hotter. This relative heating and cooling by stretching and contracting the belts permits the continuing of the refrigeration cycle.
As a specific example of the power requirements for a specific structure, we shall assume the power requirements for a single set of pulleys, such as 3 and 4.
Further assume the following:
Diameter of pulley 4=3.000 inches
Diameter of pulley 3=3.050 inches
Then,
circumference of pulley 4=9.4248 inches
circumference of pulley 3=9.5818 inches
The circumference of pulley 3 minus the circumference of pulley 4 equals 9.5818 minus 9.4248 or 0.157 inches which is required or total stretch of the belt encircling pulley 3 and 4.
unit stretch=(total stretch/length stretched)=0.157/9.4248=0.0166
Therefore, unit stretch equals 0.0166 inches/inch of length.
For a one degree F. rise in temperature, steel will stretch 0.00006 inches/inch of length.
0.0166/0.00006=276.7 deg. F. which is the temperature difference required to stretch or contract a steel belt 0.157 inches, the required amount of stretch.
The average specific heat of iron in the 32° to 392° F. range is 0.115 BTU per lb. per degree F. Assuming a belt thickness of 0.010 inches, 2 inches wide and a 24 inch length exposed in the heat transmission chamber; the volume of metal is 2×24×0.010 or 0.48 cubic inches. 0.48 cubic inches of steel times 0.283 lbs. per cubic inch equals 0.135 lbs. weight of metal involved in heat exchange. 0.135 lbs. times 0.115 BTU per lb. per F° =0.0155 BTU per F°. Average temperature increase =276/2=138°. 0.0155 times 138=2.139 BTU. 0.707 BTU=1 H.P. Assuming enough heat is transferred to achieve the 276 degree temperature change in one second, the power output is:
2.139/0.707=3.025 H.P. at 100% efficiency.
In FIGS. 9, 10 and 11, I have illustrated an alternate design which will operate with either a small or large temperature difference. This can be accomplished by using a bimetallic band 61 operating over two pulleys 62 and 63 as shown in FIG. 9. In this arrangement, heating in the chamber 64 and cooling in the chambers 65 and 66 result in changes in forces transverse to the band.
Referring to FIG. 10, which is an enlarged view of the left portion of FIG. 9, the band when wrapped around the pulley exerts a couple at the upper and lower points of tangency due to the elasticity of the band. These forces are indicated by the curved arrows 67, 68, 69 and 71.
Initially, C 1 =C 3 . In operation, C 4 >C 2 .
To begin operating, the pulley 62 is rotated in the direction indicated by the arrow 72 by an outside source. The bimetallic band 61 emerging from the heating chamber 64 will initially have a shape U but will tend to assume the curvature indicated by position U 1 (See FIG. 10). This curvature is in a direction tending to conform to the curvature of the pulley 62 and will result in a reduction in the couple at the top point of tangency. The band while in contact with the pulley and passing through the cooling chamber will be cooled, and though initially having the position indicated by the letter L, will soon tend to assume the position indicated by L 1 . This curvature is in opposition to the curvature of the pulley and results in an increase in the couple at the lower point of tangency. Resolution of the component forces results in a couple tending to rotate the pulley in the direction shown by arrow 73. The composition of the bimetallic band is such that the outer layer of the band in the illustration will have greater expansion when heated than the inner layer.
FIG. 11 is added to illustrate the resolution of forces. Therein arrows 81, 82, 83 and 84 represent couples C 1 and C 3 of FIG. 10. Arrows 85, 86, 87 and 88 represent components after initial operation, and arrows 91 and 92 represent forces after resolution.
Although only certain embodiments of the invention have been shown and described, it should be clearly understood that the invention can be made in many different ways without departing from the true scope of the invention as defined by the appended claims.
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An engine for converting temperature differentials to power or for converting power to heating or cooling. In the more obvious use, heat is applied to designated segments of metal belts to cause the designated segments to expand for the conversion of heat to power. If desired, cooling fluid is also applied to other segments of said belts to cause these other segments to contract and thus cooperate with the above stated application of heat in the conversion of temperature differences to power. In the preferred embodiment, two pairs of pulleys are provided. The two pulleys of each pair are mounted on and keyed to a common shaft. The two shafts are spaced apart but are parallel to each other. One of the pair of belts extends around one pulley of each pair and the other belt extends around the other two pulleys. The belts are positioned in planes parallel to each other. One pulley of each pair is larger than the other pulley of the pair to which it is connected by the associated shaft. The said larger pulley is also larger than the pulley to which it is connected by the associated belt. In another embodiment, only one pair of pulleys is provided and a bimetallic belt goes around this pair of pulleys.
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REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/630,165, filed on Nov. 22, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to automated devices for drying clothing and laundry. More specifically, the ambient air clothes dryer is a clothes dryer devoid of any dedicated heating elements or systems for heating the air.
[0004] 2. Description of the Related Art
[0005] The development of the automatic clothes dryer has been a great labor saving device for most households and, along with the automatic washing machine, has served to facilitate the commercial laundry industry as well. Automatic clothes dryers were initially developed when energy costs were relatively low, and accordingly make use of gas or electrical heat to accelerate the drying process. As a byproduct of the heat developed, the home or other structure is also heated, even though most of the heat is ducted to the exterior of the structure during dryer operation. Still, the residual heat output into the structure was not considered to be particularly undesirable, even in warmer conditions, as the energy costs required to operate air conditioning systems were much lower in the past.
[0006] However, with ever-increasing energy costs, the cost of operation of such conventional dryers has climbed considerably over the years, and even more so when the energy required to dissipate their heat output is considered. While conventional hot air clothes dryers have their place in very damp and/or cool climates, the heat they develop is an undesirable side effect of the drying operation in many parts of the country during much of the year. The alternative of the conventional clothes line is not suitable for many households due to the frequency of damp weather in many areas and seasons, and the time and labor required to tediously pin up each garment or article to the line and remove them, perhaps several hours later, when they are dry.
[0007] While some clothes dryers have been developed in the past that do not provide a source of heat during the drying operation, such dryers have not been found entirely satisfactory. Thus, an ambient air clothes dryer solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0008] The ambient air clothes dryer is an automated device including a motor-powered rotating drum having a fan providing axial airflow through the drum. No dedicated heating element is provided. Some embodiments include a fan motor and an additional motor to rotate the drum, while other embodiments utilize a belt or other drive from the fan output shaft to drive a jackshaft to rotate the drum, thereby saving weight, complexity, and energy. Yet another embodiment may be devoid of any fan or air circulation device, and may include only a motor to rotate the drum. This embodiment includes means for the removable and temporary installation of a conventional “box fan” therewith, to provide the air circulation required. Any or all of the embodiments may include a timer and/or humidity detector to provide for automatic shutoff of the fan and drum when the laundry is dry and/or a predetermined time has been reached.
[0009] The portability of the device allows it to be used indoors or outdoors, as desired. The device may take advantage of ambient heating sources within the home or other structure if so desired, e.g., a heat register, radiator, Franklin stove, etc., to provide some heating of the air, which then passes through the dryer drum. This also provides the beneficial effect of humidifying the air within the structure in colder weather. The device may be constructed to utilize twelve-volt power, if so desired, for use in camping when an automotive electrical system is available.
[0010] 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
[0011] FIG. 1 is a partially broken away perspective view of a first embodiment of an ambient air clothes dryer according to the present invention, showing various details thereof.
[0012] FIG. 2 is a simplified side elevation view of an alternative embodiment of the present dryer, illustrating an alternative drum drive system.
[0013] FIG. 3 is another simplified side elevation view showing another alternative embodiment of a drum drive system.
[0014] FIG. 4 is an exploded perspective view of yet another alternative embodiment of the present dryer, in which a separate portable box fan is used to provide airflow through the drum.
[0015] FIG. 5 is a simplified schematic diagram of an exemplary electrical and control system that may be incorporated with the present dryer.
[0016] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The present invention comprises various embodiments of an ambient air clothes or laundry dryer, in which unheated air at ambient temperature is blown through the dryer drum to dry clothing therein. While some slight amount of heat may be provided from the fan motor, the present ambient air dryer device does not include any form of dedicated, specific heating apparatus, as is found in conventional clothes dryers.
[0018] FIG. 1 of the drawings illustrates a first embodiment of the present dryer 10 , in which a separate fan motor 12 and drum rotation motor 14 are employed. The dryer 10 includes a housing or shell 16 having a hollow dryer drum 18 therein. The drum 18 rotates within the housing 16 , and is supported by drum support wheels 20 or other mechanism installed internally within the housing 16 . The dryer drum 18 has an impervious, generally cylindrical wall 22 having a diameter D. A screened airflow inlet end 24 is positioned adjacent the fan motor 12 with its fan 26 and fan drive shaft 28 , with a screened airflow outlet end door 30 located opposite the inlet end 24 of the drum 18 . The two screened ends 24 and 30 are preferably of a sufficiently fine mesh or gauge as to preclude the passage of small articles (e.g., loose change, buttons, etc.) therethrough, and have diameters closely approaching the diameter D of the dryer drum 18 . The screen of the outlet door 30 may have a mesh or gauge sufficiently fine to serve as a lint trap for the dryer.
[0019] The fan drive motor 12 with its fan drive shaft 28 and circular, rotary fan 26 are concentrically disposed externally to the airflow inlet end 24 of the dryer drum 18 , but within the housing 16 . The fan 26 preferably has a diameter closely approaching the diameter D of the dryer drum 18 and the inlet and outlet ends 24 and 30 of the drum 18 , in order to maximize airflow through the drum 18 . A fan guard 32 is preferably installed across the air inlet opening of the dryer housing 16 , with at least the blades of the fan 26 being captured between the guard 32 and the screened inlet opening 24 of the drum 18 .
[0020] The separate drum drive motor 14 of the embodiment 10 of FIG. 1 drives an output shaft 34 , which in turn causes the drum 18 to rotate when the drum drive motor 14 is in operation. A common switch may be used to simultaneously actuate and deactivate the fan motor 12 and drum drive motor 14 , if so desired. In the case of the embodiment 10 of FIG. 1 , the output shaft 34 has a drum belt pulley 36 at its distal end, with a drum drive belt 38 extending around the pulley 36 and around a circumferential groove 40 in the dryer drum 18 .
[0021] The configuration of the ambient air clothes dryer 10 , as well as the configurations of other embodiments disclosed herein, requires no heavy, stiff high voltage and/or high amperage electrical cable, as is universally required for the heating elements of conventional electric clothes dryers. Moreover, no gas line connection is required, as there is no use of a gas heater for the incoming air of the present dryer. Thus, the present dryer is relatively lightweight in comparison to conventional dryers with their heating systems, and requires no more power than is capable of being supplied by a conventional household electric cord. (In some embodiments, the motor(s) may be 12-volt DC, enabling them to be powered from a motor vehicle electrical system if so desired.) The light weight and simple power requirements of the present ambient air dryer allow it to be moved about readily to various locations as desired. Accordingly, external transport wheels 42 may be provided beneath one or both ends of the housing 16 , with a pair of support legs 44 being shown beneath the opposite end of the housing 16 in the embodiment of FIG. 1 . A handle 46 may be provided across one side of the housing shell 16 , to facilitate lifting of that side for rolling the device 10 as desired by means of the wheels 42 .
[0022] FIG. 2 provides a side elevation view of an alternative drum drive system, in which the fan drive is also used to rotate the drum. In FIG. 2 , the fan motor 112 drives an output shaft 128 to which the fan 126 is connected, as in the corresponding components 12 , 28 , and 26 of the embodiment 10 of FIG. 1 . However, the fan motor output shaft 128 may include a drive belt pulley 129 thereon, with a jackshaft drive belt 131 extending from the fan motor shaft pulley 129 to a driven pulley 133 on a radially offset jackshaft or drum drive shaft 134 . The shaft 134 includes a drum drive belt pulley 136 at its distal end, with a drum drive belt 138 extending around the pulley 136 and riding in a circumferential groove 140 around the dryer drum 118 . It will be seen that the dryer drum 118 and drum drive belt 138 may be identical to the corresponding components 18 and 38 illustrated in FIG. 1 and described further above. The distinction between the configuration of FIG. 1 and that of FIG. 2 is the use of a shaft and belt system driven from the concentric fan motor to rotate the dryer drum in the embodiment of FIG. 2 .
[0023] FIG. 3 provides a side elevation view of an embodiment similar to that of FIG. 2 , differing in the means used to impart rotary motion directly to the drum. In FIG. 3 , the fan motor 212 drives an output or fan drive shaft 228 and fan 226 , with the shaft 228 having a drive belt pulley 229 thereon, just as in the case of the equivalent components 112 , 128 , 126 , and 129 of the embodiment of FIG. 2 . The pulley 229 , in turn, drives a jackshaft or drum drive shaft 234 by means of a jackshaft driven pulley 233 on one end of the shaft 234 , just as in the embodiment of FIG. 2 . However, rather than driving the drum 218 by means of a belt extending around the drum, as shown in FIGS. 1 and 2 , the jackshaft or drum drive shaft 234 has a friction wheel 236 (rubber-coated, etc.) at its distal end which bears against a circumferential friction band 238 surrounding the dryer drum 218 . Rotation of the friction wheel 236 imparts rotational motion to the dryer drum 218 by means of the friction between the wheel 236 and friction band 238 around the drum. It will be seen that such a drum drive system may also be incorporated in the embodiment of FIG. 1 , with the drum drive shaft 34 having a friction wheel 236 at the distal end thereof in lieu of the pulley 36 shown, and the dryer 10 incorporating the drum 218 of FIG. 3 with its friction band 238 .
[0024] FIG. 4 provides an illustration of an additional embodiment of the present ambient air dryer, in which a portable fan is used to supply the air through the dryer drum. The dryer 310 of FIG. 4 includes a housing 316 which contains the drum 18 and drum drive mechanism comprising motor 14 , drum drive shaft 34 , shaft output pulley 36 , and drum drive belt 38 , just as in the embodiment illustrated fully in FIG. 1 . However, rather than incorporating a fan integrally therewith, as in the embodiments of FIGS. 1 through 3 , the housing 316 of the dryer 310 includes a fan receptacle 317 in the rear wall thereof, i.e., adjacent the screened air inlet end 24 of the drum. The fan receptacle 317 is configured to fit a conventional portable fan F, commonly known as a “box fan,” therein. The fan receptacle 317 may be configured to accept other types of fans, as desired. A suitable electrical outlet 319 may be provided on the housing 316 , allowing the fan F to be plugged in for operation. Power to the outlet 319 may be provided through appropriate control circuitry on or in the dryer housing or cabinet 316 , as desired, to provide control of the fan F from the ambient air dryer controls.
[0025] FIG. 5 provides a basic electrical schematic diagram of circuitry that may be incorporated with the present ambient air clothes dryer in its various embodiments. In FIG. 5 , a conventional electrical power source 410 , e.g., 115-volt ac power from the power grid, or perhaps 12-volt dc power from an automotive or other electrical source when the ambient air dryer is manufactured to accept such power, provides electrical power to the dryer through a master switch 412 . The master switch provides power to the fan motor, e.g., motor 12 of FIG. 1 , and the drum drive motor, e.g., motor 14 of FIG. 1 , through a solenoid or other appropriate switch 414 . The switch 414 may incorporate the electrical outlet 319 for incorporation in the portable fan embodiment of FIG. 3 , if so desired.
[0026] The solenoid switch 414 is not required in the simplest embodiments of the present ambient air dryer. However, the dryer in any of its embodiments may include a timer and/or humidity sensor 416 , if so desired. These components are conventional in clothes and laundry dryers, and need not be described in detail herein. The timer may be incorporated in combination with a rotary on/off switch to serve the function of the master switch 412 , if so desired. In any event, the timer and/or humidity sensor 416 is normally closed when electrical power is applied for operation of the dryer, with the electrical contacts opening when a predetermined time is reached (for the timer) or when the air flow from the dryer reaches a predetermined low level of humidity (for the humidity sensor). If either of these conditions occurs, power to the solenoid switch 414 is interrupted, thereby interrupting power to the fan and drum drive motors 12 and 14 and shutting off the dryer. The opening of the solenoid switch 414 may also trigger the operation of a buzzer, bell, or other audible or visual signaling means to alert the user of the dryer that the drying operation is complete, much as in the case of conventional clothes dryers. Where the circuit of FIG. 5 is incorporated with the portable fan embodiment of FIG. 4 , the switch 414 may control power to the outlet 319 to shut off power to the outlet 319 , thereby shutting off the fan F plugged into the outlet 319 .
[0027] In conclusion, the present ambient air laundry and clothes dryer in its various embodiments provides a significant advance in efficiency for such machines, particularly in relatively warm and/or dry environments where the device may take advantage of the ambient air conditions.
[0028] 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 ambient air clothes dryer is an automated device providing axial flow of unheated ambient air through the dryer drum. The dryer may include different drum drive systems, timer and/or humidity detector controls, and a configuration utilizing a separate, portable fan for temporary, removable installation with the dryer housing to provide airflow through the drum. The ambient air dryer greatly reduces energy requirements for drying laundry when compared to conventional heated air dryers, and is quite effective in warm and/or dry climates. The ambient air dryer is portable and may be used indoors or outdoors. The device may be configured to use twelve-volt power from a motor vehicle for use in camping. When used indoors, the device may be placed with a heat source (heat register, etc.) to draw warm air through the drum while humidifying the air as it passes through damp laundry in the drum.
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RELATED ART
[0001] Many devices have been proposed for extraction of energy from waves or in short referred to as WEC,s (Wave Energy Converters). Some of them concentrate on absorbing the potential energy of waves, others on the kinetic energy and still others exploit both.
[0002] Among the devices that exploit the kinetic energy are the pitching wave energy converters. These devices are usually attached from one side to the bottom or to some other fixed structure through one or more pivots, while the other side is free to oscillate. They are usually placed near the shore at depths from 8 m to 25 m to take advantage of the fact that most of the energy of the waves becomes kinetic and the surge phenomenon due to the inclination of the bottom. The oscillation of the device is converted to fluid oscillation by the use of piston cylinders and subsequently energy is extracted by standard methods. There are two types of such devices: The flap devices and the pole devices.
[0003] Flap devices are presented in U.S. Pat. No. 4,580,400 with the flap hanging down and using a reflective cavity, in U.S. Pat. No. 4,371,788, which is hinged to the bottom of the sea and using a reflector, in U.S. Pat. No. 6,184,590 using a flap hinged at the bottom that is mechanically connected by rods to a motor. In WO03/036081 the device uses a flap, which is entirely submerged and hinged at the bottom. US Application Publication 2004/0007881 A1 presents an entirely submerged flap that is hinged to the bottom. U.S. Pat. No. 7,834,474 presents a device that uses a flap hinged at the bottom and crossing the sea surface at its upward position. This device uses double action piston cylinders to pump fluid that is used for power production.
[0004] A pole device was first presented by S. H. Salter (see “The swinging Mace” In: Proceedings of Workshop Wave Energy R&D. Cork, Ireland 1992, European Commission Rep EU 15079 EN pp 197-206. Or see “Wave Energy Utilization: A review of the Technologies” by A. F. de Falcao, in “Renewable and Sustainable Energy Reviews” 14 (2010) pp 899-918). In that presentation a winch-drum is attached to the top of the pole. Around the drum a cable is wound several times. The ends of the cable are anchored at the sea bottom. The motion of the pole makes the winch turn and produce energy.
[0005] Another pole device is EB Frond. This device is hinged on a base placed at the bottom. The other side of the pole carries a wide fin. Hydraulic pistons cylinders absorb the energy from the relative motion between the pole and the base. The WRASPA device of the University of Lancaster is also a pole device (see “An Investigation into Power from Pitch-Surge Point Absorber WEC” by R. V. Chaplin and A. G. Aggidis, IEEE 2007). This is similar to EB Frond but it differs in the fin shape.
[0006] Finally one more pole device, whose fin resembles a triple head, is described in WO2011026173A1. A similar device is exposed in US patent application 2010/0156106.
[0007] All these devices (flap and pole) are restricted to oscillate in one direction only. However, the direction of waves, even near the shore, is known to vary by at least 90° degrees. The inability of these devices to re-orient, results in substantial loss of power. To reorient a flap device is impossible since it is hinged to the bottom in at least two points. It is possible, though, to reorient a pole device by changing the hinge at the bottom into a universal joint. However, problems arise as one needs more piston cylinders to support the pole and absorb energy from different directions. First, the motion of the pole will be undisciplined and suboptimal describing any path or in the worst case piston cylinders will oppose each other blocking the motion of the pole. Second, the pressures and flows coming from the different piston cylinders will be random rendering them useless or highly inefficient. Further, the fins on the top of the pole have to be replaced by a suitable wave catching structure to catch waves from all directions.
[0008] In this invention we present an omni directional pole wave energy converter that, uses physical laws to restrict the motion of the pole to power efficient paths (meridians) and simultaneously produces and exploits disciplined fluid flows and pressures from the cylinder pistons. Instead of a fin an appropriate structure is placed at the oscillating end of the pole to catch waves from all directions. A variation of the device allowing the wave catching structure to move along the pole, enables the devices to exploit the potential energy of the waves as well, thus increasing its efficiency.
[0009] Such a device is useful not only for producing energy at locations near the shore by taking advantage of the kinetic (and surge) motion of the waves, but also for deep sea, where it can be floating and appropriately moored.
SUMMARY OF THE INVENTION
[0010] The present invention discloses a wave energy conversion (WEC) device comprising a pole that has a wave catching structure near one end of the pole, while the other end is attached to a base with a ball joint or a universal joint. The base is fixed to the bottom or to a bearing structure. The pole is placed with the oscillating end upwards but there are embodiments with the pole hanging down. The pole is biased towards the vertical position. This is achieved by gravity in the case the pole is hanging down. In case it is pointing upwards, buoyancy may be provided by the wave catching structure at the upper part of the pole, which must have the appropriate empty, floodable and de-floodable compartments. The buoyancy and weight of the pole and wave catching structure must be adjusted so that there is a synchronism between the self frequency of the device and the frequency of the waves.
[0011] The device also consists of a power absorption assembly that absorbs power from the relative motion of the pole with respect to the base. The power absorption assembly may include double action piston cylinders. One side of each cylinder is attached to the pole by a ball joint or universal joint, and the other side is attached to the base through a ball joint or a universal joint. The motion of the pole causes the fluid in the piston cylinder to be pressed and oscillate through the ports of the cylinder.
[0012] The device also comprises one or more systems that (a) restrict the allowed paths that the pole may follow, to optimize energy absorption from the waves, and (b) regulate flow to optimize energy extraction. Such systems may consist of assemblies of conduits, check valves, manifold boxes, valves, sensors and other hydraulic components and/or computers to regulate the flow of fluid from the ports of the piston cylinders through conduits to one or more energy extracting assemblies. Such energy extracting assemblies may include accumulators, hydraulic motors that in turn move generators, or water turbines such as pelton wheels that turn generators etc.
[0013] The wave catching structure may take several embodiments like: (a) cylinder, (b) inverted frustum cone, (c) inverted frustum of pyramid, (d) any shape resulting from the revolution of a curve around the pole axis, (e) a system of fins parallel to the pole axis (3,4 or more fins), (f) a rigid cage containing one or more flexible containers filled or partly filled with fluid (air, water etc.).
[0014] The device further allows the possibility for the wave catching structure to slide along the pole. This oscillation according to the wave motion can further exploit the wave energy (potential and kinetic) by the use of power absorption components, like piston cylinders.
[0015] The device can be placed at the sea bottom or on a fixed structure or it can float. In the latter case a long leg is placed beyond the base extending downward, in the opposite to the pole direction. This leg must carry means (like vertical and horizontal fins) to resist motion horizontally and vertically. The whole device is appropriately moored.
[0016] In extreme weather conditions the device can be protected by releasing the pressure of the piston cylinders and letting the pole flex freely on the universal joint to ease stresses. Also the buoyancy maybe lowered by flooding water in empty compartments of the wave catching structure. If in floating embodiment, the flooding of the wave catching structure and/or the base and/or the lower part of the leg will cause the device to sink deeper to avoid harsh conditions near the surface.
[0017] Deployment and maintenance can be facilitated by de-flooding the base (or/and lower placed compartments if in floating form), and the wave catching structure and filling them with air. The device is then floating horizontally and can be towed to and from a harbor.
[0018] The present invention also provides a method to extract energy from waves comprising the steps of:
(a) deploying a device according to this invention (b) placing the device at the sea bottom or mooring it, if in floating form, as described in the invention (c) optimizing power absorption of the device and the extracted power
LIST OF DRAWINGS
[0022] FIG. 1 A schematic view of an embodiment of the device
[0023] FIG. 2 A view of an embodiment of the device in 3D space
[0024] FIG. 3 . The geometry and principles for motion of the device with two piston cylinders
[0025] FIG. 4 a A schematic embodiment of the device with 3 piston cylinders
[0026] FIG. 4 b The hydraulic circuit of an embodiment with 3 piston cylinders
[0027] FIG. 4 c Detail of max/min component
[0028] FIG. 5 A schematic embodiment of the device with 5 piston cylinders
[0029] FIG. 6 a A schematic embodiment of the device with 4 piston cylinders
[0030] FIG. 6 b The hydraulic circuit of an embodiment with 4 piston cylinders
[0031] FIG. 6 c Detail of optimization assembly
[0032] FIG. 7 a A schematic embodiment of the device with 6 piston cylinders
[0033] FIG. 7 b The hydraulic circuit of an embodiment with 6 piston cylinders
[0034] FIG. 8 a An embodiment of the wave capturing structure
[0035] FIG. 8 b An embodiment of the wave capturing structure
[0036] FIG. 8 c An embodiment of the wave capturing structure
[0037] FIG. 8 d An embodiment of the wave capturing structure
[0038] FIG. 9 a An embodiment of the wave capturing structure: A rigid cage containing flexible containers in upright position
[0039] FIG. 9 b An embodiment of the wave capturing structure: A rigid cage containing flexible containers in tilted position.
[0040] FIG. 9 c An embodiment of the flexible containers within the rigid cage.
[0041] FIG. 10 An embodiment fixed at the bottom
[0042] FIG. 11 A floating embodiment.
DETAILED DESCRIPTION
[0043] Referring to FIG. 1 and subsequent figures an embodiment of the device is presented as ( 1 ). It consists of a pole ( 2 ) that is attached to a base ( 7 ) with a ball (or double ball) joint or universal (or double universal) joint ( 6 ). The pole has on its one side a wave catching structure ( 9 ). In the present embodiment of FIGS. 1 and 2 , there are four fins at 90° degrees from each other. However, there are other wave catching devices that as we discuss later (see FIGS. 8 a , 8 b , 8 c , 8 d , 9 a , 9 b , 9 c ). The device also consists of double action piston cylinders ( 3 ). One end of each piston cylinder is attached to the pole ( 2 ) with a ball joint or universal joint ( 4 ) and the other end is attached to the base ( 7 ) with a ball joint or universal joint ( 5 ). The use of ball or universal joints allows the pole to move freely in all directions. In other words, the tip of the pole can describe any path on the semi sphere defined by the center at ( 6 ) and radius defined by the pole. In the embodiment of FIG. 2 , four piston cylinders are used. The piston cylinders are radially spaced at 0°, 45°, 90°, 135° degrees angles. Each piston cylinder has two ports. It is possible to have other configurations, as will be explained below, but in all cases one must consider that the motion of the pole in combination with the position of the piston cylinders, along with the use of check valves, influences the motion of the fluid in them, which in turn restricts the allowed paths of motion of the pole.
[0044] To make this clear, we will first consider a simple geometrical configuration presented in FIG. 3 . On a plane r let x′x and y′y represent Cartesian axes intersecting at the origin O. Let OP vertical to the plane r along the z axis. Let G a point on OP and F a point on Ox and E a point on Oy so that OF=OE. Suppose piston cylinder A is placed along GE and piston cylinder B along GF. We will study what happens when the tip of the pole P moves in the first upper hemi-spherical quadrant (whose projection on plane r is xOy). Let conduits a and b start from the lower port of each piston cylinder. Each of these conduits has a check valve H, I respectively and both end on a manifold J. On the outflow side of the manifold a conduit leads to a tank L so that constant pressure is applied. The tank and conduits and piston cylinders are filled with fluid. If we try to move the pole in any direction in the first quadrant the pole will not move unless we exceed the pressure exerted by the liquid in tank L. But even if we do, the pole ill not move, because of the check valves H, I and manifold J, unless the pole moves in one of three meridians: (a) The meridian lying on the plane zOx (0° degrees meridian) (b) The meridian lying on the plane zOy (90° degrees meridian) (c) The meridian at 45° degrees. This is so because, when the pressure in conduit a is greater then the pressure in conduit b the check valve I at conduit b is blocked thus blocking B and making the length GF unchangeable. But the motion, where only the length GE changes, is allowed. This is motion along the 90° meridian. The same argument reversed holds for motion along the 0° degrees meridian. It is also possible to move so that the pressure in both conduits a, b are equal. Then the check valves H, I are both open. This allows motion along the 45° degrees meridian. The restrictions described above do not prohibit the possibility of following piecewise permissible directions like: first a path along the 0° degrees meridian until some point, then move parallel to the 90° degrees meridian up to another point and then parallel to the 0° degrees meridian again then a path keeping the pressure in a and b equal etc.
[0045] An embodiment with three piston cylinders appears in FIG. 4 a . The view is from the z direction looking down with the pole at the center of the circle. The three piston cylinders are ( 31 ), ( 32 ), ( 33 ) placed at 0° degrees, 120° degrees and 240° degrees respectively. Each piston cylinder has two ports. Piston cylinder ( 31 ) has ports ( 311 ), ( 312 ), piston cylinder ( 32 ) has ports ( 321 ), ( 322 ), and piston cylinder ( 33 ) has ports ( 331 ), ( 332 ). The flows from the above ports are connected through conduits to the respective numbers in FIG. 4 b , where the hydraulic diagram for this configuration is shown. Flow from ports ( 311 ), ( 321 ), ( 331 ) is connected through check valves ( 16 ) to manifold ( 41 ) to form the assembly ( 401 ), whose out flow is ( 411 ). Similarly flow from ports ( 312 ), ( 322 ), ( 332 ) are connected through check valves ( 16 ) to manifold ( 42 ) to form assembly ( 402 ), whose out flow is ( 412 ). To understand the operation, assume for the moment that the pole moves in the direction of the 0° meridian. Then port ( 311 ) will have outflow and also ports ( 332 ) and ( 322 ) will have outflow and with equal pressure between them, but smaller than that of ( 311 ). The rest of the ports ( 312 ), ( 321 ), ( 331 ) will have inflow from tank ( 72 ), through the return assembly ( 500 ). This implies that ( 411 ) will have as out flow the flow of ( 311 ). In assembly ( 402 ), ( 322 ) and ( 332 ) will have equal pressure and therefore, one will not block the other. They will both flow and ( 412 ) will have the pressure of ( 322 ) (which is equal to ( 332 )) but smaller than ( 311 ). Suppose now that the pole moves in the direction of the 180° degrees meridian. Then ( 312 ) will have outflow and also ( 321 ) and ( 331 ) will outflow with equal pressure but less than that of ( 312 ). In this case ( 412 ) will carry the higher pressure and ( 411 ) the smaller pressure. Note that if the pole moves away from the 180° degrees meridian, then ( 321 ) will not have equal pressure to ( 331 ) and assembly ( 401 ) will block the outflow from either ( 321 ) or ( 331 ) (whichever has less pressure) resulting in the blocking of the pole to move away from the meridian. This applies to all six meridians at 0°, 60°, 120°, 180°, 240°, 300° degrees. The pole is restricted to move along those meridians only, because of the restrictive assemblies ( 401 ) and ( 402 ). The pressure in ( 411 ) is bigger than that in ( 412 ) or vice versa depending on the meridian of motion of the pole. To separate high pressure fluid from lower pressure we use a max/min component ( 60 ), whose internal structure is explained in FIG. 4 c . In the upper schema we see the inner structure of the component ( 60 ) that is symbolized by the schema at the lower part of the figure. It consists of an AND gate ( 62 ) that allows the min of the pressures A, B to pass and of an OR gate ( 61 ) that allows the max of the pressures A, B to pass. In case A=B then both the AND and the OR gate will be open and out of the max/min component we will obtain max(A,B)=min(A,B). Returning to FIG. 4 b we direct the max pressure through conduit ( 611 ) to power extraction assembly ( 701 ) and the min pressure through conduit ( 612 ) to power extraction assembly ( 702 ). The separate treatment of different pressures increases power extraction and hence component ( 60 ) can be regarded as a system for optimization of power extraction. In other configurations, as we will expose below, this system will be more involved. The power extraction assemblies ( 701 ), ( 702 ), in this embodiment consist of accumulators ( 74 ), hydraulic motors ( 70 ), generators ( 73 ). Low pressure fluid, after its use by the hydraulic motor ( 70 ), is concentrated through conduit ( 71 ) in tank ( 72 ) and forwarded through return assembly ( 500 ) back to the corresponding ports of the piston cylinders. Further optimization is also possible by transfer of fluid from assembly ( 701 ) to ( 702 ) and vice versa by monitoring the operation efficiency of the motors-generators.
[0046] An embodiment with five piston cylinders appears in FIG. 5 . The hydraulic circuit in this configuration uses ten manifolds with check valves for the following triads of ports [( 311 ), ( 331 ), ( 341 )], [( 312 ), ( 332 ), ( 342 )], [( 321 ), ( 341 ), ( 351 )], [( 322 ), ( 342 ), ( 352 )], [( 331 ), ( 351 ), ( 311 )], [( 332 ), ( 352 ), ( 312 )], [( 341 ), ( 321 ), ( 311 )], [( 342 ), ( 322 ), ( 312 )], [( 351 ), ( 321 ), ( 331 )], [( 352 ), ( 322 ), ( 332 )]. With similar arguments as for the case of three piston cylinders, we see that the pole is restricted to move along the meridians at 0°, 36°, 72°, 108°, 144°, 180°, 216°, 252°, 288°, 324° degrees only. The pressure out of the manifolds comes at three levels and appropriate but more involved optimization assembly of max/min components is needed to direct them for separate treatment by the power extraction assemblies. This embodiment has already very small loss due to misalignment of the direction of waves with one of the allowed meridians of motion. The maximum misalignment is 36°/2=18° degrees=Pi/10 rad. The cos [18°]=cos [Pi/10]=0.9510, which says that we have at maximum 5% loss. But on the average it will be cos [Pi/20]=0.987 which corresponds to 1.3% loss. So there is no need to seek configurations with many more piston cylinders.
[0047] Another embodiment with four piston cylinders appears in FIG. 6 a . It consists of two dyads of piston cylinders [( 31 ), ( 33 )] and [( 32 ), ( 34 )]. Each dyad has its piston cylinders in right angles. One dyad is displaced from the other by an angle of 45° degrees. The hydraulic diagram appears in FIG. 6 b . Assembly ( 401 ) restricts the motion of the pole. In particular, suppose the pole moves along the 45° degrees meridian. In assembly ( 401 ), only ( 331 ) and ( 311 ) will have outflow (( 312 ) and ( 332 ) will have inflow from assembly ( 500 )), which will be equal in pressure and hence there will be out flow from ( 411 ). Also ( 321 ) will have bigger pressure than ( 331 ), ( 311 ), while ( 341 ), ( 342 ) will have no flow because piston cylinder ( 34 ) is at right angles to piston cylinder ( 32 ) (no change in piston arm). The motion of the pole is restricted along the 45° degrees meridian, because any attempt to go away from it makes the pressure of ( 311 ) and ( 331 ) unequal, which blocks the check valve of either ( 311 ) or ( 331 ) and stops the motion of the pole pushing it back to the meridian. In case the pole moves along the 0° degrees meridian, we will have outflow from ( 311 ), ( 342 ), ( 321 ). The pressure of ( 311 ) will be bigger than that of ( 342 ) and ( 321 ). The motion of the pole is restricted because piston cylinder ( 33 ) and ( 31 ) are at right angles and ports ( 331 ), ( 332 ) and ( 311 ) are connected to restriction assembly ( 401 ), because of which outflow from ( 311 ) prohibits outflow from either ( 331 ) or ( 332 ), thus restricting motion only along the 0° degrees meridian. In this direction (0° degrees meridian) one may observe that if the pole stops (for example when it reaches the end of the oscillation and is ready to move back again), there is no flow in ( 311 ). This may allow ( 331 ) or ( 332 ) to have outflow and thus the pole may fold at 90° degrees from the 0° direction. This situation though is only theoretical, since almost always there will be pressure in the manifold ( 41 ) due to previous operation, which will not allow flow from ( 331 ) or ( 332 ) when the direction of the waves is in the 0° degrees meridian, while the bias of the pole towards the vertical position will not let it fold. The same observation holds for the 180° degrees meridian.
[0048] The case of motion of the pole along the 135° degrees or the 315° degrees meridian is slightly different. Suppose we move along the 135° degrees meridian, then we have flow from ( 341 ), which has also the bigger pressure, and flow from ( 312 ) and ( 331 ), which have lower pressure. However, the length of movement of the piston arm is not equal between ( 31 ) and ( 33 ) if the pole moves along the 135° meridian, as it can be shown using spherical trigonometry. Since restriction assembly ( 401 ) demands that ( 331 ) be equal to ( 312 ) in pressure, we must have equal piston arm displacement between the for the piston cylinders ( 31 ) and ( 33 ). Therefore, to have equal pressure, the pole will travel slightly off the 135° degrees meridian. It can be calculated that it will start at 135° degrees but move gradually to approximately 145° degrees as it inclines to horizontal position. This peculiarity for the 135° and 315° degrees meridians, poses no problem because the loss of power is of the order of 1−cos [10°], which is approximately 1.5%. and only for horizontal inclination of the pole. In real life conditions the pole's inclination does not exceed 30° degrees, and this peculiarity is negligible.
[0049] As in previous embodiments, the flow from ( 411 ) and from the other ports ( 321 ), ( 322 ), ( 341 ), ( 342 ) must be treated separately according to the pressure they carry to optimize power extraction. For this purpose and to economize ( 321 ) and ( 322 ), which cannot both have outflow at the same time, are connected through check valves to a manifold ( 42 ) and form assembly ( 402 ) with outflow ( 412 ). Similarly, ( 341 ) and ( 342 ) are connected through check valves to another manifold ( 43 ) forming assembly ( 403 ) with outflow ( 413 ). An optimizing assembly ( 601 ) is used to separate and direct high and low pressure through conduits ( 611 ), ( 612 ) respectively, for different treatment to separate power extraction assemblies ( 701 ) and ( 702 ). The details of construction of the optimizing extraction assembly ( 601 ) appear in FIG. 6 c ,which is easily understood once we realize that there are only three possible situations: (a) ( 412 ) has high pressure, ( 413 ) zero pressure and ( 411 ) low, (b) ( 412 ) zero, ( 413 ) high, ( 411 ) low, (c) ( 412 ) and ( 413 ) low, ( 411 ) high. It is worth noting that for this embodiment the losses due to misalignment of the direction of the motion of the waves with the meridian of motion of the pole is at maximum 45°/2=22.5° degrees=Pi/8 rad. The loss is 1−cos [Pi/8]=1-0.9239=7.6%. But on the average it will be 1−cos [Pi/16]=2%, which is quite satisfactory considering the economy and simplicity of using only four piston cylinders.
[0050] An embodiment with six piston cylinders is shown in FIGS. 7 a and 7 b . In FIG. 7 a the position of piston cylinders is shown. One triad with piston cylinders ( 31 ), ( 32 ), ( 33 ) placed at 120° degrees apart and the second triad similarly for pistons ( 34 ), ( 35 ), ( 36 ). The two triads are displaced by 30° degrees. The restrictive assemblies in this case are four: assembly ( 401 ) for ports ( 311 ), ( 321 ), ( 331 ), which are connected through check valves ( 16 ) to manifold ( 41 ), assembly ( 402 ) for ports ( 312 ), ( 322 ), ( 332 ), connected to manifold ( 42 ), assembly ( 403 ) for ports ( 341 ), ( 351 ), ( 361 ), connected to manifold ( 43 ), assembly ( 404 ) for ports ( 342 ), ( 352 ), ( 362 ) connected to manifold ( 44 ).To understand how the pressures in the manifolds operate consider for example motion of the pole along the meridian of 0° degrees. In ( 401 ) there will be flow from ( 311 ) only. In ( 402 ) there will be equal pressure flow from ( 322 ) and ( 332 ) only. This restricts motion along the meridian of 0° degrees. In ( 403 ), port ( 361 ) has zero flow because it is 90° degrees from the direction of 0° degrees and only port ( 341 ) has flow. In ( 404 ), port ( 342 ) has zero flow because it receives flow from the return assembly ( 500 ), ( 362 ) is zero because it is 90° degrees from the 0° degrees meridian and only port ( 352 ) has flow. The pressure at the outflow ( 411 ) of assembly ( 401 ) will be higher than that in outflows ( 413 ), ( 414 ) of assemblies ( 403 ) and ( 404 ) because the piston-cylinders are misaligned by 30° degrees from the direction of motion of the waves. Further, the pressure in the outflow ( 412 ) of assembly ( 402 ) is smaller than ( 413 ), ( 414 ), because the piston cylinders ( 32 ) and ( 33 ) that create flow in ( 402 ) are equally misaligned by 120° degrees from the direction of motion of the pole. Still the pressure in ( 413 ) and ( 414 ) is not equal because one is due to ( 341 ) and the other to ( 352 ). The change in length of the arms of the piston cylinders ( 34 ) and ( 35 ) is not the same when one contracts and the other expands as one can show using spherical trigonometry. We already encountered this phenomenon in the four piston cylinder embodiment.
[0051] There will be a difference making the one slightly bigger than the other in pressure. Hence, in a six piston cylinder structure we get four levels of pressure. The optimization power extraction assembly ( 600 ) consists of four min/max components. When outflows ( 411 ), ( 412 ) one has high pressure and the other low pressure, ( 413 ) and ( 414 ) have almost equal middle level pressure and vice versa. The power extraction optimization assembly ( 600 ) separates levels of pressure starting with the highest ( 611 ) and in decreasing order ( 612 ), ( 613 ), ( 614 ) and leads them to separate power extraction assemblies ( 701 ), ( 702 ), ( 703 ), ( 704 ). The pressure difference in ( 612 ), ( 613 ) is not high and hence ( 702 ), ( 703 ) maybe reduced to a single assembly. As we already mentioned in other embodiments further optimization is possible by monitoring the operation level and efficiency of each power extraction assembly and transferring fluid from one to the other through controlled interconnections.
[0052] It is further understood that when six piston-cylinders are used we have 12 possible meridians of motion 30° degrees apart. Thus, the maximum misalignment of the meridian of motion of the pole from the direction of the motion of the wave is 30°/2=15° degrees. Therefore, the max loss is 1−cos [15°]=1−cos [Pi/12]=3.4%, while the average loss will be 1−cos [Pi/24]=0.9%. Hence. losses from this reason are minimal.
[0053] One may construct other embodiments with 7 piston cylinders, or 8 piston cylinders consisting of two independent tetrads, or 10 piston cylinders consisting of two independent pentads or 12 piston cylinders consisting of two independent hexads, etc. But at this point it appears as an unnecessary complexity.
[0054] The wave catching structure ( 9 ) may take several forms: (a) The fin form has already been shown in FIG. 1 and FIG. 2 and again in FIG. 8 b . Apart from the four fin form ( 92 ), three or more than four fins are possible forms. (b) The cylinder with axis the axis of the pole. (c) The inverted frustum six sided pyramid ( 93 ) (see FIG. 8 c ). This is appropriate for a three piston cylinder solution, where the pole is restricted to move along six equally spaced meridians. The frustum pyramid must be positioned so that each of each six faces looks one meridian. The frustum pyramid is inverted because for a given volume of material allocated to the wave catching structure it is better to have a wider vertical section on the upper part where the energy of the waves is higher. (The opposite argument holds when the pole is hanging down) (d) The eight-sided pyramid frustum ( 94 ) in FIG. 8 d is appropriate for a four piston cylinder configuration. In this case each face of the pyramid must look at one of the eight meridians along which the pole is restricted to move. (e) The frustum cone or a truncated ellipse or other appropriate curve by revolution around the pole axis as in ( 91 ) see FIG. 8 a , for embodiments with more piston cylinders. An alternative form for a wave catching structure is that described in FIG. 9 a , 9 b , 9 c . The structure consists of a rigid cage ( 95 ), within which a flexible container or a composition of flexible containers ( 96 ) is located. The flexible container is filled or partly filled with fluid (like fresh water and/or air etc.). The pressure of the wave, as it arrives, will deform the flexible container giving it a shape like the one in FIG. 9 b , where the side accepting the wave is flattened, while the other assumes the shape of the cage. This deformation makes wave catching more efficient than having a rigid structure and adapts to waves coming from any direction. The flexible container is useful to consist of several compartments like, for example, the one depicted in FIG. 9 c . In this form the flexible container is made up of donuts placed one on top of the other following the shape of the cage. By having separate compartments one can control the buoyancy of the structure more closely, keeping the upper containers more buoyant than the lower ones and adjusting the pressure in each one so that the desired deformation is achieved. This ability to adjust, may also be used to adjust to different sea states.
[0055] The wave catching structure ( 9 ) is not required to be rigidly fixed to the pole. One may notice that if allowed to slide along the pole, it will catch the potential energy of the waves when in vertical position, while when in inclined position, it will catch a combination of the potential and kinetic energy of the waves. We may improve the efficiency of the device by absorbing energy from this motion as well, apart from the energy absorbed by the oscillatory inclination of the pole. Towards this aim we may use piston cylinders ( 10 ) (see FIG. 10 ) to convert the oscillatory motion of the wave catching structure along the pole into fluid oscillation and use it to extract energy by the same or a separate set of power extraction devices as previously described. In FIG. 10 an embodiment is presented that is fixed to the bottom of the sea. The sea surface ( 15 ) almost covers the wave catching structure ( 9 ). The pole is able to incline according to the number of piston cylinders ( 3 ) and the corresponding allowed meridians absorbing energy through the same piston cylinders ( 3 ), while the wave catching structure ( 9 ) is allowed to slide along the pole absorbing extra energy through piston cylinders ( 10 ).
[0056] A floating embodiment is shown in FIG. 11 . The device is the same as that shown in FIG. 10 . The only difference is that below the base ( 7 ) a leg ( 12 ) extends downward. The leg carries means to resist horizontal motion like the fins ( 13 ) and means to resist vertical motion like the disk ( 14 ). The leg must be deep enough to take advantage of the fact that wave energy diminishes exponentially with distance from the surface and hence at distance greater than half a wave length such energy is very close to zero. The whole device is moored by lines ( 11 ). The buoyancy of the pole ( 2 ) may be independently adjusted either by partially flooding its inside or/and adding a float to the pole—for example at the base ( 7 ).
[0057] The device is simple to construct and deploy. The base ( 7 ) or/and the disk ( 14 ) or/and the wave catching structure ( 9 ) can be filled with air forcing the device to float horizontally. In this position it can be towed from and to a harbor for deployment or maintenance.
[0058] In extreme weather conditions the device may be allowed to flex freely on the universal joint ( 6 ) by short circuiting the piston cylinders ( 3 ) thus easing the stresses. In parallel one may decrease buoyancy of the wave catching structure to keep the pole inclined. If it is floating, its buoyancy may be reduced, thus letting it sink deeper to avoid the harshness of the conditions at the surface.
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A wave energy converter ( 1 ) consisting of a pole ( 2 ) with a wave catching structure ( 9 ) connected to a base ( 7 ) through a ball or universal joint ( 6 ). The pole oscillates as the waves hit the different sides of the wave catching structure. The pole is biased towards the vertical position. The motion of the pole activates devices for absorption and extraction of energy such as piston cylinders ( 3 ) with one end attached to the pole and the other to the base ( 7 ) by ball or universal joints ( 4 ) and ( 5 ), which also restrict the motion of the pole along specific meridians by use of appropriate hydraulic components. The possibility of motion of the wave catching structure along the pole increases the absorption of wave energy. Being able to exploit waves from any direction and also to assume a floating form, it is suitable for both deep and shallow waters.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a sheathing for veins, a method for its manufacture, and its application in surgery.
2. Description of the Related Art
Medicine is frequently confronted with the task of treating cardiovascular diseases, such as arteriosclerosis for instance, caused by changes in blood vessels. Modern surgery employs, in addition to, e.g., deobliteration methods, substitute-vessel implants in the form of bypasses for reconstructing arterial vessels. Known, for example, are vessel implants manufactured from synthetic materials, or synthetic materials combined with natural materials.
Detrimental interactions with the physiological environment in patients' bodies may occur if full-synthetic materials are employed. Serious complications, such as thrombosis or restenosis of vessel implants, that may require expensive post operations may occur when synthetic materials are substituted for coronary or peripheral vessels with small lumen. It is thus desirable to employ implants formed from natural vessel material, since they beneficially affect natural endothelialization and the anti thrombogenic properties of vessel walls. Such biological substitute-vessel materials are generally obtained from veins. However, implanting veins in the arterial vessel system may cause increases in wall thickness to occur during arterialization. If those increases are accompanied by intimahyperplasy due to the differing compliances of veins and arteries, they may ultimately lead to restenosis of the implants. It will be beneficial to externally encase or reinforce native veins in order that they will be reliably able to perform their intended function as, for example, a coronary or peripheral bypass for arterial blood transport, over the long term. External sheathing or stiffening ribs can adapt the compliance of natural vein material to suit the arterial system and thus both reduce incidences of intimahyperplasy and allow achieving high non closure rates over the long term. Moreover, the aforementioned sheathing will also allow implantation of varicose, ectatic, or thin-walled veins that have not been employed to date due to their unfavorable hemodynamic properties. The latter will be the only means for employing vessel materials from patients' own bodies as substitutes for vessels having small lumen, particularly in the case of patients suffering from multiple vessel imperfections.
A vessel prosthesis where a woven sheathing is drawn over a natural blood vessel is known from German Patent DE 4340755. A natural blood vessel spirally wrapped in crossed fibers is described in European Patent EP 687164. U.S. Pat. No. 5,645,581 discloses a tube, whose manufacture is described in U.S. Pat. No. 5,755,659, having crossed fibers spirally wrapped around its longitudinal axis.
According to German Patent DE 19910340, a tube, sheath, or tubing is employed as sheathing for a vein to be used as artery prosthesis. An external reinforcement for vessel prostheses having a duo layer, tubular, polymer-fiber sheathing is known from World Patent WO 00/54703.
The known reinforcements for vessel material have a number of disadvantages. For example, numerous, complex, procedures are required for preparing them and attaching them to implant vessels. Additional tissue adhesives are required in order to attach the reinforcements. Reinforcements based on metals may adversely impact handling of prostheses and foster incompatibility reactions. Problems, particularly problems in the anastomosis area, may occur due to loose ends of wires.
The problem addressed by the invention is thus making available a sheathing for veins that will overcome the problems arising from the state of the art, will reinforce veins to be employed as surgical implants for use as durable vessel substitutes, may be simply and inexpensively manufactured following ordinary manufacturing procedures and manufactured on ordinary manufacturing equipment, and will be simply and reliably applicable in surgery.
SUMMARY OF THE INVENTION
That problem is solved by a sheathing for reinforcing natural veins for use as surgical implants in the form of textile netting that is fabricated by forming a seamless, tubular, essentially pile-less, knit fabric and has loops having large, open apertures having essentially polygonal shapes, in particular, polygonal shapes having rounded corners.
The invention also comprises a method for manufacturing a sheathing for reinforcing natural veins for use as a surgical implant in the form of textile netting fabricated by forming a seamless, tubular, essentially pile-less, knit fabric that has loops having large, open apertures having essentially polygonal shapes.
The present invention is particularly suited to use as sheathing for reinforcing native veins in order to provide surgical implants for use as vessel substitutes in human medicine and veterinary medicine.
The vein sheathing may beneficially be manufactured in the form of open-pored, textile tubing by means of knitting. In the case of one embodiment, the tubing may be manufactured on ordinary circular knitting machines used for manufacturing small-bore tubing. In the case of another embodiment, a dual-bar raschel machine may be used for manufacturing the tubing. Knitting equipment is generally known to specialists in the field, and thus shall not be explained in detail here.
In the case of one embodiment, vein sheathing according to the invention may be formed by circular knitting employing plain-tricot interlocking. In the case of another, preferred, embodiment, vein sheathing according to the invention may be formed by knitting employing a combination of interlocking techniques. Tricot-Atlas, tricot-strand, strand/weft, and combinations employing fillet needles may be mentioned as examples of such combined knitting techniques. According to the invention, knit fabric knit employing tricot-Atlas interlocking is preferred for sheathing veins. However, various other types of knit fabrics and combination knits, such as open meshes or closed meshes, may be employed.
The netting's polygonal loops may have various shapes, depending upon the knitting technique chosen. In the case of one embodiment, the netting's loops may be rhombic. Rhombic loops may be formed, particularly in the case of plain-tricot fabrics. In particular, the clear diameter of the rhombs may fall within the range 100 μm to 600 μm, in particular, within the range 100 μm to 400 μm, or, if larger loops are desired, preferably within the range 300 μm to 600 μm. In the case of knit fabrics knit employing tricot-Atlas interlocking, loops having, in particular, honeycomb shapes, may be formed by rounding off corners. The clear diameter of the loops may, preferably, fall within the range 400 μm to 1,600 μm, in particular, within the range 800 μm to 1,200 μm, or, particularly preferred, within the range 600 μm to 1,000 μm.
It will be particularly beneficial if the tubular knit fabric is essentially formed from biocompatible polymer fibers. Examples of such biocompatible polymers are synthetic polymers in the form of homopolymers, copolymers, terpolymers or polymer blends, natural polymers, or combinations of synthetic and natural polymers. Employment of resorbable, synthetic polymers is also feasible. In the case of a preferred embodiment of the vein sheathing according to the invention, a high-capillarity polyester yarn fabricated from polyethylene terephthalate (PET) is employed. PET is noted for its good biocompatibility, and is thus particular suited for use as an implant material.
According to the invention, the sheathing for veins exhibits essentially no pile. The knit fabric may thus have essentially smooth surfaces on its outer and inner walls. In the case of a special embodiment, the sheathing may be essentially free of textured fibers.
The vein sheathing may be beneficially formed from multifilament yarn. The sheathing according to the invention may be formed from yarn having 2 to 500 filaments, in particular, having 5 to 250 filaments, and preferably having 10 to 100 filaments. The yarn employed according to the invention may have a gauge of, preferably, 50f40 dtex. The knit fabric of the sheathing according to the invention may have a mesh width falling within the range 100 μm to 1,000 μm, in particular, 300 μm to 600 μm.
In the case of plain-tricot interlocking, which is also termed “single-tricot interlocking,” knitting employs a single guide bar only. A suitable choice of the number of strands in the yarn and the course density and wale density of the knit fabric will allow adjusting the inner diameter of the knit tubing for sheathing veins as desired. In the case of tubular sheathing knit employing single interlocking, in particular, plain-tricot interlocking, the number of strands may beneficially fall within the range 5 to 25, the course density may beneficially fall within the range 10 to 20 per centimeter, the wale density may beneficially fall within the range 15 to 25 per centimeter, and the nominal diameter may beneficially fall within the range 2 mm to 10 mm. Knit fabric having low wall thicknesses will be the result, particularly in the case of plain-tricot interlocking. The wall thicknesses of plain-knit tubing and plain-tricot tubing, may preferably fall within the range 0.10 mm to 0.25 mm.
In the case of the combined knitting technique, in particular, knitting employing tricot-Atlas interlocking, knitting employs a pair of guide bars and special needles. In particular, the knit tubing obtained has a structure similar to that of a honeycomb. Yarn having fewer strands may be employed in order to obtain a mesh having a looser structure. The inner diameter of the knit tubing for encasing veins may be adjusted as desired by suitably choosing the number of strands in the yarn employed and the course density and wale density of the knit fabric. In the case of tubular sheathing knit employing combined interlocking techniques, in particular, tricot-Atlas interlocking, the number of strands may beneficially fall within the range 15 to 90, the course density may beneficially fall within the range 20 to 40 per centimeter, the wale density may beneficially fall within the range 20 to 30 per centimeter, and the nominal diameter may beneficially fall within the range 2 mm to 15 mm. Wall thicknesses may preferably fall within the range 0.10 mm to 0.30 mm, in particular, may fall within the range 0.15 mm to 0.25 mm. According to the invention, a yarn having a gauge of 50f40 dtex may be preferably employed.
Due to the tighter interlooping of the strands of yarn in the case of the combined knitting technique, the combined knitting technique yields more stable wales and courses than in the case of plain-tricot interlocking. Such a knit fabric may exhibit lower stretchability and greater resistance to distortion. Knit tubing having lower lumen expandability may be obtained in this manner. Knit fabrics according to the invention thus have better abilities to resist stresses due to arterial blood pressure.
Structural features of knit fabrics for vein sheathings manufactured employing plain-tricot interlocking and tricot-Atlas interlocking according to those knitting techniques described as preferred embodiments will be more clearly evident from the accompanying figures.
FIG. 1 depicts a 25×-magnification of a plain-tricot knit fabric. The loop apertures formed in the knit fabric have approximately rhombic to square shapes having clear widths falling within the range 300 μm to 600 μm. The strands of yarn are singly interlooped along the courses and wales, which allows a certain amount of distortion of the loops and stretching of the knit fabric.
FIG. 2 depicts a 25×-magnification of a tricot-Atlas knit fabric. The loop apertures formed in the knit fabric have approximately honeycomb to rectangular shapes having clear widths falling within the range 400 μm to 1,200 μm, in particular, falling within the range 600 μm to 800 μm. The strands of yarn are also interlooped along the courses and wales in order to yield greater resistance to distortion of the loops.
Knit tubing obtained employing the knitting techniques described above may be pretreated in manners that will make it suitable for sheathing veins. In the case of one embodiment of the invention, the untreated knit fabric may be pretreated by cleansing. In the case of another embodiment of the invention, the untreated knit fabric may be pretreated by thermal shrinking and cleansing.
Cleansing of the untreated knit fabric may be performed in three stages. The material is initially placed in hot water at a temperature of 60° C. and stirred. Residual moisture is then extracted in an extraction apparatus using isopropanol, which will also remove any avivage residues. Finally, the knit fabric is pretreated once again, this time in hot water at a temperature of 40° C. Following cleansing, the knit tubing is dried in a suitable manner, for example, in a laminar-flow box.
In the case of another embodiment, the untreated knit tubing may also be pretreated by shrinking, in which case, shrinking will be performed prior to the cleansing described above. Shrinking may be performed by dipping the knit tubing in boiling water and allowing to remain therein for a suitable period.
Cleansed and, if shrinking has been performed, shrunk, knit tubing may be drawn onto a metal mandrel, each end of the tubing clamped to the respective end of the mandrel, and thermoset at 160° C., which will cause the inner diameter of the knit tubing to expand to varying extents relative to the declared inner diameter of the untreated material, a phenomenon that will be described in detail under Examples 4 and 5, below. Thermosetting may be performed in a single stage. Thermosetting may be alternatively performed in two stages, in which case, the knit tubing will be expanded to an even greater extent.
Knit tubing is preferably thermoset without regard to any pretreatment by shrinking it may have received. In other words, the thermosetting process employed is not determined by the type of pretreatment by shrinking that may have been employed. Since the ends of the knit tubing are clamped to the respective ends of the metal mandrel during thermosetting, it will no longer be able to shrink by much following thermosetting, which, in the case of non preshrunk knit tubing, will lead to larger pores than in the case of shrunk knit tubing. Sheathing according to the invention may beneficially be characterized by the fact that it retains its shape.
The retaining clamps may be removed and the vein sheathing cut to lengths ranging from about 10 cm to 60 cm, preferably ranging from about 10 cm to 30 cm, and packed once thermosetting has been concluded and the metal mandrel has cooled down to room temperature.
Determinations of the normalized radial tensile strengths of various samples knit employing plain-tricot interlocking and combined knitting techniques, such as tricot-Atlas interlocking, showed that the tensile strengths of the knit tubing fell within the range 2 N/mm to 10 N/mm, in particular, fell within the range 2 N/mm to 6 N/mm, depending upon the type of knitting involved and the treatment that the knit tubing had received. The radial tensile strength of knit tubing that had not been preshrunk was less than that of knit tubing that had been preshrunk.
Measurements of the longitudinal tensile strengths of plain-tricot knit tubing yielded values ranging from 70 N to 100 N for samples that had been preshrunk and had not been preshrunk.
The tensile elasticities of the vein sheathing along the radial direction were determined for forces ranging from 2 N to 12 N. Elastic elongations in the radial direction ranging from 3% to 10%, in particular, ranging from 5% to 8%, for plastic elongations of the same order of magnitude ranging from 5% to 15%, in particular, ranging from 6% to 13%, were determined for samples knit employing plain-tricot interlocking and combined interlocking techniques.
The sheathing for veins according to the invention may be cut to suitable lengths and suitably packed, ready for use, in order to make it available for use in surgery. In particular, the sheathing material according to the invention may be sterilized in a suitable manner. A suitable sterilization method may be either chosen from the usual physical or chemical methods for deactivating microorganisms or be a combination of such methods. One possible sterilization method includes treatment with ethylene oxide. Sterilization of sheathing according to the invention may preferably be performed employing γ-radiation.
The vein material to receive sheathing according to the invention involved is a natural vein taken from a mammal. Such veins, or segments of veins, may be taken from deceased donors. Alternatively, such veins, or segments of veins, may be taken from living donors. Vein donors may be animals, for example, pigs. Vein donors may be human beings. It will be particularly preferable if the vein to be sheathed may be taken from the patient who is to receive the sheathed vessel implant. Such an embodiment is particularly preferable, since healing of the patient's bodily tissues without any problems arising is to be expected and incompatibility reactions to the implant may be minimized. No additional attachment of the sheathing using tissue adhesives will be necessary if a natural vein is sheathed according to the invention, which will allow further reducing the technical effort involved in implantation and risks of complications occurring.
In the following, the present invention will be explained through detailed descriptions of particular embodiments in the form of examples. In the examples, the individual features of the invention may be implemented either alone, or in combination with other features thereof. The examples are for the purpose of explaining the invention and making it more readily comprehensible only, and shall not be construed as representing restrictions of any kind.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Example 1
Manufacture of Knit Tubing
A knit fabric knit employing tricot-Atlas interlocking employing a pair of guide rails is manufactured as the raw material for the vein sheathing. Polyethylene-terephthalate-fiber yarn in a gauge of 50f40 dtex is knit at a course density of about 35 per centimeter and a wale density of about 25 per centimeter. Yarn having 20 strands will yield knit tubing having a nominal diameter of 4 mm. Yarn having 80 strands will yield knit tubing having a nominal diameter of 14 mm.
Example 2
Pretreatment by Cleansing
The untreated knit tubing obtained under Example 1 is cleansed, without shrinking it, by stirring it in hot, demineralized water at a temperature of 60° for 30 min. Under a second step, the material is cleansed and any residues present extracted using isopropanol in a Soxhlet apparatus for a period ranging from 15 min to 3 h, depending upon the quantity of material involved, which will eliminate any avivage residues. In a third cleansing step, the material is, once again, incubated in hot water, this time at a temperature of 40° C., for 10 min, under constant stirring. In a final step, the cleansed material is dried overnight in a laminar-flow box.
Example 3
Pretreatment by Shrinking
The untreated knit tubing obtained under Example 1 is shrunk in boiling, demineralized water at a temperature falling within the range 97° C. to 100° C. for 5 min. In an initial step, the shrunk material is then cleansed in hot, demineralized water at a temperature of 60° C., under constant stirring. In a second step, the material is cleansed and any residues present extracted using isopropanol in a Soxhlet apparatus for a period ranging from 15 min to 3 h, depending upon the quantity of material involved, which will eliminate any avivage residues. In a third cleansing step, the material is, once again, incubated in hot water, this time at a temperature of 40° C., for 10 min, under constant stirring. In a final step, the shrunk, cleansed material is dried overnight in a laminar-flow box.
Example 4
Thermosetting Plain-Tricot Knit Fabrics
Knit tubing pretreated according to Example 3 having a declared inner diameter of 3 mm is cut to a length of 40 cm, drawn onto a metal mandrel having an outer diameter of 6 mm, and thermoset in a single step. Knit tubing having declared inner diameters of 4 mm or 5 mm may be drawn onto mandrels having outer diameters of 7 mm or 8 mm, respectively, and thermoset, where the final inner diameter of the vein sheathing will equal the outer diameter of the metal mandrel employed.
In the case of a two-step thermosetting, tubing having a declared inner diameter of 3 mm is drawn onto a metal mandrel having an outer diameter of 5 mm in an initial step of the thermosetting procedure and drawn onto a mandrel having an outer diameter of 6 mm in a second step of the thermosetting procedure, and thermoset following each step. Tubing having a declared inner diameter of 4 mm is expanded to yield inner diameters of 7 mm and 8 mm and thermoset following these same procedures.
Example 5
Thermosetting Tricot-Atlas Knit Fabrics
Unlike the plain-tricot knit tubing described under Example 4, tricot-Atlas knit tubing may be only slight expanded. In the case of single-step thermosetting, such tricot-Atlas tubing having a declared inner diameter of 7 mm is drawn onto metal mandrels having outer diameters of 6 mm, 7 mm, or 8 mm and thermoset. Cleansed, shrunk knit tubing may be treated in the same manner. In the case of two-step thermosetting, tricot-Atlas tubing having a declared inner diameter of 7 mm is initially thermoset on a metal mandrel having an outer diameter of 7 mm and thermoset a second time on another metal mandrel having an outer diameter of 8 mm once it has cooled.
Example 6
Properties of Vein Sheathing
Vein sheathing manufactured according to the examples described above will have well-defined geometric and physical properties.
The mean wall thickness of sheathing manufactured employing plain-tricot interlocking is 0.17 mm±0.01 mm. The mean wall thickness of sheathing manufactured employing tricot-Atlas interlocking falls within the range 0.22 mm±0.01 mm to 0.23 mm±0.01 mm.
Measurements of their radial tensile strengths indicate a strong dependence of the values obtained therefore on the type of pretreatment employed. Shrinking in boiling water may significantly increase their tensile strengths in some cases.
The tensile strengths determined for typical samples appear listed in Table 1, below:
TABLE 1
Normalized Radial
Tensile Strength
[N/mm] and the Number
of Strands in
Type of
Manufacturing Parameters/
the Yarn Employed
Knit Tubing
Method
(n)
Plain tricot
Inner diameter expanded
4.5 ± 1.6
from 4 mm to
n = 13
8 mm (in two steps,
4 mm → 7 mm, and
7 mm → 8 mm), following
preshrinking
in boiling water.
Inner diameter expanded
4.6 ± 1.6
from 3 mm to
n = 26
6 mm (in two steps,
3 mm → 5 mm, and
5 mm → 6 mm), following
preshrinking
in boiling water.
Inner diameter expanded
2.3 ± 0.6
from 5 mm to
n = 13
8 mm (in a single
step), not preshrunk.
Inner diameter expanded
3.5 ± 1.0
from 3 mm to
n = 13
6 mm (in two steps,
3 mm → 5 mm, and
5 mm → 6 mm), not
preshrunk.
Tricot-
Inner diameter held
4.9 ± 0.4
Atlas N
constant at 6 mm
n = 13
(thermoset in a
single step), following
preshrinking
in boiling water.
Inner diameter held
4.4 ± 0.4
constant at 6 mm
n = 13
(thermoset in a
single step), not
preshrunk.
Tricot-
Inner diameter held
5.9 ± 0.4
Atlas N2
constant at 6 mm
n = 13
(thermoset in a
single step), following
preshrinking
in boiling water.
Inner diameter held
4.6 ± 0.4
constant at 6 mm
n = 13
(thermoset in a
single step), not
preshrunk.
Example 7
Compliances of Sheathed Veins
In order to test the compliances of veins having sheathing, sheep jugular veins were sheathed in various types of tubular polyester (Dacron) netting at a flow rate of 300 ml/min and a modulating pressure having an amplitude of 50 mm(Hg) and tested for their dynamic compliances and diameters at various pressures. The measured values were compared to those for native sheep carotid arteries and jugular veins and a vein substitute fabricated from polytetrafluoroethylene (PTFE).
The diameter of the sheep jugular veins employed was 14.7 mm±2.92 mm, and their circumferential compliance was 2.78±1.4%/100 mm(Hg). The diameter of the sheep carotid arteries employed was 6.6 mm±0.27 mm, and their circumferential compliance was 3.3±0.9%/100 mm(Hg). The circumferential compliance of the PTFE vein substitute employed was 0.6±0.05%/100 mm(Hg). The outer diameters of the stents decreased to mean values of 7.4 mm±0.12 mm, and thus virtually equals the artery diameter. The circumferential compliances of veins equipped with stents varied from 1.98%/100 mm(Hg) to 0.74%/mm(Hg), depending upon the structures of the stents involved.
Veins sheathed in a textile construction, as stipulated by the invention, exhibited a nonlinear compliance, as is observed in the case of natural blood vessels, particularly in the case of arteries. Long-term efficacies and extended service lives of the sheathed, native, vessel prostheses may thus be expected, where incidences of intimahyperplasy will also be reduced.
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Sheathing for reinforcing natural veins for use as surgical implants in the form of textile netting that is configured by forming a seamless, tubular, essentially pile-less, knit fabric and has loops having large, open apertures having essentially polygonal shapes is made available.
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This application is a continuation of application Ser. No. 07/582,786, filed Sept. 17, 1990, now abandoned, which is a continuation of application Ser. No. 07/262,350, filed on Oct. 25, 1988, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a data processing apparatus for processing code data or image data.
2. Related Background Art
Various printing apparatus, such as laser beam printers, have rapidly become popular in recent years.
Such printing apparatus can be divided into a controller unit and a printer unit in view of their functions. The controller unit receives various data such as character code data from a host computer, for example, edits said data as image information (dot information) in units of a character or of a page, and sends said information as an image signal together with various print control signals to the printer unit. Said printer unit is equipped with a sheet feeding mechanism and an image forming mechanism having a semiconductor laser unit, a photosensitive drum etc., and effects a printing operation on a recording sheet, according to the control signals and image signals from the controller unit. In the following description, the interface signals between the controller unit and the printer unit, including the image signals and the control signals such as commands or status signals, will be collectively called a video interface signal.
However, in such printing apparatus, well improved efficiency of use of the printer unit is not always obtained because only one controller unit can be connected to the printer unit. Also such printer is uneconomical because each host apparatus has to be equipped with a printer unit.
The above-explained printing apparatus are disclosed for example in U.S. Pat. No. 4,823,192, 4,786,923, 4,866,555 and 4,835,618 and in U.S. Pat. application Ser. No. 07/554,187, filed Jul. 20, 1990 (effective U.S. Filing data Apr. 23, 1987), but further improvements have been desired.
SUMMARY OF THE INVENTION
An object of the present invention is to eliminate the above-explained drawbacks.
Another object of the present invention is to provide an improvement on a data processing apparatus used for a printing apparatus and the like.
Still another object of the present invention is to provide a data processing apparatus of high economic effect.
Still another object of the present invention is to enable connection of plural data sources to a printer unit.
Still another object of the present invention is to provide a data processing apparatus capable of improving the efficiency of use of the printer unit.
Still another object of the present invention is to provide a data processing apparatus capable of resolving various inconveniences when plural data sources are connected to a common printer unit.
Still another object of the present invention is to provide a data processing apparatus capable, in case of a request for the switching of connection of image signal and the like to a printer unit, of discriminating whether the switching of the signals to the printer unit is possible by inspecting the operation state of the printer unit, and, if, for example, sheet transportation or printing operation is in progress, prohibiting the switching of an interface signal until the process in progress is terminated.
According to the present invention, a data processing apparatus is provided, comprising data processing means capable of connecting to first and second data sources simultaneously, the two data sources being different from each other. The data processing means further comprises, according to one embodiment, means for processing data from the first source, to produce a first image signal, means for supplying to a printing unit either that first image signal or a second image signal from the second source, and means for inhibiting simultaneous supply of both signals to the printing unit. According to another aspect, the data processing means includes means for processing data from at least one of the data sources and means for selecting data entry from the first or the second source. According to a third embodiment, the data processing means includes means for processing sent from the first source to produce a first image signal, and means for selecting between supply of the first image signal, and supply of the second image signal from the second source, to a printing unit.
Still other objects and features of the present invention, and the advantages thereof, will become fully apparent from the following description to be taken in conjunction with the attached drawings, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a schematic structure of a laser beam printer of an embodiment of the present invention and connection with external equipment;
FIG. 2 is a view showing interface signals between a printer unit and a data processing apparatus or an external controller;
FIG. 3 is a flow chart showing a printing sequence in a control unit of the embodiment of FIG. 1;
FIG. 4 is a block diagram showing a structure of a connection switch unit for selecting a controller unit or an external controller; and
FIG. 5 is a schematic cross-sectional view of a laser beam printer in which the present invention is applicable.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Now the present invention will be clarified in detail by description of the preferred embodiment thereof shown in the attached drawings.
In a printing apparatus such as a laser beam printer, in addition to video interface signal lines connecting the printer unit with the controller unit, there may be provided video interface signal lines to the printer unit, arranged to be directly connectable with the exterior for connection with another external apparatus (hereinafter referred to as "external controller"), thereby printing image data from a host computer through the controller unit, or printing an image with a common printer unit by directly controlling the printer unit from the external controller.
In such case, as shown in FIG. 4, the video interface signal lines to the printer unit 41 are branched and one part of the lines is connected, to a connector 44 of the external controller 42, and the other part is connected to the controller unit 45 for entering data from the host computer 43. Also there may be provided, at the branching portion, mechanical or electrical switch means for making connection only to the external controller 42 or the controller unit 45 at a given timing, thereby preventing the collision of video signals at the printer unit 41.
However, in the structure shown in FIG. 4, the video interface signals to the printer unit 41 can be switched at an arbitrary timing. Consequently, the switching of the video signals may take place in the course of a printing operation, thereby causing an interruption in the image signals or providing a half-blank print from the printer unit 41.
Also if the signal switching takes place in the course of transportation of a recording sheet in the printer unit 41, the controller unit 45 (or the external controller 42) that has newly acquired the controlling right resets the printer unit 41, so that the sheet transporting mechanism is stopped, eventually causing sheet jamming.
Consequently, the printing apparatus embodying the present invention is constructed in the following manner.
The printing apparatus is provided with input/output means constituting an interface for printing data corresponding to plural data sources; image forming means for image formation based on the printing data; switch means for switching the input/ output means to guide the printing data from each data source to the image forming means; detecting means for detecting the printing state in the image forming means; and means for determining the timing of switching by the switch means in accordance with the printing state.
In the above-explained structure, the input/ output means effects interface function of the printing data corresponding to plural data sources, and the image forming means executes the image formation based on the printing data. The switch means executes the switching of the input/output means, thereby sending the printing data from various data sources to the image forming means. The timing of switching by the switch means is determined in accordance with the detected state of printing in the image forming means.
[Structure of laser beam printer (FIG. 1)]
FIG. 1 is a block diagram schematically showing the structure of the controller unit 100, namely a data processing apparatus, of a laser beam printer of the present embodiment.
In FIG. 1, 101 indicates a host computer for supplying the laser beam printer with printing data such as character codes. The printing data and various control data from the host computer 101 are supplied to a CPU 104 through a host interface 105, which is composed of an ordinary 8-bit parallel interface or a serial interface such as RS232C, for transmitting and receiving 8-bit code input signals and various control signals for handshake and error display functions.
An external controller 103 for supplying the laser beam printer with video signals,.independently from the host computer 101. The video signals from the external controller 103 are supplied, either through a video interface 106 to the CPU 104, or directly to a printer unit 102 for image formation through a printer interface 112. The external controller 103 can also be of the same structure as the data processing apparatus 100, for generating dot patterns based on code signals sent from another host computer.
The CPU 104, for controlling the entire data processing apparatus 100, produces various control signals in accordance with a control program stored in a ROM 107 shown in a flow chart of FIG. 3, and sends printing data to the printer unit 102 for effecting image formation. The ROM 107 also stores various data and pattern information such as various character patterns, thus functioning as a character generator for providing character patterns in response to input character codes. A RAM 108 is used as a work area of the CPU 104 for temporarily storing various data, and is provided with flag areas, for example, a video flag to be explained later.
An image memory 109 stores dot information developed as a pattern by the pattern data of the ROM 107 in response to the code information from the host computer 101, or the entered dot information, in the form of a bit map. A switch 110 switches the image data source supplying the image data to the printer unit 102. When the switch 110 is off, there is selected a control mode (hereinafter referred to as an internal mode) in which the data processing apparatus 100 controls the printer unit 102 on the basis of the data from the host computer 101, but, when the switch 110 is on, there is selected a mode (hereinafter referred to as an external mode) in which the printer unit 102 is controlled by the external controller 103. The state of the switch 110 is inspected by the CPU 104 in accordance with the control program stored in the ROM 107, and is utilized in the switching control of data source as will be explained later.
A video signal generator 111, for converting the image data (dot information) of the image memory 109 into video signals, supplies the printer unit 102 with video signals of a line at a time, in synchronism with a synchronization signal from the printer unit 102. The printer interface 112 is used for exchange of the interface signals between the printer unit 102 and the data processing apparatus 100.
The external controller 103 is capable of directly sending the data to the printer unit 102, through the video interface 106 and the printer interface 112. A video signal 23 to be supplied to the printer unit 102 and a beam detection signal BD 24 from the priter unit 102 are directly exchanged between the video interface 106 and the printer interface 112. Other interface signals between the external controller 103 and the printer unit 102 are exchanged between the video interface 106 and the CPU 104.
If the CPU 104 is unable to use the printer unit 102 for the printing of data from the host computer 101, due to a printing operation executed by the external controller 103, the CPU 104 sends a busy signal, indicating the disabled state for data reception, to the host computer 101 through the host interface 105.
[Description of an Interface with the printer unit (FIG. 2)]
FIG. 2 illustrates the interface signals between the printer unit 102 and the data processing unit 100.
In FIG. 2 there are shown a READY signal 20 generated from the printer unit 102 and a status signal indicating a status as to whether the printer unit 102 is ready; a PRINT signal 21 to be supplied by the data processing unit 100 for initiating sheet feeding in the printer unit 102 when it is ready (READY signal 20 being on); and a TOP signal 22 to be produced as a pulse signal by the printer unit 102 when the recording sheet passes through a predetermined position. In response to the signal 22 utilized as a vertical synchronization signal, the data processing unit 100 turns off the PRINT signal 21, thereby preparing for a next request for sheet feeding. Also in response to the TOP signal, the data processing unit 100 starts to send the image data of a page to the printer unit 102.
There are also shown a VIDEO signal 23 supplied from the data processing unit 100 or the video interface 106 (external controller 103) to the printer unit 102 in the amount of a scanning operation with the laser beam, in response to image clock signals; a beam detection (BD) pulse signal 24 produced from the printer unit 102 at each scanning operation of the laser beam, indicating the scanning position of the beam as disclosed in the U.S. Pat. No. 4,059,833 and utilized as a horizontal synchronization signal; and a sheet feed signal 25 produced from the printer unit 102 and maintained in the on state from the start of sheet feeding to the completion of sheet discharge from the printer unit 102. Similar video interface signals are exchanged between the printer unit 102 and the external controller 103.
[Function (FIG. 3)]
FIG. 3 is a flow chart showing the sequence of input and switching of the printing data supplied from the host computer 101 through the data processing unit 100 or from the external controller 103, and the output of video signals to the printer unit 102.
At first, step S1 initializes the data processing unit 100, thereby turning off a video flag in the RAM 108. Thus, the READY, TOP and FEED signals supplied from the video interface 106 to the external controller 103 are all turned off, thus advising the external controller 103 of the unavailable state of the printer unit 102.
Then step S2 checks the state of the video flag in the RAM 108, and, if it is off, indicating the internal mode, step S3 discriminates whether the switch 110 is on. If it is off, the sequence proceeds to step S4 for receiving the data from the host computer 101 through the host interface 105. Next, step S5 executes page editing, by analyzing the received data, reads the corresponding pattern data from the ROM 107, determines the positions of characters on a page, and executes pattern development in the image memory 109.
Then, step S6 discriminates whether the image data of a page have been stored in the image memory 109, and, if stored, step S7 activates the printer unit 102 and causes the video signal generator 111 to send the video signals to the printer unit 102 for image formation.
On the other hand, if step S3 identifies that the switch 110 is on, indicating the external mode, the sequence proceeds to step S8 for discriminating whether a sheet is in transportation in the printer unit 102. If in the course of transportation, the sequence returns to step S3 to continue the interface operation with the host computer 101. The discrimination is made by the state of the FEED signal 25 from the printer unit 102.
When the FEED signal 25 is turned off, indicating the complete discharge of the sheet from the printer unit 102, the sequence proceeds to step S9 for sending the BUSY signal from the host interface 105 to the hostcomputer 101, thereby advising of the disabled state for data reception of the data processing unit 100 and prohibiting the data input from the host computer 101. Then step S10 turns on the video flag in the RAM 108, and sequence returns to the step S2. The BUSY signal is cancelled before the data reception in step S4.
If the video flag is on in step S2, the sequence proceeds to step S11 for receiving the input signals from the external controller 103 through the video interface 106, sending the same to the printer unit 102 through the printer interface 112, also receives the input signals from the printer unit 102 through the printer interface 112 and sending the same to the external controller 103 through the video interface 106.
Then step S12 checks the state of the switch 110, and, if it is on, the sequence returns to step S11, but, if it is off, the sequence proceeds to step S13 for discriminating whether the sheet transportation is in progress in the printer unit 102. If the sheet transportation is in progress, the sequence returns to step S11, but, if it is not in progress (if the FEED signal is off), the completion of transportation is identified, and step S14 turns off the READY signal etc., of the video interface 106. The input of the video signals from the external controller 103 is prohibited in this manner. Then step S15 turns off the video flag in the RAM 108, and the sequence returns to step S2.
Therefore, either in the internal mode or in the external mode, the switching of the interface is conducted only after the completion of printing of a page, so that incomplete printing can be avoided.
Though the present embodiment has been explained by reference to a laser beam printer for collective printing of data in units of a page, it is not limited to such case but is applicable to various printing apparatus such as an ink jet printer or a LED printer.
Also in the present embodiment the enabled/disabled state of switching of the video interface signals is discriminated by the FEED signal, but such discrimination can naturally be made with a suitable signal or a suitable timing of signal adequate for the printer unit to be employed.
Particularly in printer units with complex structure, the state thereof cannot be represented by one or two signals line, but can only be understood through the exchange, for example of command codes and status codes (request/response codes) in serial signals, between the control unit and the printer unit. Also in such case, it is possible, in response to a request for switching the video interface signals, to determine the timing of the switching by sending a status request command in serial data from the control unit (data processing unit) to the printer unit, and discriminating the state of the printer unit from a response status signal received from the printer unit.
Also in the present embodiment, when the video interface signals from the external controller 103 are enabled, a part of the video interface signal between the external controller 103 and the printer unit 102 is supplied to the external controller 103 and the printer unit 102 through the CPU 104, which inspects the movement of the signals simultaneously with the transfer thereof. However, there may also be adopted an alternative structure, in which all the video interface signal lines are formed directly between the external controller 103 and the printer unit 102 in the same manner as between the data processing unit 100 and the printer unit 102 and are provided with a switch circuit controllable from the data processing unit 100 and means allowing the data processing unit 100 to inspect the signal status between the external controller 103 and the printer unit 102, whereby the enabled/disabled statue of switching of the video interface signals is checked for determining the switching.
Also in such case, the VIDEO signal from the external controller 103 is preferably made switchable by a switching circuit, because, in case of disabling the video signal from the external controller 103, it is made possible to physically interrupt the video signal and to prevent eventual perturbation of the reproduced image caused by the stray signal transmitted from the external controller 103 to the printer unit 102.
In the present embodiment, the switching of the video interface signals of the external controller 103 and the host computer 101 is conducted by the switch 110, but it is also possible to add signal lines from the external controller 103 and the host computer 101 to the control unit 104, thereby enabling one to enter a switching request from the outside.
As explained in the foregoing, the present embodiment inspects the operation state of the printer unit when a request is entered for switching the video interface signals, thereby avoiding the destruction of the printed image or the sheet jamming, resulting from the switching of the interface signals in the course of a printing operation or a sheet transporting operation.
FIG. 5 is a schematic cross-sectional view of a laser beam printer in which the present invention is applicable.
In FIG. 5, there are an exposure device 221 provided with a scanner and a laser unit; a photosensitive drum 222; a developing unit 223 for rendering visible a latent image formed on the photosensitive drum 223; a sheet cassette 224; a sheet feeding roller 205 for feeding sheets, one by one, from the cassette 224 to a transport roller 206; a registration shutter 207 for temporarily stopping the sheet transported by the transport roller 206, thereby synchronizing the sheet feeding with the laser beam projection and the rotation of the photosensitive drum 223; feeding rollers 208 for feeding the sheet to a transfer section 209; a fixing unit 210 for fixing the toner image transferred onto the sheet; a stacker 211 for received the discharged sheets; and a detachable auxiliary memory 212 incorporating a built-in ROM and utilized as a character generator.
In such laser beam printer, the timing of sheet transportation, image development, etc., is controlled by a sequence controller 213.
A data processing unit 214 converts code signals, supplied from an unrepresented host computer (not shown), into image signals, and the laser beam is turned on and off in response to the binary signals produced from the data processing unit.
The data processing unit 214 corresponds to the data processing unit 100 shown in FIG. 1, and the components except the data processing unit 214 and the auxiliary memory 212 in FIG. 5 correspond to the printer unit 102 shown in FIG. 1.
The character generator 212 is used when pattern signals other than the character font (pattern signal) stored in the data processing unit 214 are required, and the pattern signals in the character generator 212 are read in response to code signals entered by the data processing unit 214.
The present invention is not limited to the foregoing embodiment but is subject to various modifications within the scope and spirit of the appended claims.
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A printing unit allows connection of two or more signal sources, thereby improving the efficiency of use of the printing unit. For this purpose the printing unit or printer has a first image signal source for supplying a first image signal. The first image signal source is connectable with a second image signal source for generating a different image signal, and has a control unit for controlling the function of the second signal source.
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This application is a continuation of application Ser. No. 68,497, filed July 1, 1987, now abandoned.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a method for eliminating endotoxins from raw cotton.
(2) Description of the Prior Art
Endotoxins, characteristic components of the cell wall of gram-negative bacteria, have been found in cotton fiber and plant parts, as well as in the atmosphere of textile mills processing cotton fibers. These endotoxins have been implicated as a causative of byssinosis, a lung disease found in some cotton textile workers.
Water-washing under relatively severe processing conditions has been used to reduce endotoxin in cotton lint but this causes serious problems in the ultimate processing of the cotton to manufacture yarns and fabrics.
In medical practices, high temperatures are used to destroy endotoxins on glassware and medical equipment; however, at these temperatures, cotton lint readily degrades.
SUMMARY OF THE INVENTION
This invention provides methods for effectively eliminating endotoxin from raw cotton without detrimental effects in the processing of the fiber into yarns and fabric.
In these processes for effectively eliminating endotoxin from raw cotton, cotton lint or dust is treated with one of the following solvents, neat or containing acid or base at moderate temperature, namely: ethanol containing sodium hydroxide, ethanol containing hydrochloric acid and dimethylsulfoxide. The solvents are then removed from the raw cotton.
The primary object of this invention is to provide a process for eliminating endotoxin, a suspected causative agent of byssinosis, from raw cotton fiber without decreasing the processability of the fiber into yarns and fabrics.
A second object of the present invention is to provide a process for eliminating endotoxin from raw cotton that utilizes azeotropic solvents that can be recycled to make the process more economical by avoiding large replacement of solvents.
A third object is to provide a process for eliminating endotoxin from raw cotton that utilizes a solvent (ethanol) with a high vapor pressure at room temperature to furnish dry cotton in a short time with little expenditure for drying energy.
A fourth object of the present invention is to provide a process for eliminating endotoxin from raw cotton that utilizes chemicals that are ordinarily used in commerce, thus avoiding exotic handling, and chemicals that can be obtained from farm commodities such as ethanol.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of this invention is applicable to raw cotton or cotton dust amd is based on the discovery that endotoxin molecules contain active groups that can be deactivated by deesterification of their long chain fatty acid groups or phosphate moieties. Endotoxins, which are found in the cell walls of gram negative bacteria, consist of a heteropolysaccharide component and a covalently bound lipid component. The lipid component is responsible for the endotoxic properties. The lipid moiety is attached through several common organic functionalities: these include carbon ester, phosphate ester, and amide linkages. Some reagents that attack these functionalities or solvate the whole molecule can be used to "detoxify" raw cotton or cotton dust.
Cotton lint or dust is immersed in one of the following solvents (with or without additives) which are effective for detoxifying raw cotton or cotton dust: 95% ethyl alcohol containing sodium hydroxide, or (2) 95% ethyl alcohol containing hydrochloric acid, or (3) dimethylsulfoxide. The solvent is then removed from the cotton by any satisfactory means, such as filtration, centrifugation, etc.
The cotton is then rinsed with neat solvent and allowed to air dry.
The treatments described effectively eliminate endotoxins from the fiber or dust as measured by Limulus Amoebocyte Lysate gelation.
95% ethyl alcohol is used because it is an azeotrop and can be recycled. It is also economically available as a commercial 95% grade.
An effective range of 95% alcohol to sodium hydroxide or hydrochloric acid is 270-400: 1. Effective range of temperature is 60° to 80° C.
Ratio of dimethylsulfoxide to cotton is 30-100:1 on a wt basis.
EXAMPLE 1
A ten gram sample of cotton was immersed in 500 ml of 95% ethyl alcohol containing 1.0 g sodium hydroxide that had been heated to 60° C. The cotton remained in the solvent for one hour, then the solvent was removed from the cotton sample by vacuum filtration. The cotton sample was then rinsed with an additional 500 ml of neat solvent and allowed to air dry. The results of the Limulus Lysate Gelation test were as follows: Endotoxin in ppm was 1.0 which was 11% of the original value for the untreated cotton.
EXAMPLE 2
A ten gram sample of cotton dust was immersed in 500 mL. of 95% ethyl alcohol containing 1.0 g. sodium hydroxide that had been heated to 60° C. The dust remained in the solvent for one hour, then was filtered through a buchner funnel to remove excess solvent. The dust sample was then rinsed with an additional 500 ml of neat solvent and allowed to air dry. The results of the Limulus Lysate Gelation test were as follows: Endotoxin in ppm was 29, which was 14% of the original value for the untreated dust. This compared with endotoxin value of 112, which was 55% of the untreated control when 100% ethyl alcohol was used as the treating agent; an endotoxin value of 136 ppm, which was 66% of the untreated control was obtained when 95% ethyl alcohol was used as the treating agent.
EXAMPLE 3
A ten gram sample of cotton was treated as in Example 1 with the use of 2.7 g. of concentrated hydrochloric acid in place of sodium hydroxide. Endotoxin value obtained was 31 ppm, which was 15% of the untreated control.
EXAMPLE 4
A ten gram sample of cotton was treated as in Example 1 except 500 ml dimethylsulfoxide was substituted for the ethyl alcohol sodium hydroxide solution. After filtration, the sample was dried in vacuo at 30 millitorr. Endotoxin value obtained was 20 ppm, which was 5% of the untreated control.
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A method for reducing endotoxin in cotten fiber or dust is disclosed. Cotton fiber or dust is detoxified in a solution selected from the group consisting of 95% ethanol and hydrochloric acid; 95% ethanol and sodium hydroxide; and dimethylsulfoxide.
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[0001] This application is a continuation of U.S. patent application Ser. No. 10/879,091 filed Jun. 30, 2004, which is a continuation of U.S. patent application Ser. No. 09/930,447, filed Aug. 16, 2001 (now U.S. Pat. No. 6,804,630), which claims priority to Korean Patent Application No. 50037/2000, filed Aug. 28, 2000. The entire disclosure of the prior applications are considered as being part of the disclosure of the accompanying application and is hereby incorporated by reference therein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method for measuring a quantity of usage of a device, in particular, to a method for measuring a quantity of usage of a CPU.
[0004] 2. Background of the Related Art
[0005] There are various kinds of algorithms for predicting a quantity of usage of a system in the related art. In general, more complicated algorithms yield more credible predictions; less complicated algorithms yield less credible predictions.
[0006] In addition, a method for calculating a quantity of usage of a CPU can be differentiated in accordance with an operating system. For example, in a MS-Windows 9× system, system usage of a CPU is updated by the CPU itself using its own algorithm. However, it is recommended to use the registry information when an application program is developed.
[0007] Furthermore, because an Operating System (OS) kernel takes charge of the CPU multi-tasking in all threads in a present ready-to-run state, the OS kernel generally knows whether there are OS threads in the ready-to-run state or an action state (all threads do not wait for certain event to resume execution). For example, when the OS determines there are no threads in the ready-to-run state, a value of a power management timer is read, and the CPU is maintained in sleep mode. In this mode the power management timer operates independently from the CPU, and measures accurately time duration of reads (regular increase with a fixed rate of 3.579545 Mhz). After that, the OS reads the value of the power management timer when the CPU is waken up.
[0008] In addition, measuring time difference between initial timer read in the sleep mode of the CPU and second timer read in the wake mode is a measure of idle time of the CPU. In other words, the CPU idle time can be measured by dividing a total of the difference between the second timer and initial timer for a large sampling interval, by the sampling interval. It can be described as in Equations 1 and 2,
Idle Ticks=Sum (across sampling interval)[Second Timer Read-Initial Timer Read] [Equation 1]
CPU Idle(%)=Idle Ticks×Tick Period(s)/Sampling Interval(s)×100% [Equation 2]
Herein, the first timer read describes a processor in sleep mode (initial timer read), and the second timer read describes the CPU is in the wake mode.
[0009] In contrast, related art algorithms yield large values of CPU usage, even though the system does not perform an operation. In addition, in the related art, there is no time interval information available for updating a quantity of usage of a CPU, accordingly it is not appropriate for measuring a quantity of usage of a CPU in short time. In addition, in the related art, because an algorithm has to be amended in order to adapt it to the MS-Windows system or a complicated code is required, it degrades the MS-Windows system performance.
SUMMARY OF THE INVENTION
[0010] An object of the invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described hereinafter.
[0011] An object of the present invention is to provide a method for measuring a quantity of usage of a CPU which is capable of getting directly a result by using various functions provided by the operating system on the behalf of a registry storing a quantity of usage of a CPU inside the system.
[0012] In order to achieve the object of the present invention, the method for measuring a quantity of usage of the CPU comprises reading execution time of all threads excluding a system thread with a known time interval, adding the values, subtracting a total of the execution time of the former stored thread from the grand total, and measuring a quantity of usage of a CPU by dividing the subtracted execution time by the known time interval.
[0013] To achieve at least the above objects and advantages in a whole or in parts and in accordance with the purpose of the present invention, as embodied and broadly described, a method for measuring a quantity of usage of a CPU in a system, including reading execution time of all threads excluding a system thread with a certain timer time interval, adding the read values, subtracting a total of execution time of the former stored thread from the grand total, and measuring a quantity of usage of a CPU by dividing the subtracted execution time of the thread by the certain timer time.
[0014] To further achieve at least the above objects and advantages in a whole or in parts and in accordance with the purpose of the present invention, as embodied and broadly described, a method for measuring CPU usage, including reading an execution time of a thread over a time interval, adding the execution times to obtain a grand total, reading a total execution time for a previously stored thread, subtracting the total execution time for the previously stored thread from the grand total to obtain a result, and outputting the result.
[0015] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
[0017] FIG. 1 is a detailed flow chart illustrating a method for measuring a quantity of usage of a CPU in accordance with an embodiment of the present invention.
[0018] FIG. 2 illustrates an interface between a procedure for calculating a quantity of usage of a CPU and an outer program.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] Hereinafter, a thread and a handle in accordance with the present invention will be described, and an embodiment in accordance with the present invention will now be described in detail with reference to accompanying FIGS. 1 and 2 . First, a thread used in a Windows system is an execution unit in an application program. The each thread is combined with CPU commands, and a set of CPU registers, stacks, etc.
[0020] In the Windows OS, a process can have several threads, and the thread can make other threads again. In the meantime, a kernel as the core of the Windows OS uses a service called a scheduler allocating CPU time to each execution thread. When a process is getting made, the system makes automatically one thread for the process. The thread is called a ‘basic thread’ of the process, the basic thread can make additional threads, and the each additional thread can make threads also.
[0021] In addition, in the Windows system, it is not possible to approach the kernel, a Graphic Device Interface (GDI) or other object directly, but it is possible through a handle. In general, because the objects have mobility in a memory by a memory manager of the Windows, it is possible to search and approach the objects only through their handles.
[0022] A first embodiment in accordance with the present invention will now be described in detail with reference to accompanying FIGS. 1 and 2 . FIG. 1 is a detailed flow chart illustrating a method for measuring a quantity of usage of a CPU in accordance with a preferred embodiment of the present invention. In other words, a quantity of usage of a CPU is calculated by using a system service provided from MS-Windows. In Windows, a VMM (Virtual Machine Manager) service usable in an embodiment of a VDD (Virtual Device Driver) is provided. In other words, a service related to a timer and threads is used in the VMM service, and preferably operating at a ring 0 level.
[0023] In general, a program operated in the system is classified as a thread, and the thread is a minimum unit of execution. Herein, the execution means the CPU is used. As described in FIG. 1 , a variable (SUM) storing the sum of the execution time of all threads excluding the system thread is initialized as in step S 10 . A handle value Hd 1 is then read as a pointer of the system thread in step S 11 , and the next thread handle value Hd 2 is read in step S 12 . After reading the handle value Hd 1 of the system thread and handle value Hd 2 of the next thread, they are compared in step S 13 to determine whether the read values are the same. In other words, it is judged whether the all thread values have been read by comparing the handle value read most recently with the handle value of the system thread.
[0024] Herein, the thread handles are executed repeatedly by scheduling of the operating system. The operating system also manages information about the thread and execution of it. In addition, Windows has the VMM service information about the thread execution. For example, the VMM service comprises a function (Get_Sys_Thread_Handle) finding a handle of the first thread (system thread), a function (Get_Next_Thread_Handle) finding a handle of the next thread, and a function (_GetThreadExecTime) finding execution time after a thread generation etc.
[0025] After that, in the comparing process of step S 13 of the thread handle, when the thread handle value of the system is different from the next thread handle value, execution time of the next thread handle up to the present is read in step S 14 . The execution time is then added to the variable SUM in step S 15 . In judging whether the all thread handles are read by comparing the read values, when the thread handle value of the system is different from the next thread handle value, the above-mentioned process is performed repeatedly until the next thread value approaches to the thread handle value of the system.
[0026] When the thread handle value of the system is the same as the last thread handle value, the execution time of the all thread handles excluding the handle value of the system thread is stored in the variable SUM. Accordingly, the sum execution time (before SUM) of the thread handles stored formerly is subtracted from the total execution time (present SUM) of the thread handles stored in the variable SUM, and the subtracted value is divided by the time interval at step S 16 . Herein, the value divided by the time interval is a quantity of usage of a CPU (CPU_USAGE).
[0027] For example, when the total execution time of the formerly stored thread handles is 100 seconds and the total execution time of the present thread handles is 105 seconds after a 10 second interval, a value found by dividing 10 seconds by 5 seconds as the ratio between the execution time (100 seconds) of the former stored thread handle and the execution time (105 seconds) of the present execution thread handle is 50% as the quantity of usage of the CPU (CPU_USAGE). In other words, the execution time for the interval is found by calculating a total of the execution time of all the thread handles excluding the handle of the system thread at each interval by using the VMM service, and subtracting the former calculated total execution time from the grand total. And, a quantity of usage of a system is measured by dividing the found execution time for the interval by the interval.
[0028] In the meantime, when the interval is set shorter, the calculated quantity of usage of the CPU shows more sudden change than a case when the interval is set longer, in order to decrease the sudden variation, a quantity of usage of a CPU is compensated by finding an average value between the former calculated quantities of usage of a CPU (CPU_USAGE_PREV) and the present calculated quantity of usage of a CPU (CPU_USAGE_NOW) in step S 18 . In other words, when the interval is short in step S 17 , the calculated quantity of usage of the CPU shows a sudden variation. It shows sudden variation also however, in an application construction responding sensitively in accordance with a quantity of usage of a CPU. Accordingly, the above-described sudden variation of the calculated quantity of usage of the CPU can be prevented by compensating the calculated quantity of usage of the CPU. On the contrary, when the interval is sufficiently long, the calculated quantity of usage of the CPU is maintained as it is in step S 19 . The total procedure ends after storing the usage values and reserving the time for the next procedure.
[0029] FIG. 2 illustrates an interface between a procedure for calculating a quantity of usage of a CPU and another program. It is possible to update a quantity of usage of a CPU calculated by the algorithm of FIG. 1 to a registry or to access in the Windows program through an interface between an application program (win App) and a V×D or other device driver. As described above, the calculated quantity of usage of the CPU of FIG. 1 is updated continually to a memory. In the other device driver (V×D), a quantity of usage of a CPU can be gotten through an interfacing method between device drivers. In addition, a method reading a quantity of usage of a CPU directly by using the application program and device I/O control can be used.
[0030] As described above, the method for measuring the quantity of usage of the CPU in accordance with the present invention can measure a quantity of usage of a CPU with higher confidence by using various functions provided by an operating system. In addition, a power consumption in a system (computer) decreases by adjusting a clock pulse of a CPU with the method for measuring the quantity of usage of the CPU in accordance with the present invention. In addition, the method for measuring the quantity of usage of the CPU in accordance with the present invention can be adapted to various applications based on the system execution requirement, and it is very useful for an application monitoring and reporting a load of a CPU in accordance with an operation state of a system.
[0031] In addition, because the method for measuring a quantity of usage of a CPU in accordance with the present invention is embodied in a device driver (V×D) level, control of a system is useful. In addition, because the method for measuring a quantity of usage of a CPU in accordance with the present invention uses a basic service provided from MS-Windows, there is no need to amend an algorithm in order to adapt it for the other MS-Windows nor does it require a complicated code, and the present invention can measure a quantity of usage of a CPU simply, and without lowering performance of the MS-Windows system.
[0032] The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. The present teaching can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art.
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The present invention relates to a method for measuring a quantity of usage of a CPU, in particular to a method for measuring a quantity of usage of a CPU which is capable of getting a credible quantity of usage of a CPU without amending an algorithm in order to adapt it to the an operating system, e.g., MS-Windows System, or requiring a complicated code. The method uses various algorithms provided by the operating system on the behalf of a registry storing a quantity of usage of a CPU inside a system. Accordingly the present invention can measure a quantity of usage of a CPU easily without lowering a performance of the operating system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and a method for controlling shifting operations of an automatic transmission for an automotive vehicle, and more particularly to improvements in such apparatus and method, for reducing shifting shocks of the transmission when the shift lever is moved from its neutral position to one of its forward and reverse drive positions.
2. Discussion of the Prior Art
U.S. Pat. No. 3,738,199 discloses an electronically controlled automatic transmission, in which an operation of the transmission shift lever from its neutral position to one of its forward drive positions causes the automatic transmission to be shifted to a transient position, which is one of the speed positions of the transmission other than the first-speed or lowest-gear position, in order to reduce the shifting shock. This manner of controlling the automatic transmission is referred to as "anti-squat shifting control", since the squatting of the vehicle upon shifting of the shift lever from the neutral position to a forward drive position can be prevented. More specifically, when the shift lever is moved from its neutral position, appropriate frictional coupling devices of the automatic transmission are commanded to be engaged to establish the transient position (other than the first-speed position). The transmission is held in the transient position for a predetermined suitable time (e.g., 0.8 second) after the operation of the shift lever from the neutral position. Then, the transmission is commanded to be shifted to the first-speed position.
For example, a transmission shift lever has three forward drive positions "D", "S" and "L", while a transmission has a total of four speed or gear positions, "1st-speed", "2nd-speed", "3rd-speed" and "OD" (overdrive position), as indicated in FIG. 3. If the shift lever is shifted from the neutral position "N" to the DRIVE position "D", by way of example, the transmission is shifted to the 1st-speed position by operating the clutches C0 and C1 to the engaged position, if the anti-squat shifting control is not effected. If the transmission is operated in the anti-squat shifting control mode, however, the transmission is first shifted to its 2nd-speed position, with the clutches C0 and C1 and brake B2 brought to the engaged position, for instance. Thereafter, the brake B2 is disengaged or released, to shift the transmission to the 1st-speed position.
According to the anti-squat shifting control as indicated above, the shifting shock of the transmission is reduced by an amount corresponding to a difference in the gear ratio between the 1st-speed and 2nd-speed positions. Further, the degree of the squatting phenomenon of the vehicle (i.e., lowering of the stern or tail of a vehicle) upon starting of the vehicle can be significantly reduced.
Laid-open Publication No. 61-116160 of unexamined Japanese patent application discloses a technique in which the anti-squat shifting control is effected only when the running speed of the vehicle is zero and when the speed of the engine exceeds a predetermined upper limit. This arrangement is derived from the recognition that the transmission undergoes a particularly large shifting shock when the shifting of the shift lever from its neutral position to the DRIVE position occurs at a relatively high speed of the engine, i.e., when the vehicle is started (i.e., shifted into a drive gear) with the engine speed at a relatively high level. In other words, the arrangement is based on the concept that the vehicle should be started fast when the shifting of the shift lever from the neutral position to the DRIVE position occurs while the engine speed is relatively low.
In the conventional anti-squat shifting control arrangements discussed above, the anti-squat shifting of the transmission is accomplished unconditionally in response to any shifting operation of the shift lever from the neutral position to one of the drive positions, or alternatively the determination as to whether the anti-squat shifting is effected is based on only the vehicle speed and the engine speed at the time of the shifting of the shift lever from the neutral position. In the latter case according to the laid-open Publication No. 61-116160, the anti-squat shifting is not effected if the vehicle and engine speeds upon operation of the shift lever from its neutral position are not satisfied. Namely, the transmission is not controlled in the anti-squat shifting mode, even if the above-indicated conditions are satisfied a short time after the operation of the shift lever from the neutral position.
Recently, there is a growing demand for "full-time" 4-wheel drive vehicles which are always driven by four drive wheels. These 4-wheel drive vehicles wherein the engine power is distributed to the four wheels experience a reduced power loss of the engine, as compared with the ordinary 2-wheel drive vehicles, even when the vehicles are started with the transmission placed in the low-gear position and the engine running at a high speed. In the 2-wheel drive vehicles, the wheel tires may slip on the road surface when the drive torque exceeds the total friction force between the two drive wheel tires and the road surface. In the 4-wheel drive vehicles, however, the four drive wheels are less likely to slip on the road surface because of the distribution of the drive torque to the four wheels, whereby the power transmission system including the automatic transmission should have increased strength sufficient to withstand the relatively large load, particularly at the time of abrupt starting of the vehicles at relatively high speeds of the engine. Therefore, the 4-wheel drive vehicles require accurate anti-squat shifting control of the automatic transmission. Accordingly, the monitoring of the conditions in which the anti-squat shifting of the transmission is effected should be more suitably carried out, in the 4-wheel drive vehicles.
The engine speed as one of the conditions to effect the anti-squat shifting control of the transmission may be replaced by the currently required output of the engine, which is, for example, a currently detected amount of operation of the accelerator pedal of the vehicle. If the accelerator pedal is monitored upon shifting of the shift lever from the neutral position, or for a very short time after the shifting of the lever, the determination as to whether the operation amount of the accelerator pedal exceeds a predetermined limit or not is unstable and unreliable, since the accelerator pedal may be further depressed after the monitoring time is over. In this situation, the anti-squat control of the automatic transmission may be not properly accomplished so as to minimize the shifting shock of the transmission and the squatting of the vehicle.
SUMMARY OF THE INVENTION
It is therefore a first object of the present invention to provide a method of controlling an automatic transmission for a motor vehicle, wherein the determination as to whether predetermined conditions for effecting an anti-squat shifting of the transmission are satisfied or not continues even after the transmission shift lever has been shifted from the neutral position to one of the forward and reverse drive positions, so that the anti-squat shifting control of the automatic transmission may be achieved in a more stable and reliable manner.
A second object of the invention is to provide an apparatus suitable for practicing the method indicated above.
The first object may be attained according to one aspect of the present invention, which provides a method of controlling an automatic transmission for a motor vehicle, wherein the transmission has a plurality of gear positions which are selectively established, and is shifted to and temporarily held in a predetermined one of the gear positions other than the lowest-gear position, upon an operation of an operator-controlled shifting member from a neutral position to one of drive positions, to effect an anti-squat shifting of the transmission in response to the operation of the shifting member, so as to reduce a shifting shock of the transmission and avoid a squatting of the vehicle, comprising the steps of: detecting an operation of the shifting member from the neutral position to one of the drive positions; determining whether at least one condition for effecting the anti-squat shifting has been satisfied within a predetermined first time period after the operation of the shifting member, or not; and if the at least one condition is determined to have been satisfied within the first time period, commanding the transmission to be shifted to the above-indicated predetermined one gear position.
As indicated above, the anti-squat shifting of the transmission to its predetermined gear position for reducing the shifting shock takes place when the predetermined condition or conditions is/are satisfied within the predetermined time period after the operation of the operator-controlled shifting member from its neutral position to one of the drive positions such as DRIVE, SECOND, LOW and REVERSE as usually provided on ordinary automatic transmissions. The principle of the invention lies in that the determination relating to the predetermined condition or conditions for effecting the anti-squat shifting to the predetermined one gear position is not effected only at the time of operation of the shifting member, but is continued for the predetermined time period. According to this principle, even if the predetermined condition or conditions is/are not satisfied at the very moment of the operation of the shifting member, the transmission is shifted to the predetermined one gear position other than the lowest-gear position(usually, the 1st-gear or 1st-speed position), if the condition or conditions is/are satisfied a certain time after the operation of the shifting member, provided that the certain time is within the predetermined time period. Thus, the time is within the predetermined time period. Thus, the present invention permits improved stability and reliability of the anti-squat shifting control of the automatic transmission, so that the transmission is controlled with reduced shifting shock while permitting a smooth and rapid starting of the vehicle, depending upon the specific situation of the vehicle when and after the shifting member is moved from the neutral position to one of the forward and reverse drive positions.
For example, the following three conditions may be used to determine whether the anti-squat shifting of the transmission should be effected, or not: a first condition that a running speed of the vehicle is equal to or lower than a predetermined reference value; a second condition that an angle of opening of a throttle valve of the vehicle is equal to or larger than a predetermined reference value; and a third condition that the shifting member is not placed in the neutral position. All of these three conditions should be satisfied within the predetermined first time period, so that the transmission is shifted to the predetermined one anti-squat gear position.
The transmission may be held in the predetermined one gear position for a predetermined second time period following the predetermined first time period. In this case, the transmission is usually shifted down from the predetermined anti-squat gear position to the lowest-gear position upon expiration of the second time period.
According to another form of the invention, the method further comprises a step of determining, for a predetermined second time period following the predetermined first time period, whether the condition or conditions for the anti-squat shifting is/are satisfied, or not, and a step of shifting the transmission to the lowest-gear position when the predetermined one condition or any one of the conditions is dissatisfied.
The second object may be achieved according to another aspect of the invention, which provides an apparatus for controlling an automatic transmission for a motor vehicle, having a plurality of frictional coupling devices selectively operated for establishing a plurality of gear positions, and wherein the transmission is shifted to and temporarily held in a predetermined one of the gear positions other than the lowest-gear position, upon an operation of an operator-controlled shifting member from a neutral position to one of drive positions, to effect an anti-squat shifting of the transmission in response to the operation of the shifting member, so as to reduce a shifting shock of the transmission and avoid a squatting of the vehicle, comprising: detecting means for detecting an operation of the shifting member from the neutral position to one of the drive positions; time measuring means for measuring a lapse of time after the detection of the operation of the shifting member; determining means for determining whether at least one condition for effecting the anti-squat shifting has been satisfied within a predetermined first time period after the operation of the shifting member, or not; and commanding means for selectively operating the plurality of frictional coupling devices, for shifting the transmission to the predetermined one gear position, if the at least one condition is determined to have been satisfied within the first time period.
The apparatus may further comprise a shift position sensor operable as the above-indicated detecting means, for detecting a currently selected position of the shifting member, a vehicle speed sensor for detecting a running speed of the vehicle, and a throttle sensor for detecting an angle of operation of a throttle valve of the vehicle. In this instance, the above-indicated at least one condition for the anti-squat shifting may consist of a first condition that the running speed of the vehicle detected by the vehicle speed sensor is equal to or lower than a predetermined first reference speed, a second condition that the angle of opening of the throttle valve detected by the throttle sensor is equal to or larger than a predetermined first reference angle, and a third condition that the currently selected position of the shifting member detected by the shift position sensor is not the neutral position. Namely, the determining means is adapted to determine whether all of the first, second and third conditions have been satisfied within the first time period.
In a preferred form of the above arrangement of the invention, the apparatus further comprises means for determining, for a predetermined second time period following the predetermined first time period, whether each of a modified first condition and a modified second conditions corresponding to the first and second conditions, and the third condition is satisfied or not, and means for shifting the transmission from the predetermined one gear position to the lowest-gear position when any one of the modified first and second conditions and the third conditions becomes dissatisfied during the second time period. The first modified condition requires the detected running speed of the vehicle to be equal to or lower than a predetermined reference speed which is higher than the first reference speed. The second modified condition requires the detected angle of opening of the throttle valve to be equal to or larger than a predetermined second reference angle which is smaller than the first reference angle.
BRIEF DESCRIPTION OF THE DRAWINGS advantages of the present invention will be better understood by reading the following description of a presently preferred embodiment of the invention, when considered in connection with the accompanying drawings, in which:
FIG. 1 is a schematic diagram of an example of an automatic transmission for a motor vehicle, to which the present invention is applicable;
FIG. 2 is a fragmentary view of a hydraulic control circuit incorporated in a hydraulic control device for controlling transmission;
FIG. 3 is a view showing operating states of solenoid-operated valves and frictional coupling devices of the automatic transmission, in different operating positions of the transmission;
FIG. 4 is a block diagram of an electric control system including a transmission control computer, for controlling the automatic transmission through the hydraulic control device, according to input signals from various sensors;
FIG. 5 is a flow chart illustrating a control routine for controlling the automatic transmission according to one of embodiment of the invention; and
FIGS. 6(A) through 6(G) are illustrations showing different situations in which an anti-squat control operation of the automatic transmission is effected in the embodiment of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, there is schematically shown a general arrangement of an automatic transmission for an automotive vehicle, which is controlled according to one embodiment of the present invention which will be described.
The automatic transmission includes three planetary gear units, namely, a front planetary gear mechanism 1, a rear planetary gear mechanism 2, and an overdrive planetary gear mechanism 3.
The front and rear planetary gear mechanisms 1, 2 have respective sun gears 4, 5 which are connected to each other. The front planetary gear mechanism 1 further includes a carrier 6 which is connected to a ring gear 7 of the rear planetary gear mechanism 2. These carrier 6 and ring gear 7 are connected to a carrier 8 of the overdrive planetary gear mechanism 3.
The automatic transmission is coupled to a torque converter 9, which is connected to an engine of the vehicle. More specifically, the automatic transmission incorporates: a clutch C1 disposed between a turbine shaft 10 connected to the torque converter 9, and a ring gear of the front planetary gear mechanism 1; a clutch C2 disposed between the turbine shaft 10 and the sun gear 4 of the front planetary gear mechanism 1; a brake B1 disposed between a transmission case 12, and an assembly of the mutually connected sun gears 4 and 5; a one-way clutch F1 and a brake B2 which are disposed in serial connection with each other, between the sun gear assembly 4, 5 and the transmission case 12, such that the clutch F1 and brake B2 are in parallel with the brake B1; and a brake B3 and a one-way clutch F2 which are disposed in parallel with each other, between the transmission case 12 and a carrier 13 of the rear planetary gear mechanism 3.
The overdrive planetary gear mechanism 3 has a gear ratio smaller than "1", so that it provides a highest-gear position of the transmission for the most economical running of the vehicle. The overdrive planetary gear mechanism 3 has the carrier 8, a sun gear 14, a clutch C0 and a one-way clutch F0 which are disposed in parallel with each other between the carrier 8 and sun gear 14, and a brake B0 disposed between the sun gear 14 and transmission case 12.
This automatic transmission provides an output through a counter gear 16 connected to a ring gear 15 of the overdrive planetary gear mechanism 3.
The clutches C0, C1 and C2 and the brakes B0, B1, B2 and B3 of the automatic transmission are selectively activated to selectively establish operating positions of the transmission, under the control of a hydraulic control device 18 (FIG. 4) which includes a hydraulic circuit as indicated in FIG. 2.
The hydraulic circuit incorporates a shift lever valve 20 operatively connected to a shift lever 90 (FIG. 4) of the vehicle. The shift lever 90, which is operated by an operator of the vehicle, has six operating positions P (PARKING), R (REVERSE), N (NEUTRAL), D (DRIVE), S (SECOND) and L (LOW). The shift lever valve 20 has the corresponding operating positions, P, R, N, D, S and L, as indicated in FIG. 2.
The shift lever valve 20 has an input port 21 which receives a line pressure of the hydraulic system, which is obtained such that a hydraulic pressure produced by a hydraulic pump 30 is adjusted by a primary regulator valve 40, in a known manner.
When the shift lever 90 is placed in the DRIVE position D, the transmission is selectively placed in one of four positions, i.e., 1st-speed, 2nd-speed, 3rd-speed and overdrive (OD) positions. With the shift lever 90 placed in the SECOND position (S), the transmission is selectively placed in one of the 1st-speed, 2nd-speed and 3rd-speed positions. In the LOW position (L), the transmission is placed in the 1st-speed or 2nd-speed position.
Reference numeral 50 in FIG. 2 denotes a 1-2 shift valve for shifting the automatic transmission between the 1st-speed and 2nd-speed positions. Reference numeral 60 denotes a 2-3 shift valve for shifting the transmission between the 2nd-speed and 3rd-speed positions. Reference numeral 70 denotes a 3-4 shift valve for shifting the transmission between the 3rd-speed and overdrive positions. The shift valves 50, 60 and 70 have respective spools 51, 61, 71 which are biased by respective springs 52, 62, 72, in the upward direction as seen in FIG. 2. With the line pressure applied to pilot ports 53, 63, 73 of the valves 50, 60, 70, the corresponding spools 51, 61, 71 are moved in the downward direction, against the biasing forces of the springs 52, 62, 72. The movements of the spools 51, 61, 71 cause the valves 50, 60, 70 to attain predetermined functions for controlling the automatic transmission, in response to an operation of the shift lever 90, as described below.
The pilot ports 53, 63, 73 indicated above are connected to an output port 22 of the shift lever valve 20. The output port 22 is brought into communication with the input port 21 when the shift lever 90 and the shift lever valve 20 are placed in the DRIVE (D), SECOND (S) or LOW (L) position. More specifically, the output port 22 is connected to the pilot port 63 of the 2-3 shift valve 60 through a conduit 23 to which a solenoid-operated valve S1 is connected. Further, the output port 22 is connected to the pilot ports 53 and 73 of the 1-2 shift valve 50 and 3-4 shift valve 70, through a conduit 24 to which another solenoid-operated valve S2 is connected.
The solenoid-operated valves S1 and S2 are provided with respective ports 25, 26. These ports 25, 26 are closed when the solenoid coils of the valves S1, S2 are deenergized or held OFF, so that the line pressure in the conduits 23, 24 is maintained. When the coils of the valves S1, S2 are energized or turned ON, the ports 25, 26 are opened, whereby the pressure in the conduits 23, 24 is released into a drain of the hydraulic system.
The solenoid-operated valves S1 and S2 of the hydraulic control device 18 are controlled by a transmission control computer 80 (FIG. 4), as described below.
The clutch C1 is connected to the output port 22 of the shift lever valve 20, while the clutch C2 is connected to a port 64 of the 2-3 shift valve 60. The port 64 is supplied with the line pressure when the valve spool 61 is moved against the biasing action of the spring 62. The clutch C0 is connected to a port 74 of the 3-4 shift valve 70. The port 74 is supplied with the line pressure when the valve spool 71 is held in its upper position (in FIG. 2) by the spring 72. The brakes B1, B2 and B3 are connected to ports 54, 55 and 56, respectively of the 1-2 shift valve 50, while the brake B0 is connected to a port 75 of the 3-4 shift valve 70.
With the hydraulic control device 18 thus constructed, the 1st-speed position, 2nd-speed position, 3rd-speed position and overdrive position (OD) are selectively established, with the solenoid-operated valves S1, S2, clutches C0-C2 and brakes B0-B3 being placed in the appropriate operating states as indicated in FIG. 3, depending upon the currently selected position of the shift 5 lever valve 20. In FIG. 3, the ON or engaged state of the valves, clutches and brakes are represented by "o", while the OFF or disengaged state is represented by "x".
Referring to FIG. 4, the transmission control computer 80 which controls the hydraulic control device 18 is adapted to receive various input signals from respective sensors which include: a throttle sensor 81 for detecting an opening angle θ of a throttle valve of the engine, which represents a currently required output or torque of the engine; a vehicle speed sensor 82 for detecting a running speed V of the vehicle; a shift position sensor 83 for detecting the currently established position (P,R,N,D,S or L) of the shift lever 90 (shift lever valve 20); a coolant temperature sensor 84 for detecting a temperature of a cooling water of the engine; a brake sensor 85 for detecting an operation or depression of a brake pedal of the vehicle; and a mode selector switch 86 for determining or sensing one of two running modes of the vehicle which is selected by the vehicle operator, i.e., either POWER mode in which the vehicle is driven with a comparatively high degree of drivability, or ECONOMY mode in which the vehicle is driven with comparatively reduced fuel consumption.
In response to the signals from the above sensors, the transmission control computer 80 controls the solenoid-operated valves S1 and S2, according to a predetermined shifting map or relationship between the throttle opening angle and the vehicle speed, in a well known manner, so that the automatic transmission is shifted from one of the four positions (1st, 2nd, 3rd, OD) to another, in dependence of the currently selected one of the three forward drive positions (D, S, L) of the shift lever 90 or shift lever valve 20.
If the anti-squat control of the automatic transmission is not effected upon operation of the shift lever 90 from its NEUTRAL position (N) to its DRIVE (D) position, for example, only the clutch C1 is supplied with the line pressure in order to shift the transmission to the 1st-speed position. However, if particular conditions are satisfied, the anti-squat control of the transmission is effected when the shift lever 90 is moved from its NEUTRAL position to its DRIVE position. Namely, the transmission is first shifted to one of the 2nd-speed position or higher gear position, and then shifted to the 1st-speed position. For example, the clutch C1 and the brake B2 are engaged to once establish the 2nd-speed position, and then the brake B2 is disengaged to shift the transmission to the 1st-speed position.
In the present embodiment, the particular conditions that should be satisfied to effect the anti-squat control of the automatic transmission consist of: (1) The vehicle speed V should be equal to or lower than a predetermined value; (2) The throttle opening angle θ should be equal to or larger than a predetermined value; and (3) The shift lever 90 should be placed in a position other than the NEUTRAL position (N). All of these three conditions should be satisfied within a predetermined time period To.
The rationale for these three conditions for the anti-squat control of the automatic transmission will be described below.
The first condition associated with the running speed of the vehicle is provided since a drive torque variation which occurs upon shifting of the transmission from the neutral position to the 1st-speed position does not cause a considerable shifting shock if the vehicle speed at the time of the operation of the shift lever 90 from the NEUTRAL position to the DRIVE position is relatively high, or if the vehicle speed rises above a predetermined upper limit within the predetermined time period To after the commencement of movement of the shift lever. In these cases, therefore, the anti-squat control of the transmission is not necessary, and the transmission should be shifted rapidly to the 1st-speed position.
The second condition associated with the currently required engine load or output (i.e., throttle valve position) is provided since the shifting shock upon shifting of the transmission from the neutral position to the 1st-speed position is not considerable when the shifting occurs while the required engine output (represented by the throttle opening angle) is relatively small. In this case, the shifting shock may be greater when the transmission is shifted from the 2nd-speed or higher gear position back to the 1st-speed position, than when the transmission is shifted directly to the 1st-speed position.
Thus, no appreciable advantage is offered by effecting the anti-squat controlling of the transmission, in the above-indicated cases. Therefore, the transmission is shifted from the neutral position directly to the 1st-speed position, so as to permit a quick starting of the vehicle, when the shift lever 90 is moved from the NEUTRAL position to the DRIVE position where at least one of the above-indicated two conditions is not satisfied.
The third condition associated with the position of the shift lever 90 (shift lever valve 20) is provided in view of a relatively high possibility of an erroneous operation of the shift lever 90 by the vehicle driver. For example, the shift lever is moved from the NEUTRAL position to the DRIVE or REVERSE position, and then back to the NEUTRAL position, within a relatively short time duration. In these cases, the execution of the anti-squat shifting of the transmission is meaningless, even though the above first and second conditions are satisfied, because the return of the shift lever 90 to the NEUTRAL position reflects the absence of the driver's intention to place the shift lever in the DRIVE position. The determination on this third condition, namely, the determination as to whether the shift lever 90 is placed in the NEUTRAL position is also carried out at the end of the predetermined time period To after the movement of the shift lever 90 from the NEUTRAL position. Consequently, a negative decision may be obtained on this third condition, in the above-indicated cases wherein the shift lever 90 which was once moved from the NEUTRAL position is returned to the NEUTRAL position within the time period To.
In the present embodiment, therefore, the automatic transmission undergoes the anti-squat shifting only if all the three conditions discussed above have been satisfied within the above-indicated first time period To and if these conditions exist upon expiration of the time period To. In this instance, the automatic transmission is shifted in the anti-squat shifting mode, i.e., once shifted to the 2nd-speed or higher gear position, held in that position for a predetermined second time period T1, and then shifted to the 1st-speed position, for minimizing the shifting shock which would otherwise be considerable upon operation of the shift lever 90 from its NEUTRAL position to the DRIVE position.
If at least one of the three conditions has been dissatisfied during the first and second time periods To, T1, the transmission is shifted directly to the 1st-speed position, or returned from the 2nd-speed or higher gear position back to the 1st-speed position, because the anti-squat shifting is or becomes meaningless or unuseful, and rather the 1st-speed position should preferably be established at once for assuring smooth and rapid starting of the vehicle. It will be understood from the foregoing description that the instant embodiment is adapted to interrupt the anti-squat shifting as soon as any one of the three conditions has been dissatisfied after the conditions were once satisfied.
While the above description refers to the anti-squat shifting control when the shift lever 90 is moved from the NEUTRAL position to the DRIVE position, it is to be understood that the anti-squat shifting control is equally applicable to the operation of the shift lever 90 from the NEUTRAL position to the other forward drive position (SECOND or LOW position) or to the REVERSE position, for the reasons which will be described.
Reference is now made to the flow chart of FIG. 5, which illustrates process steps for effecting the anti-squat shifting control routine for the automatic transmission, under the control of the transmission control computer 80.
Initially, the control flow goes to initializing step 101 wherein flags F0, F1, F2 and timers Ta and Tb are reset.
Step 101 is followed by step 102 to determine whether the content of the flag F0 is "1" or "0". This flag F0 is set to "1" when the shift lever 90 has been moved from the NEUTRAL position to any one of the forward or reverse drive positions, DRIVE (D), SECOND (S), LOW (S) and REVERSE (R). The flag F0 remains "0" until the above movement of the shift lever 90 has occurred. Since the flag F0 is reset to "0" in step 101, a negative decision (F0=0) is obtained in step 102 in the first control cycle, and the control flow goes to step 103.
In step 103, the transmission control computer 80 determines whether the shift lever 90 (shift lever valve 20) has been moved from the NEUTRAL position to one of the forward and reverse drive positions D, S, L, R. If an affirmative decision (Y) is obtained in step 103, step 104 is executed to set the flag F0 to "1", and step 105 is executed to start a timer Ta for measuring the predetermined first time period To after the detection of movement of the shift lever 90 from the NEUTRAL position to one of the drive positions D, S, L, R.
If a negative decision (N) is obtained in step 103, i.e., if the shift lever 90 is not moved from the NEUTRAL position to one of the drive positions D, S, L, R, the control flow returns to step 102.
Once the flag F0 is set to "1", step 102 is followed by step 106 to determine whether the content of a flag F1 is "1" or "0". This flag F1 is set to "1" when the anti-squat shifting of the automatic transmission has been accomplished. Since this flag F1 is also reset to "0" in step 101, a negative decision (N) is obtained in step 106 in the first execution of this step 106. Consequently, the control flow goes to step 107.
Step 107 and the subsequent steps are implemented to determine whether the above-indicated three conditions for effecting the anti-squat shifting of the transmission have been satisfied or not. In step 107, the control computer 80 determines whether the content of the timer Ta is equal to the predetermined first time period To, or not. If the transmission remains in the 1st-speed position for a time longer than the time period To after the operation of the shift lever 90 from the NEUTRAL position to one of the forward and reverse drive positions, the transmission is commanded in step 108 to be continuously maintained in the 1st-speed position. Then, step 109 is executed to reset the flags F0, F1, F2 and the timers Ta, Tb. The control flow then returns to step 102.
As a result, the transmission is held in the 1st-speed position even after the expiration of the first time period To from the moment of detection of the operation of the shift lever 90 from the NEUTRAL position to one of the drive positions, as indicated in FIG. 6(A). Namely, the anti-squat shifting of the transmission is not effected in this case.
Before the first time period To has not passed after the operation of the shift lever 90 from the NEUTRAL position, step 107 is followed by step 110 in which the control computer 80 determines whether the vehicle speed V is equal to or lower than a predetermined level V1, or not. This speed level V1 is almost or near zero. That is, step 110 is provided to check if the vehicle is almost stopped or stationary. If the vehicle speed V is equal to or lower than the predetermined level V1, or if the vehicle is almost stopped, step 110 is followed by step 111 to determine whether the opening angle θ of the throttle valve is equal to or larger than a predetermined value θ 1, or not. If an affirmative decision (Y) is obtained in step 111, the control flow goes to step 112 to determine whether the shift lever 90 is placed in the NEUTRAL position, or not. If the shift lever 90 is not in the NEUTRAL position, all the three conditions for effecting the anti-squat shifting of the transmission have been satisfied (in steps 110, 111 and 112), the control computer 80 produces in step 113 a command to shift the transmission to the 2nd-speed position or higher gear position (3rd-speed or overdrive position), whereby the anti-squat shifting of the transmission is achieved. Subsequently, the flag 1 is set to "1" in step 114, for indicating that the three conditions have been satisfied. In the present embodiment, steps 107, 110, 111 and 112 correspond to means for determining whether the three conditions for the anti-squat shifting of the automatic transmission, and step 113 and subsequent steps including step 120 correspond to means for temporarily placing the transmission in the 2nd-speed or higher gear position.
If any one of the three conditions of steps 110-112 has not been satisfied, the control flow goes to step 115 in which a command is generated to shift the transmission to the 1st-speed position.
Once the flat F1 has been set to "1", step 106 is followed by step 116 to determine whether the content of the flag F2 is "1" or "0". The flag F2 is set to "1" when all of the three conditions for the anti-squat shifting are satisfied upon expiration of the first time period To. If any one of the three conditions is not satisfied at that moment, the flat F2 is reset to "0".
Since the flag F2 is reset to "0" in step 101, step 116 is followed by step 117 when the step 116 is initially executed. Steps 117, 118 and 119, which correspond to step 110, 111 and 112, respectively, are provided to again determine whether the three conditions have been satisfied. However, steps 117 and 118 use reference values V2 and η2 which may or may not be different from the values V1 and θ1 used in steps 110 and 111. That is, the value V2 is equal to or larger than the value V1, and the value θ2 is equal to or smaller than the value θ1. The difference between the values V1 and V2, and the difference between the values θ1 and θ2, are desirable to provide a hysteresis between the conditions for effecting the anti-squat shifting of the transmission, and the conditions for releasing or terminating the anti-squat shifting, so as to avoid a hunting of the control system which might arise where the reference values in steps 117 and 118 are equal to those in steps 110 and 111.
When steps 117, 118 and 119 confirm that all the three conditions are still satisfied, the control flow goes t step 120 to determine whether the predetermined first time period To has passed. If the time period to has not yet passed, the control flow returns to step 102. If the time period To has passed, step 120 is followed by step 121 in which the flag F2 is set to "1". Then, the control flow goes to step 122 in which the timer Tb is started to measure the predetermined second time period T1, which follows the first time period To and in which the transmission is held in the predetermined 2nd-speed or higher gear position, provided that the three conditions for the anti-squat shifting control of the transmission are satisfied after the first time period To.
In any one of the three conditions of steps 117, 118, 119 is not satisfied, the corresponding step is followed by step 123 in which the transmission is shifted to the 1st-speed position. Then, step 124 is executed to reset the flags F0, F1, F2 and timers Ta, Tb, and the control routine of FIG. 5 is terminated. In this case, the transmission is first shifted to the 2nd-speed (or higher gear position) when all the three conditions have been once satisfied (steps 110, 111, 112), and is then shifted to the 1st-speed position if any one of the three conditions becomes unsatisfied before the first time period To has passed. The present situation is illustrated in FIG. 6(B).
In the case where the flag F2 is set to "1" in step 121, step 116 is followed by step 125.
In step 125, the control computer 80 determines whether the content of the timer Tb becomes equal to the predetermined second time period T1, or not. Until the content of the timer Tb becomes equal to "T1", step 125 is followed by step 126. In step 126 and subsequent steps 127, 128, the control computer 80 again determines whether the three conditions are satisfied, or not. The conditions in these steps 126-128 are the same as those in steps 110-112.
If steps 126-128 confirm that all the three conditions are satisfied, the currently established state of the control system is maintained. Namely, the transmission remains in the 2nd-speed or higher gear position. If any one of the three conditions becomes dissatisfied in steps 126-128, the transmission is shifted to the 1st-speed position in step 129, and the flags F0, F1, F2 and timers Ta, Tb are reset in step 130 before the control returns to step 102. Thus, as indicated in FIG. 6(C), the transmission placed in the 2nd-speed position (or higher gear position) upon expiration of first time period To is shifted down to the 1st-speed position if any one of the three conditions has become unsatisfied during the lapse of the second time period T1, i.e., before the time period T1 has passed. This situation is illustrated in FIG. 6(C).
If step 125 reveals that the content of the timer Tb has become equal to the second time period T1, the control flow goes to step 131 in which the transmission is shifted to the 1st-speed position, and step 132 to reset the flags and timers F0, F1, F2, Ta, Tb. This situation is illustrated in FIG. 6(D), in which the transmission is shifted to the 2nd-speed or higher gear position with the three conditions satisfied prior to the passage of the first time period To after the operation of the shift lever 90 from the NEUTRAL position to one of the forward and reverse drive positions D, S, L, R (steps 107, 110, 111, 112, 113), and the transmission is held in the same position until the sum of the first and second time periods To, T1 has passed (116-122, 125-128, 131), for which the three conditions remain satisfied. In this case, the transmission is held in the 2nd-speed or higher gear position for the longest time.
It will be understood that the adjustment of the first time period To provides improved versatility in determining as to whether the anti-squat shifting of the transmission is effected or not. The time period To is determined, for example, by the nominal output of the specific engine, and/or depending upon whether the vehicle has a 2-wheel or 4-wheel drive system. If the time period To is zero, the anti-squat shifting control of the transmission may be completely disabled.
According to the anti-squat shifting control of the transmission as described above, the transmission is shifted down from the 2nd-speed or higher gear position to the 1st-speed position as soon as the vehicle speed rises above the predetermined level V1 or V2 as a result of a rapid increase in the throttle opening at the time of starting of the vehicle. Further, the time during which the transmission is held in the 2nd-speed or higher gear position does not exceed the sum of the first and second time periods To and T1. Thus, the present arrangement may reduce the shifting shock of the vehicle, while permitting a rapid and smooth starting of the vehicle.
FIGS. 6(E), 6(F) and 6(G) illustrate three cases in which the three conditions have been satisfied at different times and remain satisfied until the second time period T1 has lapsed. It will be seen from these figures that the duration during which the transmission is held in the 2nd-speed or higher gear position (3rd-speed or overdrive position) increases depending upon the time at which the three conditions have been satisfied. Namely, the duration is the longest (To +T1) when the conditions have been satisfied at the earliest time (i.e., at the beginning of the first time period To), and the shortest (T1) when the conditions have been satisfied at the latest time (i.e., immediately before the expiration of the time period To). Generally, hydraulically operated frictional coupling devices of an automatic transmission cannot be engaged at the time when the shift lever 90 (shift lever valve 20) has been operated from the NEUTRAL position to a drive position. Consequently, the engine is held in a non-loaded condition for a certain time after the operation of the shift lever. This means that the earlier the time of satisfaction of the three conditions the longer the time of duration for which the accelerator pedal is kept depressed with the engine in the non-loaded condition. The present arrangement wherein the duration of the transmission held in the 2nd-position or higher gear position is increased with the timing of satisfaction of the three conditions, is based on the above fact, and is suitable for accomplishing the anti-squat shifting control of the transmission, in an optimum manner for preventing the shifting shock while permitting the smooth starting of the vehicle.
While the vehicle is usually started with the shift lever 90 moved from the NEUTRAL position to the DRIVE position, the shift lever may be shifted to the SECOND (S), LOW (L) or REVERSE (R) position to start the vehicle. In these cases, too, the principle of the present invention is practiced. It is noted that step 103 determines whether the shift lever 90 is moved from the NEUTRAL position to any one of the forward and reverse drive positions D, S, L and R. When the anti-squat shifting of the transmission is effected in the case of the shift lever movement from the NEUTRAL position to the REVERSE position, the transmission is first shifted to a high gear reverse position), with the brake B0 being engaged and clutch C0 being released.
The position to which the transmission is shifted prior to the shifting to the 1st-speed position, for an anti-squat shifting according to the present invention, is selected depending upon the specifications of the vehicle such as the nominal engine output rating and the drive system (2-wheel drive or 4-wheel drive). If a considerably large shifting shock of the transmission is expected upon shifting of the shift lever from the neutral position to a drive position, the transmission is shifted to an accordingly higher gear position (e.g., 3rd-speed position or overdrive position), for providing an effective anti-squat shifting of the transmission.
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A method and an apparatus for controlling a vehicle automatic transmission which has a plurality of selectively established gear positions and is shifted to and temporarily held in a predetermined one of the gear positions other than the lowest-gear position, upon operation of a shift lever from its neutral position to one of drive positions, if a predetermined condition is satisfied within a preset time period after the shift lever operation. The transmission is generally shifted down to the lowest-gear position after it is held in the predetermined one gear position. This anti-squat shifting of the transmission responsive to the shift lever operation from the neutral position, contributes to reduction in the shifting shock and prevention of squatting of the tail or stern of the vehicle when the shift lever is moved from the neutral position to a drive position such as DRIVE, SECOND or LOW, in which the transmission is selectively placed in the two or more gear positions (e.g., 1st-gear, 2nd-gear, and 3rd-gear positions).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to the mining of minerals from underwater and in particular to the harvesting of mineral nodules located on the floor of an ocean.
2. Description of the Prior Art
Ferromanganese nodules or aggregates are known to exist in large quantities on ocean floors, frequently at depths varying from 5,000 to 19,000 feet. Previously, means have been suggested for scraping or picking up the loose aggregates from the sea floor and transmitting them to the surface. U.S. Pat. No. 3,588,174 discloses a collector that is towed across the undersea floor, dislodging the aggregates partially by water spray, the aggregates being pumped to the surface in a stream of water within a conduit. U.S. Pat. No. 3,802,740 and Canadian Pat. No. 692,998 disclose devices that also collect aggregates from an undersea floor and transmit them in a conduit to the surface. Such devices convey the collected aggregate to the surface by utilizing submerged pumps. A submerged pump usually requires a protective capsule and may be difficult to service, especially at great depths.
It is known to use dual concentric pipes for well drilling, as shown in U.S. Pat. No. 1,461,240, where water is pumped down the annulus, then returned up the inner pipe to create a suction to draw loose material from the floor. This education system cannot be used with the high hydrostatic pressure that occurs at depths of 5,000 to 19,000 feet. Dual concentric pipes are also known in well drilling using gas as a circulation medium, as in U.S. Pat. No. 3,065,807.
SUMMARY OF THE INVENTION
The invention may be summarized as an underwater harvester of mineral nodules or aggregates that uses a dual concentric string of pipe extending from a surface vessel to a submerged gathering apparatus for supplying water and power to the gathering apparatus and for conveying the aggregate to the surface. Water is pumped down an annular passage in the dual string and through a conduit loop leading to an inner pipe. Crushed and collected aggregates are placed into the conduit loop for conveyance to the surface. A portion of the downward flow is distributed to the harvester for collecting and crushing the aggregates.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view of apparatus constructed in accordance with the teachings of this invention.
FIG. 2 is a cross sectional view of the dual pipe for use with the mining equipment of FIG. 1, as seen looking along the lines II--II of FIG. 4.
FIG. 3 is a cross sectional view of the dual pipe shown in FIG. 4 as seen looking along the lines III--III.
FIG. 4 is a vertical cross sectional view of a dual pipe used in conjunction with the mining equipment shown in FIG. 1.
FIG. 5 is a partial cross sectional view of a pressure converter used in conjunction with the mining equipment of FIG. 1.
FIG. 6 is a partial cross sectional view of the pressure converter of FIG. 5 with its sliding valve shown in a different position.
FIG. 7 is a partial cross sectional view of the pressure converter of FIG. 5 as seen from the top as shown in the drawing.
FIG. 8 is perspective view, partially broken away, of a gathering apparatus used in conjunction with the apparatus of FIG. 1.
FIG. 9 is an enlarged fragmentary side elevational view, partially broken away, of the gathering apparatus of FIG. 8.
FIG. 10 is a storage bin and feeder mechanism used in conjunction with the mining apparatus of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates schematically the mining apparatus for mining mineral aggregates or nodules 11 from an undersea floor 13, including a surface vessel A for towing the undersea equipment. A string of dual concentric pipes B, connected from the surface vessel A to the undersea equipment, serves as a tow line and as a conduit for water pumped from the surface vessel to the undersea equipment and back to the surface along with crushed nodules. A pressure converter C converts the high pressure stream of water being pumped by the pumps on the surface vessel to a lower pressure higher volume for use with the gathering apparatus D. The gathering apparatus D collects and crushes the nodules 11 and conveys them to a temporary storage bin and feeder mechanism E. Storage bin and feeder mechanism E, suspended at the end of the dual string approximately 50 feet above the undersea floor surface 13, tows the gathering apparatus D approximately 200 feet behind it. The bin and feeder mechanism E temporarily stores the crushed nodules 11, and gravity feeds them into the dual pipe B for transmission to the surface. The pressure converter C, gathering apparatus D, and storage bin and feeder mechanism E serve as harvesting apparatus or means for collecting and transmitting the aggregates to the surface vessel.
Dual Pipe
The dual pipe string B is shown in FIGS. 2, 3, an 4. Referring to FIG. 4, wherein the upper end of the pipe is on the left side of the drawing, an outer pipe 15 is made up of a plurality of sections or stands, each 30 or more feet long. Each stand contains an externally upset threaded box section 17 on its upper end and an externally upset threaded pin section 19 on its lower end, defining a joint for screwing the stands together. The box section 17 and pin section 19 each have external shoulders 18, 20, respectively, to limit the make-up position. The box section 17 has an internal shoulder 21 that is spaced a selected distance below the end 23 of the threaded pin 19 when fully made up.
An inner pipe 25 is carried concentrically within the outer pipe 15, and is made up of a plurality of sections or stands to form a continuously open inner passage 27 and an annular passage 29 between the walls of the inner pipe 25 and outer pipe 15. The upper end of each stand of inner pipe 25 has an enlarged portion 31 for receiving the lower end 33 of the upper stand, defining a joint for connecting the inner pipe stands together. The lower ends 33 are cylindrical and fit telescopingly within the enlarged portion 31. A seal 35, between the inner end 33 and enlarged portion 31, prevents leakage.
Each stand of inner pipe 25 has a plurality of centralizers or spokes 39 attached to the inner pipe 25 and closely received within the outer pipe to maintain the pipes in concentric relation to each other. As shown in FIGS. 2 and 3, each set of spokes 39 is a group of two or more, preferably three radial projections spaced apart 120° for allowing water to pass through the annular passage 29. One set of spokes 39 is located near the lower end of the inner pipe stand 25 and another near the middle. The upper set of spokes 39, located near the enlarged portion 31 has a rigid metal ring 41 attached to the periphery of the spokes 39 for carrying the inner pipe 25 within the outer pipe 15. Ring 41 is larger than the inner diameter of the outer pipe 15 and rests on internal shoulder 21 of the outer pipe 15. A resilient ring seal 43 is seated within a shoulder on the upper side and outer portion of ring 41. The inner width of seal 43 extends from the outer periphery of ring 41 inward to a point slightly short of the inner wall of the outer pipe 15, so that while deformed no part of the seal will be extended into the annular passage where a high flow rate of water occurs. Seal 43 is thicker than its shoulder within which it seats, so that the seal is deformed by the end 23 of the threaded pin 19 when the outer pipe stands are fully made up. The distance between the internal shoulder 21 and end 23 of threaded pin 19 when the outer stands are fully made up is slightly larger than the width of the metal ring 41 so that a clearance 45 exists when the outer pipes 15 are fully made up. Seal 43 minimizes leakage into the threads from the annular passage 29. It is expected that the string of dual pipes B would not be pulled very often, thus frequent inspection or cleaning of threads would not be possible, resulting in corroded threads if a seal was not present.
A suitable inner pipe 25 is 103/4 inch outer diameter, J-55, 44 pounds per foot A.P.I. (American Petroleum Institute) casing with 0.400 inch wall thickness. A suitable outer pipe 15 is 20 inch outer diameter, X-135 grade, 104 pounds per foot A.P.I. casing or line pipe with 1/2 inch wall. The pipes may be lowered into the sea by screwing the outer stands 15 together, while the inner pipes 25 simultaneously telescope and seal within each other. When pulling the string, the inner pipes may be removed for cleaning, inspection, or may be racked and stored within the outer pipes.
PRESSURE CONVERTER
A portion of the water pumped down the annular passage 29 will be returned along with crushed nodules 11 up the inner passage 27, while another portion will be used to collect and crush the nodules. The flow pressure at the bottom of the drill string should be relatively high, for example 2000 psi., while only 200 psi. is required for collecting and crushing. This pressure is converted by pressure converter C as shown in FIGS. 5, 6, and 7.
Referring to FIG. 7, a high pressure inlet 47 leads to a manifold 49 that has two inlet ports 51a, b spaced apart from each other. A sliding valve 55 is located in a cylindrical valve chamber 57 adjacent the inlet ports 51a, b. The valve 55 has two cylindrical plugs 59a, b closely received in the valve chamber 57 and of width at least equal to inlet ports 51a, b so that they may be closed by the plugs 59a, b. The plugs 59a, b are spaced apart on a shaft so that when one port 51 is covered, the other port is fully opened. Two exhaust ports 61a, b are located on the opposite sides of ports 51a, b, and are of a size sufficient to be closed by plugs 59a, b. The exhaust ports 61a, b may lead to the surrounding sea, or be used for other high pressure uses. The exhaust ports 61a, b are spaced so that when one is closed by plug 59, the other exhaust port is open. The exhaust ports 61a, b are spaced one port width wider on each end than the inlet ports 51a, b so that when an exhaust port is open on one side, the corresponding inlet port on that side will be closed.
Four ports 63a, b, c, d are located on the lower surface of the cylindrical valve chamber as shown on the drawing, two ports being adjacent each end of the valve stroke. Ports 63 are of a size to be closed by the plugs 59 and are spaced so that when one port 63 on each end is closed, the other port on the same end is open. Also on each end, one port 63 is aligned with an exhaust port 61 and one port 63 with an inlet port 51, so that they may be closed simultaneously by the valve plugs 59. In the position as shown in FIG. 7, inlet port 51a is closed along with port 63b, while port 63a and exhaust port 61a are open. Intake port 51b is open along with port 63c, while exhaust port 61b and port 63d are closed. Valve 55 may be reciprocated within the valve chamber 57 to reverse the opening and closing of ports.
Referring to FIG. 5, ports 63a, d, lead directly to a high pressure chamber 65. Port 63b, c are connected by internal passages 67a, b to ports 63a, d, thus also lead to high pressure cylindrical chamber 65. A high pressure piston 69 is reciprocally carried in the high pressure cylinder 65 and is connected by a shaft 71 to a substantially larger piston 73 in an adjacent low pressure cylindrical chamber 75. High pressure chamber 65 is separated from low pressure chamber 75 by a wall 77 through which the shaft 71 slidably passes. A seal 79 within wall 77 prevents leakage from the high pressure chamber 65 to the low pressure chamber 75.
Wall 77 also provides separation between the valve chamber 57 and the low pressure chamber 75. A shaft 81 slidably passes through wall 77 and also through low pressure piston 73. A seal 83 within wall 77 prevents leakage from the valve chamber 57 to the low pressure cylinder 75. Enlarged portions 85a, b, provided on shaft 81, are larger than the aperture in low pressure piston 73 within which the shaft 81 loosely passes. The enlarged portions 85a, b are spaced apart a selected distance so as to be contacted by the low pressure piston 73 near each end of its stroke to shift the valve 55 to the opposite position.
Four one-way valves 87a, b, c, d, two opposite each end, are located in the low pressure chamber 75. On each end, the one-way valves are opposed so that when the piston 73 is moving toward them, the inward opening valve, or intake valve, will be closed and the outward opening valve will be open. The intake valves allow water to enter from the surrounding sea when open. The outlet valves are connected to the gathering apparatus D. Valves 87c, d are shown as poppet-type, while valves 87a, b are shown as hinged-type. These types may be interchanged and other valves used as well.
In operation, high pressure water pumped through the annular passage 29 will pass to inlet 47 of the manifold 49. If the pressure converter C is in the position as shown in FIGS. 5 and 7, the high pressure water will flow into the valve chamber 57 via inlet port 51b as shown by the arrows. This high pressure water flows then through port 63c, since port 63b is closed by plug 59a, and since access to exhaust port 61b is blocked by plug 59b. Referring to FIG. 5, the high pressure water then flows, as indicated by the arrows, down into the right hand side of the high pressure cylinder 65. This forces the high pressure piston 69 to the left, drawing with it the low pressure piston 73. Water within chamber 75 on the left of low pressure piston 73 will be forced out the outlet port 87b, the intake port 87a remaining closed since it operates only one way. This water flow then passes to the gathering apparatus D. The exhaust fluid from high pressure chamber 65 on the left side of piston 69 proceeds through port 63a out exhaust port 61a.
When low pressure piston 73 nears the end of its stroke, it will contact enlarged portion 85a, pushing valve 55 to the left, as shown in FIG. 6. In the position shown in FIG. 6, high pressure can no longer enter the high pressure chamber on the right side of the piston because inlet port 51b will be blocked. The high pressure water flow rather enters through the now opened inlet port 51a and port 63b. This causes the piston 69 to move to the right pushing piston 73. High pressure fluid on the right side of high pressure piston 69 will be exhausted through port 63d out exhaust port 61b. As the low pressure piston 73 is pushed to the right it will force fluid out outlet valve 87d, as shown in FIG. 6. At the same time intake valve 87a will open, allowing surrounding sea water to enter the low pressure chamber 75 on the left side of low pressure piston 73. When low pressure piston 73 nears the end of its stroke to the right, it will contact enlarged portion 85b, shifting valve 55 back to the right as shown in FIG. 5, and thereby causing reciprocation.
The output pressure is lowered by a factor proportional to the different cross-sectional areas of the pistons 69 and 73. A suitable size of pressure converter for converting 625 gallons per minute at 2000 psi. to 6,250 gallons per minute at 200 psi. consists of a one foot diameter high pressure piston 69 and a three foot diameter low pressure piston 73, with a five foot stroke. Linear piston speed is kept below two feet per second to give an approximate five second stroke.
GATHERING APPARATUS
Referring to FIGS. 8 and 9, the gathering apparatus D, towed on the undersea floor 13 by cable 89, comprises an inclined ramp, chute, or channel 91 carried on a frame or skis 93. Channel 91 is passive and is made up of a plurality of overlapping sheets 95 decreasing in width from the leading edge 97 to the rearward edge 99. A row of flat jet nozzles 101 are mounted at each overlapped intersection to direct water spray up the channel 91. A leading row of flat jet nozzles 103 are mounted in front of the channel 91 on curved pipes 105. Pipes 105 are oriented so that the nozzles 103 are slightly beneath the undersea floor surface, which is normally covered with sediment. The nozzles 103 are directed generally upward and rearward, toward the inclined channel 91. The inclination of channel 91 controls the depth at which the leading edge 97 cuts the surface. Preferably the leading edge 97 is level or slightly lower then the undisturbed undersea floor 13. The inclination is controlled by hydraulic cylinders 107, which are in turn controlled from the surface vessel A.
A pair of cylindrical roller crushers 109 are mounted directly behind rearward edge 99, with the tops of the rollers level or below the edge 99 so that nodules will fall into the rollers to be crushed. The roller crushers 109 are corrugated, rotate in opposite directions to each other, and are spaced apart a selected distance for the desired crushed size. The axes of the rollers are perpendicular to the direction of travel of the gathering apparatus D. The roller crushers 109 are rotated by a water motor, which is actuated by water pressure from pressure converter C.
A cover 111 of sheet metal encloses inclined channel 91 to prevent nodules from escaping. An expanded metal enclosure 113 covers the area above roller crushers 109 to prevent nodules from escaping but allows turbid water to flow through.
In the preferred embodiment, three channels 91 are connected together in parallel. An eduction system 115 comprised of metal conduits extends over and around the channels 101 to provide a frame or support, and to convey water to the nozzles 91, 103, roller crushers 99, and the return flow to bin and feeder mechanism E.
A conduit 116 extends below, around the back and over each crusher 109 and channel 91. These conduits are interconnected by upper and lower transverse conduits 118 to provide a frame for three channels 91. Plugs 120 are located within vertical conduits 122 spaced between the upper and lower transverse conduits 118 to prevent incoming flow from entering the return portion of conduits 116.
Fluid converter C provides a large volume of water at approximately 200 psi. through a flexible hose 117 to the eduction system 115. A portion of the supply water passes beneath roller crushers 99 as indicated by the arrows to educt or draw the crushed nodules along the eduction system 115 to flexible hoses 119 for conveyance to bin and feeder mechanism E.
The hydraulic cylinder 107 for each channel 91 extends between the eduction system 115 and the cover 111. Tow hitches 121, located between the enclosure 113 and eduction system 115 allow lateral and longitudinal flexing.
In operation the surface vessel A tows the gathering apparatus D at a slow rate by the dual pipe B, bin and feeder mechanism E, and cable 89. Water flow, supplied from the surface pumps through the annular passage 29 of the dual string B and through the pressure converter C, is sprayed out nozzles 103 to dislodge nodules 11 as the sled is towed along on its skis 93. Nozzles 101 force the nodules up the inclined channel 91, further dislodging sediment. The nodules are then crushed by roller crushers 109, and further sediment is freed. Portions of this sediment will flow out through enclosure 113. The turbid water and crushed nodules are drawn or educted through conduits 116 and hoses 119 to bin and feeder mechanism E. The turbid water and sediment is diluted by the fresh water being pumped from pressure converter C through hoses 117 to the eduction system 115. The size of the nodules varies but they are normally found within the range from three to six inches in diameter. It is expected to crush them to 1/2 inch maximum diameter.
BIN AND FEEDER MECHANISM
Referring to FIG. 10, the crushed nodules are educted along conduits 119 to bin 124. The conduits are simply hooked over the open topped bin for discharging the aggregate. Two ball valves 123a, b are located below the bottom of bin 124, and provide communication to the feeder mechanism 125. The feeder mechanism 125 comprises two spherical chambers 125a, b mounted below bin 124 and ball valves 123a, b. Two ball valves 127a, b are located below the bottom of the feeder chambers 125 and provide communication to a conduit 129. Ball valves 123 are opposed to each other and opposed to ball valves 127. That is, as shown in FIG. 10 when the top valve 123b is open, its corresponding bottom valve 127b is closed. Simultaneously top valve 123a of feeder chamber 125a will be closed and bottom valve 127a open. Ball valves 123, 127 are operable by hydraulic actuaters 131, 133, controlled at the surface or by other sensor means.
Conduit 129 extends from below the bottom valves 127 in a loop up to a "T" intersection or distribution chamber 135. Distribution chamber 135 is located below the bottom of bin 124 and at the end of the dual pipe string B. Distribution chamber 135 is in communication with the water supplied from the annular passage 29, and distributes a portion of this water to the pressure converter C and to conduit 129. The downstream end of conduit 129 is in communication with the inner passage 27 of dual string B.
In operation one feeder chamber 125 will be emptying into conduit 129 while the other feeder chamber 125 will be filling. As shown in FIG. 10, feeder chamber 125a is emptying into conduit 129, its top valve 123a being closed and its bottom valve 127a being open. At the same time feeder chamber 125b is filling, its top valve 123b being open, and its bottom valve 127b being closed. The aggregates fall into the conduit 129 at rate of about one feet per second. As the feeder chamber 125a is being emptied, clean water pumped from the surface through conduit 129 will fill the chamber. When substantially all of the aggregates have been emptied from feeder chamber 125a, valve 127a will close and valve 123a will open. Aggregates from the bin will then fall into the feeder chamber 125a. As they fall, the water in the chamber that they displace will rise up into the bin 124, displacing the turbid water, which flows over the sides of the open topped bin. This eliminates much of the sediment from the water and further cleanses the nodules prior to being transmitted to the surface. As feeder chamber 125a is refilling, feeder chamber 125b is releasing aggregates into conduit 129. Consequently a continuous stream of aggregates will be provided up the inner passage 27.
The high pressure obtainable by the surface pumps allows a relatively high solids - low volume content of up to 37% crushed nodules by weight. The filling and feeding cycle is expected to take approximately five minutes. In the preferred embodiment, a 20 foot diameter 30 foot high bin 124 is used. Feeder chambers 125a, b are 12 feet in diameter, and 12 inch ball valves 123, 127 are used.
It is accordingly seen that an invention having significant improvements has been provided. Use of the dual string provides water power for collecting, crushing, and transmitting aggregate to the surface, without the need for downhole pumps.
While this invention has been described in only one of its forms it should be apparent to those skilled in the art that it is not so limited but is subject to various changes and modifications without departing from the spirit or scope thereof.
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A dual passage string of pipe for use in cycling fluid from a ship to an undersea mineral aggregate gathering apparatus. The string of pipe is made up of sections of concentric inner and outer pipes. The outer pipes are screwed together and the inner pipes slide telescopingly within each other. The inner pipes are suspended in the outer pipes at their upper ends by a rigid supporting ring supported by an internal shoulder in the outer pipe. The internal shoulder is located at the base of the threads and is separated from the lower end of the male threaded section. A resilient seal ring is carried between the supporting ring and the male threaded section for preventing water from entering the threads to avoid corrosion.
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SUBJECT OF THE INVENTION
This invention relates to a method of making articles useful in conditioning fabrics. More particularly, it relates to making fabric softening articles employed in automatic laundry dryers to soften laundered materials.
BACKGROUND OF THE INVENTION
Fibers, yarns and threads, fabrics, manufactured textile articles and laundry have been treated to impart desirable properties to them. They have been made antibacterial, fire-retardant, shrinkproof, stiff, soft, antistatic, soil repellent, creaseproof, permanently pressed, water repellent, and stain resistant. They have been dyed, printed, perfumed, sized, starched and lubricated. Compositions for modifying the yarns, fabrics and manufactured articles made from them have been deposited on the surfaces to be treated as solids, liquids, solutions, dispersions, emulsions, sprays, gases and vapors. They have applied at various temperatures, including those above and below room temperature, although employment at ambient temperatures has generally been preferred.
Treatments of laundry have generally taken place either in the washing machine or after completion of laundering and drying. Thus, laundry has been made soft, antibacterial, antistatic and perfumed by incorporating appropriate materials in the detergent composition or wash water and in some cases, in the rinse water. Sizings, starches, lubricants, such as silicones, water repellents and stain repellent compounds have generally been applied to the laundry after washing and drying, as sprays or in baths. Solvents have been used in the dryer for dry cleaning effects on textiles and water has been dispensed from a container in the dryer to moisten laundry and prepare it for ironing. Powdered absorbents have been mixed with textiles in a tumbling container much like an automatic clothes dryer, to help in removing soil from such articles. Also, pressurized sprays have been used to apply various materials to drying or dried laundry. With respect to softening laundry and making it antistatic, however, the usual method employed in conjunction with the normal home washing process is to incorporate a substantive conditioning agent in the rinse water, from which it is adsorbed onto the laundry, to remain thereon when dried.
Recently, an effort has been made to utilize the dryer for the application of conditioning agents to the laundry in a process which does not greatly modify the ordinary drying operation but allows the coating of the laundry with a conditioning agent during the drying process. In U.S. Pat. No. 3,442,692, it is taught that particular cationic softening agents may be vaporized in the dryer from flexible papers, cloths and sponges, into which they have previously been absorbed. To make such products, solutions of conditioning agents were used and the absorbents were immersed in such solutions and dried before being inserted into the dryer with a load of laundry. Such a method has been found by the present applicant to be inefficient, since much of the absorbed material is unavailable for application to the laundry being treated. Also, the removal of solvents is often a hazardous operation and is generally costly. Because the active conditioning material might melt, heat should be used judiciously in removing solvent. At times, this necessitates the employment of vacuum or low temperature drying techniques. Accordingly, the present invention is considered to be a significant improvement over the procedures of the prior art.
DESCRIPTION OF THE INVENTION
Although various prior art methods for conditioning laundry and softening fabrics are disadvantageous in various ways, use of the present invention allows the production of conditioning articles which are easily employed, safe to use, of excellent effectiveness, reasonably economical to use and easy to manufacture by the present method. The manufacturing method is safe, produces an excellent product, is fast and inexpensive and is adaptable to high speed inexpensive commercial processes which produce exceptionally uniform articles that give reproducible softening and conditioning effects, in use. Although the present invention is useful in making articles for applying conditioning and treating compositions to fabrics or laundry in an apparatus such as an automatic clothes dryer, the articles are primarily useful in conditioning damp, previously laundered textiles and clothing, of either synthetic or natural fibers, to make them soft and free of annoying electrostatic effects.
In accordance with the present invention, a method of manufacturing an article for conditioning fabrics by making contact with them and applying conditioning material to the surfaces of said fabrics comprises raising the temperature of a conditioning composition comprising said conditioning material until it forms a melt, maintaining the melt at a temperature at which it is fluid and readily applicable to a base for the conditioning article, applying said fluid composition to a base article so that a surface thereof, adapted to contact a fabric to be softened, is coated with said composition, and cooling the composition on said surface sufficiently to convert it to a solid state, in which it is adherent to the base. In preferred embodiments of the invention, the conditioning agent is a softening and/or antistatic agent, the base on which it is applied is substantially solid and dimensionally stable, preferably also being form retaining, and the application of the melted conditioning composition is at a temperature in a preferred range, with cooling being effected to about ambient or slightly higher temperature by contact of the coated article with air or other gas to remove heat from the melt. Also preferably, application of the conditioning composition is effected by dipping the article to be coated into a melt of the conditioning composition or by spraying the melted composition onto the surface to be treated. The application of the conditioning agent and cooling thereof are effected relatively quickly, for best results.
Various objects, details, constructions, operations, uses and advantages of the invention will be apparent from the following description, taken in conjunction with the illustrative drawing of some apparatuses for effecting the method of the invention, in which drawing:
THE DRAWING
FIG. 1 is a schematic sectional elevation of a continuous apparatus for applying a melt of conditioning agent to the surfaces of bases for fabric conditioning articles;
FIG. 2 is a schematic sectional elevation of a continuous apparatus for spraying a melt of conditioning agent onto surfaces of bases for fabric conditioning articles ;
FIG. 3 is a schematic sectional elevation of a continuous apparatus for applying a melted conditioning agent to the surfaces of a strip or sheet of base material for fabric conditioning articles;
FIG. 4 is a cross-section of a ball made of paper or other water or solvent absorbing material coated according to the method illustrated in FIG. 1, showing the presence of conditioning agent on the surface of the ball, without penetrating it; and
FIG. 5 is a comparative illustration in vertical cross-section of another ball of absorbent material treated with a solution of conditioning agent that had penetrated to the interior thereof, where the conditioning agent is useless in effecting conditioning of fabrics.
DETAILED DESCRIPTION OF THE INVENTION
As is illustrated in FIG. 1, continuous belt 11, moving in the direction of the arrow around rollers 13, carries base articles 15, in this case, fairly light weight hollow balls formed from paper pulp, fastened to the belt by any suitable means, and causes them to descend into a tank 17 containing a melt of coating composition 19. Belt 11 is of open work mesh material and its path into melt 19 is governed by additional end rollers 13 or holding means located near the lower corners 21 and 23. After picking up a coating of the conditioning composition, the coated objects, still held to the belt, are advanced upward and out of the coating composition and under manifold-type distributor 25 through which air 27, supplied by blower 29 and passing through pipe 30 is directed onto the coated articles, to cool them. They are then removed from the belt and packed for shipment, storage and use.
The coating composition 19 in coating tank 17 is maintained at a desirable elevated temperature by circulation through line 31, pump 33 and heat exchanger 35 and back through line 37 into the coating tank. By downwardly directing line 37 at 39, currents are created in the tank and help to maintain the conditioning composition stirred up and homogeneous. Although pump 33 preferably operates continuously, its speed may be adjusted, as desired, to give best coating action. Thermostat 41, responsive to the temperature of the conditioning composition in tank 17, by means of probe 43, regulates the amount of heat added by heat exchanger 35 to the circulating composition.
In FIG. 2 is shown the coating of a brick-shaped polystyrene foam base article on a face, sides and ends by means of a spray of conditioning composition. The light weight shaped foam may have corners and edges rounded for better contact with materials to be conditioned and for more even application of coating composition to the article. Composition 45 in tank 47 is gravity fed to sprayer 49 from which it is discharged through orifice 51, forming a spray 53 which coats the upper face, sides and ends of a base article 55 to produce a coated conditioning article 57. The articles to be coated with conditioning composition are fed past the sprayer 49 by continuous belt 59 which is advanced in the direction of the arrow over main rollers 61 and 63 and supporting rollers 65. The drive means for advancing roller 63 are not illustrated.
After the coating of conditioning agent has been sprayed onto the base article, the coated article is advanced along belt 59 to a cooling station, wherein air or other suitable cooling gas 67 is directed onto a plurality of the coated articles to cool them. The air is forced by blower 69 through duct 71, manifold 73 and out through a plurality of orifices therein, 75. The coated and cooled articles, on which coating composition has been solidified, are discharged into bin 77 and are ready for removal, packaging, storage, shipment and use.
The temperature of the coating composition is desirably regulated to the proper level, whereby also affected are the viscosity and spray rate thereof through the sprayer, by employing a thermostat 79 having a probe 81 in a tank of coating composition 45. The probe is responsive to temperatures lower than that desired so that at under such conditions electric heater 83 is activated and raises the temperature of the coating composition to that desired, at which point the heater is cut out by action of the thermostat. A source of electricity is designated by numeral 85. To maintain uniformity of the composition in the tank and to promote even heating thereof, stirrer 87 is employed.
In FIG. 3 is illustrated a means for coating a sheet or strip of base material with a fabric conditioning composition. Such apparatus is similar to that shown in FIG. 1. A special paper, fabric or polymeric sheet 91 is fed from roll 93 over or under spindle rollers 95, 97, 99 and 101 to take-up roll 103, which is motor activated. During the travel of the sheet in the direction of the arrow, it passes through conditioning composition 105 in tank 107. Such composition is at an elevated temperature to facilitate application to the base material 91 and the temperature is maintained at the desired level by means of a thermostat 108, having a probe 109 in the coating composition, which probe actuates a heater 111 when the temperature falls below that desired. Circulation of conditioning composition through the heater is effected by means of line 113, pump 115 and return line 117. Heater 111 is on only when thermostat 108 indicates that the conditioning composition requires more heat to maintain the desired coating temperature. After application of the coating, nip roll 102, in conjunction with roll 101, trims the coating to desired thickness on the strip. Then, blower 119 forces air through conduits 121 and 122 and through distributors 123 and 124, out orifices 125 and 126 and against both faces of the coated base material, whereby the coating is cooled and solidified so that the coated article may be rolled, cut, shaped or otherwise treated, packaged and stored, ready for use.
For simplicity of illustration, the spray means and cooling means employed in the apparatuses of FIGS. 1 and 2 have been shown acting on only one side of the article being treated. Clearly, additional such means may be used for coating and cooling other parts of such objects.
In FIG. 4 is illustrated a vertical sectional view of a coated object produced by the method illustrated in FIG. 1. This is a hollow ball 127 of paper, produced from pulp and uniformly coated with a layer of solidified conditioning composition 129. As will be seen from FIG. 4, a portion of the conditioning composition 129 has penetrated the surface of the paperboard to a slight degree, as indicated at 131. The rest of the paper is not impregnated with conditioning composition and the interior thereof is free of it. When a similar composition is applied as an aqueous or alcoholic solution, it penetrates the paperboard and creates, in addition to the solidified coating 133, an impregnated paperboard 135, illustrated in FIG. 5, which is undesirable. Also, in the drying operation the excess liquid that had soaked through the paperboard sphere to the interior thereof is evaporated and solid appears inside sphere wall 137 at 139. When used, the spheres illustrated in FIG. 5 give much less efficient transfers of coating compositions than do those of the type shown in FIG. 4, which are made according to the method of this invention.
The drawing illustrates methods of carrying out the present invention and advantages resulting therefrom. Especially when compared with the applications of solutions of conditioning compositions, greatly improved results are obtained by the present method, both in the method itself and the products which are results thereof. Broadly, the advantages of the present method are obtainable with a wide variety of conditioning materials, although the invention is primarily directed to the utilization of fabric softeners and antistatic agents. In addition to the preferred conditioners, other such agents that are employed in accordance with the present invention, either with the fabric softeners or separate therefrom, and either alone or in mixture with other conditioning agents are bactericides, fungicides, fire retardants, shrinkproofing agents, sizes, such as starch, soil repellents, creaseproofing agents, water repellents, stain repellent compounds, dyes and other coloring agents, lubricants, odor counteractants and perfumes. Various compounds of these types, which are solids, liquids or of a waxy nature are known and may be applied to base article to form conditioning articles. They are meltable at temperatures within suitable ranges for application and use but if they are not, the melting ranges thereof may be adjusted by the use of mixtures or of particular carriers of desired melting points. Thus, for example, petroleum waxes, fatty acids, mono-, di- and triglycerides may be employed, as may be mixtures of higher and lower melting conditioning agents. Viscosity depressants may also be used to thin down the coating material for more effective application. For example, 5% of sodium acetate may be so employed. In some cases, minor proportions of water and solvent, usually no more than 10% of each of these, preferably less than 5% thereof and most preferably, less than 2% thereof may be present to aid in maintaining a homogeneous conditioning composition and to help in adjusting the melting point. Of course, other plasticizers and solidifying agents known to the art may also be used to adjust softening and melting temperatures of the conditioning agents. It will be apparent however, that it is much preferable to use conditioning materials of melting points in the desired ranges so that solvents, plasticizers and carriers need not be employed.
With respect to fabric softeners and antistatic agents that are useful in making the fabric softening articles of this invention, various anionic, cationic and nonionic substances may be used. The utilities of many of these materials in fabric softening articles have been discovered by the present applicant and other workers in the research laboratories of his assignee company and the listing of such useful materials hereinafter is not to be considered as an indication that the present inventor discovered their utilities as coating compositions for fabric softening articles. Rather, he has found that they are applicable to base articles by means of his process, produce better fabric softening articles and are capable of being processed by the present inventive method more effectively than was the case when solutions thereof were applied. In some cases, knowledge of the present invention and the utilization of melts of conditioning agents may have aided in the discovery of such other useful compositions.
Among the fabric softeners and antistatic agents that are usable in accord with the present invention are the nonionic surface active materials, including higher fatty acid mono-lower alkanolamides, higher fatty acid di-lower alkanolamides, block copolymers of ethylene oxide and propylene oxide, having balanced hydrophilic and lipophilic groups, polymers of lower alkylene gylcols, polyalkylene glycol ethers of higher fatty alcohols and polyalkylene glycol esters of higher fatty acids. Among the anionic agents are the higher fatty acid soaps of water soluble bases, higher fatty alcohol sulfates, higher fatty acid mono-glyceride sulfates, sarcosides, taurides, isethionates and linear higher alkyl aryl sulfonates. Cationic compounds include the higher alkyl-di lower alkyl amines, di-higher alkyl lower alkyl amines and quaternary compounds, especially quaternary ammonium salts, e.g., quaternary ammonium halides.
Specific examples of surface active materials of the types described above are given in the text Synthetic Detergents by Schwartz, Perry and Berch, published in 1958 by Interscience Publishers, New York. See pages 25 to 143. Among the more preferred of these are:
Nonionic -- nonylphenoxy polyethoxy ethanol; stearic monoethanolamide; stearic diethanolamide; block copolymers of ethylene oxide and propylene oxide (Pluronics®);
Anionic -- sodium soap of mixed coconut oil and tallow fatty acids; sodium stearate; potassium stearate; sodium laurate; tallow alcohols sulfate;
Cationic -- dilauryl dimethyl quaternary ammonium chloride; hydrogenated tallow alkyl trimethyl ammonium bromide and benzethionium chloride.
Although various bases may be used, of different characteristics, shapes and materials of construction, with the advantages of the present invention resulting, it is generally preferred that the base article should be a solid which is dimensionally stable. Additionally, it is preferred that it be form retaining. Thus, although strips of flexible material may be processed by the method of this invention and will be manufactured more readily and will be of better characteristics than similar materials which are impregnated with a conditioning agent from solution or dispersion, such sheets or strips are not considered to be form retaining, although they may be characterized as dimensionally stable. Thus, they will tend to be folded or bent more readily, with possible cracking and release of coating material from the surfaces thereof, and therefore are not as advantageous for the present purposes as are the form retaining products, such as spheres, cylinders, bars or bricks of fairly light weight bases with conditioning composition coated onto the surfaces thereof. In addition to being form retaining, it is desirable that the materials used should be of a melting point so that they do not change shape drastically during application of the conditioning agent. Also, although they may be somewhat porous, the pore sizes should be small enough so that the conditioning composition melt does not penetrate the pores to such an extent that much of the conditioning material is made inaccessible to clothing or laundry to be treated by tumbling contact with the conditioning article. The degree of impregnation or penetration of the melt is dependent also on the viscosity thereof, which varies with the temperature employed. Processing technique also affects coating quality. For example, if cooling is too slow or is effected too late, more conditioning agent will be able to penetrate into the substrate. By controlling these four variables, penetration into the article to be coated is controllable. Among suitable materials of construction to be employed are paper, paperboard, molded paper pulp articles, wood, plastics, foamed plastics, e.g., polystyrene foam, cellulose foams, metals. The size of the base article may be regulated as desired and various sizes are suitable, ranging from volumes as small as that of a 1/8 inch sphere to as much as 0.1 cubic foot.
Coating methods that may be used include dipping and spraying, as illustrated in the drawing, plus the use of roll applicators or doctor blades, application of a stream of melt to a fast moving article surface, spattering or virtually any other suitable technique. In some cases, the melt may be created by contacting a heated base surface with a meltable solid conditioning agent.
Whatever the type of process employed to produce a melted conditioning agent, it will usually be desirable to have the temperature of the melted conditioning composition within the range of 40° C. to 200° C. Below the lower temperature, the product will normally be too susceptible to softening in storage. Even at about this lower temperature, the product would generally be employed without heat in order to rub off conditioning agent on fabrics to be treated, without excessive softening and melting of the conditioning agent, which would tend to cause spotting and staining of the laundry being treated. Products melting over 200° C. do not soften appreciably enough at the usual temperatures of an automatic dryer, usually about 50° C. to 90° C. Within the 40° C. to 200° C. range a preferred range of application temperatures to the conditioning article base is from 50° C. to 150° C. and it is most preferred that this be from 60° C. to 100° C. The melting point of the conditioning composition will usually be from 50° C. to 110° C., most preferably from 60° C. to 90° C. This melting point is of importance in connection with the action of the treated article on fabrics to be conditioned in an automatic dryer. Thus, the coating composition should be softened sufficiently by the temperature of the dryer so that, in conjunction with the softening and dissolving effect of moisture in the recently laundered clothing being dried, the conditioning material will be satisfactorily removed from the conditioning article and will be deposited on the clothing to be treated. By satisfactory application to the laundry it is meant that more than a minimal amount will be deposited during a normal drying cycle and the application rate will not be so great as to cause deposits of lumps of material on the clothing to be conditioned, with the resulting uneven softening and sometimes, with staining resulting.
At the temperatures of application mentioned, the viscosity of the conditioning composition will be a suitable viscosity, generally from 5 to 500 centipoises and preferably from 10 to 100 centipoises. At such viscosities, penetration of the pores of base materials, such as paperboard, corrugated board, polystyrene foam and wood, will not be so rapid as to cause impregnation of the article with conditioning composition. Generally, the penetration will be from 0.0001 to 0.010 inch, which is sufficient to allow the conditioning material to hold tightly to the substrate. Of course, the degree of penetration will depend in part upon the time of exposure of the article to be coated to the melt of conditioning composition. Therefore, this time will usually be kept quite short, generally from 0.001 to 30 seconds, and often, especially when sprays or "printing" roll applicators are used, about 1 second or less, e.g., 0.01 to 1 second. If desired, plural dips or sprays may be utilized to build up a coating of conditioning composition. To make certain that the coating is uniform on the object, the object may be spun, drained, reversed in position or treated in other manner to maintain a uniform coating of the molten conditioning agent on the base. Also, cooling should be effected rapidly to freeze the coating in position and to minimize penetration.
Cooling will normally be undertaken immediately after withdrawal of the article from the conditioning composition melt. Usually, no more than 10 seconds will go by before active cooling is effected and even before this time some cooling usually occurs by conduction and radiation. Conduction cooling may be accelerated by utilizing an initially cold article. The temperature of the cooling fluid, which is preferably a gas, such as air, but may also be any of other suitable gases, will usually be within the range of -10° C. to 60° C. and is preferably below ambient, generally no higher than 20° C. Cooling will usually be done quickly, preferably within from 0.1 to 30 seconds and most preferably will be almost instantaneous, generally being less than 1 second. A skin may be formed on the outside of the coated article by a blast of cooling air to freeze the coating composition in place in uniform thickness on the article.
The thickness of the coating composition may be controlled to be that most desirable for the particular use intended for the product. Coating thickness is controllable by the characteristics, sizes, settings and use conditions of nip rolls, doctor blades and spray nozzles and depends too on fluid viscosity. Generally, such thickness is from 0.0002 to 0.25 inch, preferably being from 0.001 to 0.10 inch and most preferably being from 0.001 to 0.01 inch. As was indicated previously, the thickness can be controlled by adjusting the coating temperature, the temperature of the object being coated, the temperature of the air blast, the viscosity and nature of the coating composition, spacing of nip rolls or doctor blades, nozzle sizes, etc.
The following examples are given to illustrate specific embodiments of the invention. They are not to be interpreted as limiting. Unless otherwise indicated, all measurements are given in inches, temperatures are in degrees Centigrade and parts are by weight.
EXAMPLE 1
Utilizing the apparatus illustrated in FIG. 1, hollow paper balls, about 1/8 inch thick having an outside diameter of about 2-1/2 inches and made from wood pulp, are dipped in a melt of 50 parts of stearic monoethanolamide and 50 parts of stearic diethanolamide at a temperature of 80° C. for a period of 10 seconds. The coated balls are withdrawn and are promptly (within 2 seconds) subjected to an air blast at 0° C., which almost immediately solidifies the coating exterior and maintains it of uniform thickness about the paper ball. Complete solidification takes place in about 20 seconds. The thickness of coating is about 0.10 inch, corresponding to a loading weight of about 3 grams. Loading weights of conditioner from about 0.5 to 15 grams per dryer load (5 to 10 lbs.) are useful. The conditioning composition penetrates the surface of the paper to a depth of about 1/64 inch and does not enter the hollow interior. The coated articles are tested by being added to an automatic laundry dryer during the one hour drying cycle in which 8 pounds of mixed laundry are dried at a temperature of about 80° C. After completion of drying, the laundry is found to be conditioned. It is soft and static-free. Examination of the coated balls shows that a significant proportion of the coating has been removed therefrom by a combination of softening by heat and moisture and rubbing against the tumbled laundry.
EXAMPLE 2
A composition comprising 1 part of potassium stearate and 2 parts of lauric monoethanolamide is heated to a temperature of about 100° C. and is sprayed onto polystyrene bricks having rounded edges and being of dimensions 3 inches × 2 inches × 1/2 inch, using an apparatus such as that illustrated in FIG. 2. The coating is applied to a thickness of about 0.15 inch to a face, sides and ends of the brick and spraying takes about 5 seconds per article. Within 10 seconds of spraying, the coated surfaces are cooled by air at a temperature of 10° C. and an air flow rate of about 500 feet per minute. The coating applied is sufficiently hard to be removed and dropped into a bin with other such items. After packing, cooling to room temperature, storing and shipping, such an item is tested with a 6 pound load of laundry, mostly cotton, but with some nylon and polyester-cotton blend fabrics, to be dried in an automatic dryer at 70° C. The brick is fastened to the dryer drum by suitable means, with conditioning surfaces outwardly disposed. After 45 minutes drying, the clothes are no longer damp and upon testing, it is shown that they are static-free and have been satisfactorily softened. Examination of the polystyrene foam brick shows that almost all the conditioning material has been removed from the surfaces thereof.
In similar manner, following the above-described procedure, other conditioning compositions are applied to different articles. Thus, mixtures of sodium coco-tallow fatty acids kettle soap (1 part), lauric monoethanolamide (1 part), stearic diethanolamide (0.6 part) and perfume (0.2 part) may be applied, either with or without the addition of 1 part of paraffin, to articles of paper, vermiculite, polyurethane foam (rigid), balsa wood, or wire mesh. Surprisingly, although the perfume is volatile, it does not flash off significantly and therefore, is useful as a conditioning agent. Also, water and alcohol may be present as long as the quantity employed does not require evaporation to solidify the coating on the base article, when cooled.
Thicknesses may be regulated by modifying the temperature, viscosity, spray pressure, time of dwell in the spraying zone, temperature of the article being sprayed, nip roll and doctor blade settings, nozzle size, etc. Also, greater thicknesses may be obtained by passing the object through the spray zone a plurality of times. Products so made according to this example will have conditioning effects on laundry, will not excessively penetrate the base article surface and will be satisfactorily removed from that article to be deposited on the laundry without staining or spotting.
EXAMPLE 3
Paper strips are made, coated on both sides with a softening and antistatic composition comprising 5 parts stearic monoethanolamide, 2 parts dimethyl di-hydrogenated tallow ammonium chloride, 0.1 part bactericide (benzethonium chloride), 0.1 part fluorescent brightener (stilbene derivative) and 0.2 part perfume, together with 1 part of Carbowax®400 (polyoxyethylene). A melt of the conditioning composition is made and held at a temperature of 100° C., using the apparatus of FIG. 3. A sheet or strip of paper, standard bond having 25% cotton content and being about 0.005 inch thick, is fed into the melt, held there for about 5 seconds, while moving forward, withdrawn through nip rolls to regulate coating thickness and is then cooled by air flow, with the air being at 15° C. Cooling occurs almost instantaneously and a thickness of coating composition of about 0.005 inch is obtained on each side of the paper. The paper is held in the air stream for about 10 seconds and is then sufficiently hard to be rolled. Subsequently, after further cooling, it is cut, if desired, packed, stored and shipped for ultimate use. When sheets of said paper of dimensions 6 inches × 12 inches are used, in a standard automatic clothes dryer with an 8 pound load of mixed cotton, polyester and nylon fabric laundry, with the cotton articles comprising a major proportion thereof, excellent softening is obtained and most of the conditioning composition is removed from the paper. In some cases, the paper becomes folded so that transfer of conditioning composition is inhibited and in such situations conditioning is not as effective. It is also noted that the clothing treated has bactericides, brightener and perfume thereon, contributing their properties to the treated articles.
Some of the compositions described hereinabove are subjects of other patent applications of the present applicant and other researchers at the laboratories of his assignee company. They are described herein to illustrate the present invention but is not to be considered that such described composition, article or methods of use are claimed as the invention of the present inventor. His present invention relates primarily to a method for making these conditioning articles more safely, efficiently and economically than was previously known.
This invention has been described with respect to drawings, illustrations and examples thereof but it is clear that it is not to be limited to them but embraces equivalents within the spirit of the invention.
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An article for conditioning fabrics by contacting them and applying conditioning material to the fabric surfaces is made by raising the temperature of a conditioning composition including said conditioning material until it forms a melt, in which state it is fluid and readily applicable to a base for the conditioning article, and applying said fluid composition to a base article so that a surface thereof is coated with the composition. Following application, the composition is cooled sufficiently to convert it to the solid state, in which it forms an adherent coating on the base.
The process is especially useful in coating form retaining bases with a layer of a conditioning material such as a fabric softener, which is designed to be rubbed off onto tumbling damp laundry in an automatic laundry dryer, while the dryer is being heated. The method of application lends itself to speedy and commercially satisfactory production techniques, in which the homogeneity of the conditioning composition is maintained, as is the uniformity of the coating, at controllable application rates. Problems associated with flammability of solvents, using evaporation processes to remove solvent materials and the recovery of solvents from the conditioning composition are also obviated.
This is a continuation of application Ser. No. 82,238 filed Oct. 20, 1970, now abandoned.
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This invention relates to a method of purifying an activated sludge-waste water mixture, in which a gas comprising molecular oxygen is automatically introduced by controlling the ventilation intensity, and to an activated sludge-waste water purifying apparatus having a controllable ventilating device for the automatic introduction of molecular oxygen into at least one activating tank.
The purification of waste water by means of activated sludge has given technically satisfactory results. It is necessary in the process to control the oxygen content in a minimum of one activating tank. Control is normally effected by measuring the actual oxygen content and by ventilating the activating tank in dependence on the measured value. The purification corresponds to the state of load. In plants with a very low load, purification with values of up to approximately 5 mg BOD/1 is thereby possible. However, extensive purification of this type uses up a great deal of power and is for the most part unnecessary. Moreover, in the known method of procedure, a measurable oxygen content is absolutely necessary in the waste water or respectively in the activating tank, since otherwise measurement can no longer be carried out. With this, however, even the oxygen supply can no longer be directly reduced. Further, measuring the oxygen content is very complicated and expensive, and requires great expense for operational security. Control of the ventilating device for introducing the necessary oxygen is also of a corresponding expense.
It is therefore an object of the invention to provide a method and apparatus of the above-named type in such a way that relatively simple control is possible.
The invention uses as a starting point the knowledge that the visible depth or respectively the clarity of the waste water is in close relationship to the desired or necessary purification.
According to one aspect the invention provides a method of purifying an activated sludge-waste water mixture, which comprises the introduction of a gas comprising molecular oxygen to the mixture in an automatically controlled manner in dependence upon the state of purification of the waste water;
in which the state of purification of the waste water is monitored by measuring the visible depth of the waste water and, depending upon this measurement, appropriate control is applied automatically over the introduction of the gas to the mixture.
According to a further aspect the invention provides an activated sludge-waste water purifying apparatus comprising:
a tank for holding an activated sludge-waste water mixture;
a controllable ventilating device for introducing automatically a gas comprising molecular oxygen to said mixture in dependence upon the state of purification of the waste water;
a monitoring device for measuring the visible depth of the waste water;
and control means for controlling the operation of the ventilating device in dependence upon the measured value of the visible depth.
A fundamental aspect of the invention is that for optimal control of the activating tank, the visible depth or respectively clarify of the waste water is measured and not, as previously, the oxygen content itself. Measuring the visible depth can be carried out relatively simply, for example by means of photocells or similar photoelectric devices, whereby the thereby gained electrical output signals can be used directly for controlling, in particular for switching on or off, the ventilating device. In the case of a two-point control, the appropriate values, at which the ventilating device is switched on or off, are first determined experimentally for each plant to be put into operation, i.e., according to the desired degree of purification, an upper visible depth switching point is determined for switching off the ventilation, and a lower visible depth switching point is determined for switching on or connecting the ventilation.
Although the visible depth of the outflow of the resettling tank can be used, very large time differences would result for changes in load during the time of the through-flow through the treatment plant to the resettling tank, so that fluctuations in load can no longer be followed. It is therefore advantageous to remove an activated sludge-waste water mixture from the activating tank, to desludge this in a bypass arrangement by means of a sludge separating device, then to measure the visible depth, and then to feed it back to the ventilating tank or activating tank or to the treatment plant supply.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of a model course of operation with the application of a method according to the invention with a two-point control; and
FIG. 2 is a schematic illustration of apparatus for carrying out the method according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
In FIG. 1, the time t is entered in hours along the abscissa and the visible depth s is entered in centimeters along the ordinate. Photoelectric devices, preferably photocells, are particularly suitable for measuring the visible depth. Photocells emit an electrical output signal, which can be used further, in dependence on the incoming light intensity, and therefore on the visible depth. Although the electrical output signal of the photocells can be processed further analogically, it is however suitable to carry out a two-point control, whereby a ventilating device is connected or respectively switched-on when there is a fall below a certain visible depth Z, and whereby the ventilating device is switched-off again when a certain visible depth A is exceeded. In addition, the output signal of the minimum of one photocell is fed to a comparator device, in which the output signal is compared with the electrical signals corresponding to both threshold values of the visible depths A or respectively Z. According in each case to the result of the comparison, an output signal is emitted, which, if necessary after suitable amplification, drives the ventilating device. Two-point controls of this type are known in themselves and are conventional, so that a detailed explanation of them is unnecessary. According to the invention, then, the visible depth between two predetermined threshold values is controlled, and the desired degree of purification is therefore adopted.
A fundamental advantage is that the (preferably used) photocells do not react to discolourations in the waste water, such as, for example, those produced by blood or testile dyes, but only to the intensity of the light coming through the waste water. In order to obtain reproducible results, this light originates preferably from an external light source.
According to FIG. 1, the switching point Z lies, for example, at a visible depth of 80 cm. and the switching point A at a visible depth 110 cm. In the case of smaller visible depths, i.e. when there is a fall below the threshold value Z of the visible depth, the ventilating device is switched on to nitrify the waste water-as indicated by the arrow N. When the threshold value A of a high visible depth is reached, the ventilating device is switched-off again, in order to achieve denitrification indicated by the arrow D. The visible depth, and therefore the oxygen content too, thus swings to and fro between the two threshold values A and Z. The switching points A and Z have thereby been experimentally determined in each case for a plant to be set in operation. As can be seen from the curve in FIG. 1, the slope of the curve changes in dependence on the degree of contamination. The switching frequency is thereby dependent on the desired degree of purification, i.e. on the respective visible depth values corresponding to the switching points and their distance apart. The arrows N and D thereby illustrate the performance setting.
It should be mentioned that when a waste water-activated sludge mixture is taken from an activating tank in operation for the purpose of determining visible depths, this removal can also be carried out intermittently, but will be suitably carried out continually.
Furthermore, particularly in the case of electrical control of the ventilating device, the switching signals are delayed accordingly to take into account the flow behaviour of the waste water to be purified.
Thus, there is disclosed a method of purifying an activated sludge waste water mixture which comprises the introduction of a gas comprising molecular oxygen to the mixture in automatically controlled manner in dependence upon the state of purification of the waste water. The state of purification is monitored simply (unlike known methods which require constant monitoring of the BOD of the mixture), by measuring the visible depth of the waste water. Depending upon this measurement, appropriate control is applied automatically over the (ventilation) introduction of the gas to the mixture.
A sample portion of an activated sludge-waste water mixture is taken from an activating tank in operation through a bypass arrangement, and the activated sludge present in the sample is separated in the bypass by an activated sludge separating device. The visible depth is then determined to control the ventilation intensity. Thereafter, the mixture is fed back to the activating tank, a ventilating tank or to a supply system of a sewage treatment plant.
Preferably, the visible depth is determined by a measuring device, and the ventilation intensity is adjusted thereafter. The arrangement may be such that control signals issued by the measuring device are delayed for a predetermined time period.
Referring now to FIG. 2 of the drawing, apparatus for purifying an activated sludge-waste water mixture comprises a tank for the mixture e.g. an activated sludge tank 1, a controllable ventilating device (5) for introducing automatically a gas comprising molecular oxygen to the mixture in dependence upon the state of purification of the waste water, a monitoring device (3) for measuring the visible depth of the waste water, and control means for controlling the operation of the ventilating device in dependence upon the measured value of the visible depth.
A sample portion of the mixture is removed from tank by an activated sludge separating device 2, and the monitoring device, shown schematically as a visible depth measuring device 3, measures the visible depth of the waste water. The measuring device 3 preferably comprises a photoelectric device having photo cells (to provide two point control known per se), and issues a control signal 5 in order to start, or stop, the operation of the ventilating device as appropriate (preferably after a predetermined time delay). A control water current is shown symbolically by reference 4.
It should be understood that FIG. 2 provides a schematic illustration only of the apparatus, which preferably has a bypass for extraction of a sample portion of the activated sludge waste water mixture, a removal device (2) in the bypass for effecting the extraction of the sample, a sludge separator (2) in the bypass to separate the activated sludge from the sample and comprising a centrifuge and/or a decanter, and a feed back device (2,3,4) for returning the removed mixture to the tank (1). The tank (1) may be an activating tank, a ventilating tank, a resettling tank or a part of a supply system of a sewage treatment plant.
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A method and apparatus is disclosed for purifying the waste water in an avated sludge-waste water mixture. In dependence upon the state of purification of the waste water, the mixture is ventilated in automatically controlled manner by a gas comprising molecular oxygen. The automatic control of ventilation is exercised by the use of a monitoring device which measures the visible depth of the waste water and, depending upon the measured value, starts-up or switches-off the ventilation.
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[0001] Priority is claimed under 35 U.S.C. §119 to Japanese Application no. 2015-221003 filed on Nov. 11, 2014 which is hereby incorporated by reference in their entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosur relates to a printing device to which print media can be supplied from multiple conveyance paths, and more specifically relates to a printing device capable of reliably preventing collisions between print media and controlling print media conveyance appropriately to the situation.
[0004] 2. Related Art
[0005] Manual feed printers are often used to print booklets such as bank passbooks. Such manual feed printers have an opening provided in the front for a user to insert a print medium such as a passbook. The print medium is then ejected from the opening (the insertion opening) after printing. The printer may also have a means for correcting skewing of the inserted print medium.
[0006] Ideally this kind of printer is provided with a conveyance path other than the path for manually inserting print media, can print to other types of print media such as paper rolls or precut sheets, and has a variety of print functions.
[0007] However, a way to prevent print media from colliding at a junction of the conveyance paths in a printer having multiple print media conveyance paths.
[0008] In a printer having a main feed section and a manual feed section, JP-A-H06-271152 proposes providing a locking mechanism that prevents releasing the manual feed table to prevent print media from both routes from overlapping.
[0009] In a manual feed printer having a function for correcting skewing of the print medium as described above, the print medium conveyance roller in the skew correction unit usually also functions as a feed roller that feeds the print medium to the print position. When such a printer is provided with a second print media conveyance path, the junction of the manual-feed conveyance path and the second conveyance path is generally designed to be upstream from the skew correction unit that also functions as a feed roller.
[0010] However, a magnetic reader is often provided between the print medium insertion opening and the junction in this type of printer, and because of the distance between the insertion opening and the junction, the user is unable to see junction. Consequently, the user may insert a passbook or other print medium into the insertion opening without seeing that another print medium is being supplied from another conveyance path, and the print media are likely to collide.
[0011] Additionally, the skew correction unit requires a member that contacts the print medium to correct any skewing, and this member is implemented as a shutter (gate) capable of opening and closing the conveyance path downstream of the conveyance roller. When executing the printing process on print media supplied from the other conveyance path, the shutter must be open to supply the print medium to the print position because of the location of the junction. Therefore, when inserting a passbook or other print medium from the manual insertion opening, the user may mistakenly shove the print mediumpast (downstream of) the shutter even when no other print medium is at the junction.
[0012] Moreover, when the print medium from the other conveyance path exits from the front, the print medium inserted from the insertion slot and the print medium being ejected may also collide.
[0013] The technology described in JP-A H06-271152 cannot solve this problem.
[0014] The disclosur is directed to a printing device in which print media can be supplied from multiple conveyance paths and which can reliably prevent collisions between print media and control print media conveyance appropriately to the situation.
SUMMARY
[0015] To achieve the above object, a printing device according to one aspect of the present disclosur includes a first conveyance path and a second conveyance path configured to conveying print media; a skew correction unit configured to correct skewing of the print medium conveyed along the first conveyance path; and a print unit configured to print on the print medium conveyed on the first conveyance path or the second conveyance path; the first conveyance path and the second conveyance path merging downstream of the skew correction unit; print media conveyed from the second conveyance path.
[0016] This configuration can reliably prevent the print medium supplied from the second conveyance path from colliding with or overlapping print media inserted to the first conveyance path because the shutter is closed when printing using the second conveyance path.
[0017] Further preferably in another aspect of the disclosur, if print media is inserted to the first conveyance path while printing on print media conveyed from the second conveyance path, the skew correction unit corrects skewing of the print medium inserted to the first conveyance path.
[0018] By correcting skewing of the print medium inserted to the first conveyance path while the print medium conveyed from the second conveyance path is being printed, this configuration can quickly start printing on the print medium inserted to the first conveyance path.
[0019] Further preferably, the printing device also has a print media exit downstream of the skew correction unit, and if print media is inserted to the first conveyance path while printing on a print medium conveyed from the second conveyance path, discharges the print medium being printed from the paper exit.
[0020] This configuration can control print media conveyance appropriately to the situation.
[0021] To achieve the above object, another aspect of the present disclosur is a control method of a printing device including a first conveyance path and a second conveyance path configured to conveying print media; a skew correction unit configured to correct skewing of the print medium conveyed along the first conveyance path; and a print unit configured to print on the print medium conveyed on the first conveyance path or the second conveyance path; the first conveyance path and the second conveyance path merging downstream of the skew correction unit, and the skew correction unit having a shutter that opens and closes the first conveyance path; and the control method including the shutter closing the first conveyance path when printing to a print medium conveyed from the second conveyance path.
[0022] Additional objects and features of the disclosur will be apparent from the following description of an embodiment of the disclosur.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic side view of a printing device according to the disclosur.
[0024] FIG. 2 is a flow chart of the conveyance control process when using a paper cassette.
DESCRIPTION OF EMBODIMENTS
[0025] A preferred embodiment of the present disclosur is described below with reference to the drawings. However the embodiment described is not intended to limit the technical scope of the disclosur. Note that in the drawings, the same or similar elements are described using the same reference numerals or the same symbols.
[0026] FIG. 1 is a schematic side view of an embodiment of a printing device according to the disclosur. The printer 1 according to the disclosur as shown in FIG. 1 has a manual-feed conveyance path 20 (first conveyance path) for manual printing, and a cassette-feed conveyance path 80 (second conveyance path) for feeding paper from a paper cassette. The printer 1 is also provided with a skew correction unit 70 (skew correction device) on the manual-feed conveyance path 20 , and the manual-feed conveyance path 20 and the cassette-feed conveyance path 80 merge downstream from the skew correction unit 70 . The shutter 40 of the skew correction unit 70 is closed when printing on media from the cassette-feed conveyance path 80 . Therefore, the printer 1 can reliably prevent the collision of print media (such as a passbook or other booklet and precut sheets), supplied from multiple conveyance paths, and the printer can print on various kinds of print media.
[0027] In one example, the printer 1 is an inkjet passbook printer such as used at a bank. As described above, the printer 1 has two conveyance paths ( 20 , 80 ) as conveyance paths for the print media 5 . As illustrated in FIG. 1 , to print on a passbook as the print medium 5 (booklet), the print medium 5 is inserted (in the direction of arrow E in FIG. 1 ) by the user from the front (the left side in FIG. 1 ) of the printer 1 , and after printing the print medium 5 is returned to and ejected from the insertion location (in the direction of the arrow F in FIG. 1 ). To print to print media 5 (precut sheet) stored in a paper cassette (not shown), the print medium 5 is fed in the direction of the arrow G in FIG. 1 , and after printing the print medium 5 (precut sheet) may be ejected from the front (in the direction of the arrow F in FIG. 1 ) or the rear (in the direction of the arrow H in FIG. 1 ).
[0028] FIG. 1 is a general side view of the configuration of the printer 1 , and in particular illustrates the conveyance routes for the print medium 5 (the booklet or the precut sheet). Parts of the printer 1 are described below with reference to FIG. 1 . Note that in FIG. 1 arrow A represents the normal conveyance direction of the print medium 5 , and the arrow B represents the reverse conveyance direction of the print medium 5 .
[0029] To manually print on the print medium 5 (booklet), a manual-feed insertion opening 10 (entrance) is provided at the front of the printer 1 for manually inserting the print medium 5 (booklet). The print medium 5 (booklet) is inserted to the manual-feed insertion opening 10 . Note that, as described above, the manual-feed insertion opening 10 is also the paper exit when the printer 1 ejects the print medium from the front.
[0030] The manual-feed conveyance path 20 is the conveyance path that carries print media 5 (booklet) inserted from the manual-feed insertion opening 10 to the print position. When discharged to the front, the manual-feed conveyance path 20 is the path carrying the print medium 5 in the reverse direction.
[0031] The skew correction unit 70 corrects skewing of the print medium 5 (booklet) inserted from the manual-feed insertion opening 10 , and includes a manual-feed conveyance roller pair 30 , the shutter 40 , a paper detection sensor (A) 50 , and paper detection sensors (B) 60 .
[0032] The manual-feed conveyance roller pair 30 is a pair of rollers that convey the inserted print medium 5 (booklet) forward, and is powered by a drive mechanism (such as a motor and power transfer device) not shown.. The manual-feed conveyance roller pair 30 can also be driven in reverse, and conveys the printed print medium 5 in reverse to discharge the print medium 5 .
[0033] The shutter 40 is a bumper (plate) capable of moving vertically (in the direction of arrows C, D in FIG. 1 ), and is powered by a drive mechanism (such as a motor and power transfer device) not shown.. The shutter 40 is raised (depicted by the dotted lines in FIG. 1 ) when correcting skewing of the print medium 5 (booklet) and blocks (closes off) the conveyance path. By driving the manual-feed conveyance roller pair 30 in the forward direction, the print medium 5 (booklet) contacts the shutter 40 and skewing of the print medium 5 (booklet) is corrected.
[0034] The shutter 40 is lowered (the location depicted by the solid line in FIG. 1 ) to open the conveyance path when conveying the print medium 5 (booklet) to the print position, and when ejecting the print medium 5 from the manual-feed insertion opening 10 . When printing using the cassette-feed conveyance path 80 , the shutter 40 is raised to block (close) the conveyance path.
[0035] The paper detection sensor (A) 50 and the paper detection sensors (B) 60 are sensors for detecting the presence of a print medium 5 , and are respectively provided before (upstream) and after (downstream) the manual-feed conveyance roller pair 30 . To check that skewing of the print medium 5 (booklet) has been corrected, multiple paper detection sensors (B) 60 are provided perpendicularly to the width (the conveyance direction (arrows A, B in FIG. 1 )) of the print medium 5 (booklet) and the vertical axis (indicated by arrows C, D in FIG. 1 ). Sensors known from the literature may be used for paper detection sensor (A) 50 and paper detection sensors (B) 60 .
[0036] Although not illustrated in FIG. 1 , a magnetic reader may be disposed to the manual-feed conveyance path 20 between the manual-feed insertion opening 10 and the manual-feed conveyance roller pair 30 for reading magnetic information from the inserted print medium 5 (booklet).
[0037] The cassette-feed conveyance path 80 is a conveyance path that carries print media 5 (precut sheets) supplied from a paper cassette not shown. The paper cassette is disposed at the upstream end of (the upstream side of arrow G) of the cassette-feed conveyance path 80 ( FIG. 1 ). In the forward conveyance direction, the cassette-feed conveyance path 80 merges with the manual-feed conveyance path 20 downstream of the skew correction unit 70 (the shutter 40 ). More specifically, the manual-feed conveyance path 20 and the cassette-feed conveyance path 80 merge at junction 90 in FIG. 1 .
[0038] An upstream conveyance roller pair 110 is a pair of rollers that conveys a print medium 5 supplied from the manual-feed conveyance path 20 or the cassette-feed conveyance path 80 in the forward direction and supplies the print medium 5 to the print position (the location of the print unit 120 ), and is powered by a drive mechanism (such as a motor and power transfer mechanism) not shown.. The upstream conveyance roller pair 110 can also be driven in reverse, and when ejecting the print medium 5 conveys the printed print medium 5 in reverse.
[0039] A paper detection sensor (C) 100 is a sensor that detects the presence of a print medium 5 and is disposed in before (upstream) of the upstream conveyance roller pair 110 in the conveyance direction. Sensors known from the literature may be used for the paper detection sensor (C) 100 .
[0040] The print unit 120 is the part that prints on the print medium 5 (a booklet or a precut sheet) supplied on the conveyance surface 150 by the upstream conveyance roller pair 110 , and has multiple nozzles for ejecting ink.
[0041] A platen 130 is disposed opposite the print unit 120 with the print medium 5 therebetween.
[0042] The downstream conveyance roller pair 140 is a pair of rollers that conveys the printed print medium 5 (booklet) in the forward conveyance direction, and is powered by a drive mechanism (such as a motor and power transfer device) not shown.. The downstream conveyance roller pair 140 can also be driven in reverse, and when ejecting the print medium 5 conveys the printed print medium 5 in reverse.
[0043] A rear exit 160 (print media exit) is used when the printed print medium 5 cannot be ejected from the front (manual-feed insertion opening 10 ).
[0044] The printer 1 also has with a controller (not shown in FIG. 1 ). The controller controls the printing process of the print unit 120 and conveyance of the print medium 5 . To control media conveyance, the controller controls operation of each roller pair 30 , 110 , 140 , and the shutter 40 on the basis of the detection results from paper detection sensor (A) 50 , paper detection sensors (B) 60 , and paper detection sensor (C) 100 . The controller may comprise a CPU, RAM, ROM, ASIC, or firmware (program), for example.
[0045] The printer 1 thus comprised conveys print media 5 as described below.
[0046] First, during manual feed printing, the user (operator) inserts a print medium 5 (booklet) from the manual-feed insertion opening 10 in the direction of arrow E ( FIG. 1 ). When the paper detection sensor (A) 50 detects that a print medium 5 (booklet) is inserted, the controller raises the shutter 40 to block (close) the manual-feed conveyance path 20 and drives the manual-feed conveyance roller pair 30 .
[0047] Driving the manual-feed conveyance roller pair 30 causes the print medium 5 (booklet) to bump into the shutter 40 , and skewing is corrected. Once the controller determines that skew correction is complete based on the results from the paper detection sensors (B) 60 , the controller lowers the shutter 40 to open the manual-feed conveyance path 20 .
[0048] The print medium 5 (booklet) is conveyed in forward as the manual-feed conveyance roller pair 30 is driven, and is detected by the paper detection sensor (C) 100 . When the print medium 5 is detected, the controller drives the upstream conveyance roller pair 110 and the downstream conveyance roller pair 140 and conveys the print medium 5 (booklet) in the forward direction.
[0049] The print medium 5 (booklet) is thus supplied to the print position and the print unit 120 then prints on the print medium 5 (booklet).
[0050] Once printing is complete, the controller drives the upstream conveyance roller pair 110 , the downstream conveyance roller pair 140 , and the manual-feed conveyance roller pair 30 in reverse to convey the print medium 5 (booklet) in reverse. The print medium 5 (booklet) passes over the open shutter 40 moving in the direction of arrow F ( FIG. 1 ) along the manual-feed conveyance path 20 and exits from the manual-feed insertion opening 10 .
[0051] Conveyance of the print medium 5 (precut sheet) is controlled as described below when printing to a print medium 5 (precut sheet) conveyed from the cassette-feed conveyance path 80 . FIG. 2 is a flow chart showing an example of the conveyance control process when printing from a paper cassette.
[0052] On receiving an instruction to feed paper from the paper cassette (step S 1 in FIG. 2 ), the controller checks whether or not the detection values from the paper detection sensors (B) 60 and the paper detection sensor (C) 100 indicate “No Paper” (step S 2 in FIG. 2 ). If the detection value from either of the paper detection sensors indicates “Paper Present” (No, step S 2 in FIG. 2 ), the controller determines that the print medium 5 is at the paper detection sensors (B) 60 or the paper detection sensor (C) 100 , and waits before feeding paper from the paper cassette.
[0053] When the detection values from both of the paper detection sensors indicates “No Paper” (Yes, step S 2 in FIG. 2 ), the controller determines that no print medium 5 is at the paper detection sensors (B) 60 or the paper detection sensor (C) 100 , and closes the shutter 40 to close the manual-feed conveyance path 20 (step S 3 in FIG. 2 ).
[0054] The controller then begins feeding paper from the paper cassette (step S 4 in FIG. 2 ). When the detection value from the paper detection sensor (C) 100 indicates “Paper Present” (Yes step S 5 in FIG. 2 ), the controller determines that the print medium 5 (precut sheet) from the paper cassette has been conveyed up to the paper detection sensor (C) 100 , and drives the upstream conveyance roller pair 110 and the downstream conveyance roller pair 140 (step S 6 in FIG. 2 ).
[0055] The print medium 5 (precut sheet) is then conveyed to the print position, and processed by print unit 120 . The controller periodically checks the detection value from the paper detection sensor (A) 50 (step S 7 in FIG. 2 ) until the printing process is complete (No, at step S 11 in FIG. 2 ).
[0056] If the detection value from the paper detection sensor (A) indicates “No Paper” (Yes at step S 7 in FIG. 2 ), the controller determines no print medium 5 (booklet) was inserted from the manual-feed insertion opening 10 and takes no particular action.
[0057] If the detection value of the paper detection sensor (A) indicates “Paper Present” (No at step S 7 in FIG. 2 ), the controller determines that a print medium 5 (booklet) was inserted from the manual-feed insertion opening 10 and determines whether a skew correction flag is set (step S 8 in FIG. 2 ). The skew correction flag is set (stored) when a skew correction process is run (completed) in step S 9 described below.
[0058] The controller takes no particular action if the skew correction flag is set (is stored; Yes at step S 8 ). Processing then returns to step S 11 .
[0059] However, if the skew correction flag is not set (is not stored) (No at step S 8 in FIG. 2 ), the controller runs a skew correction process (step S 9 in FIG. 2 ). More specifically, the manual-feed conveyance roller pair 30 conveys the print medium 5 (booklet) at the paper detection sensor (A) 50 forward until the print medium 5 (booklet) contacts the shutter 40 , which is closed. Once the controller determines from the paper detection sensors (B) 60 that skew correction is complete, the controller sets (stores) the skew correction flag (step S 10 in FIG. 2 ). Processing then returns to step S 11 .
[0060] Once the printing process ends (Yes at step S 11 in FIG. 2 ), the controller determines which exit to eject the printed print medium 5 (precut sheet) from based on whether or not the skew correction flag is set. More specifically, if the skew correction flag is set (Yes at step S 12 in FIG. 2 ), the controller determines that a print medium 5 (booklet) is on the manual-feed conveyance path 20 waiting to be printed, and selects the rear exit 160 . If the skew correction flag is not set (No at step S 12 in FIG. 2 ), the controller determines there is no print medium 5 (booklet) on the manual-feed conveyance path 20 and selects the manual-feed insertion opening 10 .
[0061] When the rear exit 160 is selected, the controller continues to drive the upstream conveyance roller pair 110 and the downstream conveyance roller pair 140 in the forward direction, and ejects the printed print medium 5 (precut sheet) from the rear exit 160 (step S 13 in FIG. 2 ).
[0062] When the manual-feed insertion opening 10 is selected, the controller drives the upstream conveyance roller pair 110 and the downstream conveyance roller pair 140 in reverse and opens the shutter 40 to open the manual-feed conveyance path 20 . The controller then drives the manual-feed conveyance roller pair 30 in reverse to eject the printed print medium 5 (precut sheet) from the manual-feed insertion opening 10 .
[0063] In either case, once the media has been ejected, the controller stops driving the conveyance roller pairs and resets the skew correction flag (step S 15 in FIG. 2 ). This completes conveyance control when the print medium is supplied from the paper cassette ends.
[0064] This embodiment describes a configuration having a conveyance path from a paper cassette (cassette-feed conveyance path 80 ) as a conveyance path separate from the manual-feed conveyance path 20 , but instead of or in addition thereto may have a conveyance path for feeding a print medium 5 stored as a roll. In this case, the manual-feed conveyance path 20 and the separate feed path will also merge downstream from the shutter 40 , and conveyance of the print media is controlled in the same manner as described based on FIG. 2 when feeding the print unit from the separate feed path.
[0065] As described above, in a printer 1 according to this embodiment, the junction 90 where the manual-feed conveyance path 20 and the cassette-feed conveyance path 80 merge is downstream of the skew correction unit 70 (shutter 40 ) in the forward conveyance direction, and because the shutter 40 is closed when printing using the cassette-feed conveyance path 80 , print media 5 (precut sheet) supplied from the paper cassette can be reliably prevented from colliding or overlapping with a print medium 5 (booklet) inserted by the operator from the manual-feed insertion opening 10 .
[0066] Providing a new shutter to prevent print media 5 collisions is also not necessary.
[0067] When the user inserts a print medium 5 (booklet) from the manual-feed insertion opening 10 while printing using the cassette-feed conveyance path 80 , skewing of the inserted print medium 5 (booklet) is corrected while printing, and the print unit can then quickly transition to printing the inserted print medium 5 (booklet).
[0068] Finally, when a print medium 5 (booklet) is inserted from the manual-feed insertion opening 10 while printing using the cassette-feed conveyance path 80 , conveyance is controlled so that the print medium 5 (precut sheet) supplied from the cassette-feed conveyance path 80 is ejected from a rear exit 160 , and conveyance can be controlled appropriately to the situation.
[0069] The printer 1 can thus print to various kinds of media with no problems.
[0070] The scope of the disclosur is not limited to the foregoing embodiment, and includes the disclosur described in the accompanying claims and equivalents thereof.
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A printing device including: a first conveyance path and a second conveyance path configured to conveying print media; a skew correction unit configured to correct skewing of the print medium conveyed along the first conveyance path; and a print unit configured to print on the print medium conveyed on the first conveyance path or the second conveyance path; the first conveyance path and the second conveyance path merging downstream of the skew correction unit; print media conveyed from the second conveyance path.
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FIELD OF DISCLOSURE
[0001] The claimed subject matter relates generally to cloud-based computing and, more specifically, to techniques for generating one or more cloud images based an analysis of changes to various nodes within a service.
BACKGROUND OF THE INVENTION
[0002] One definition of cloud computing is network-based services which appear to be provided by virtual hardware running on one or more real machines. Typically, cloud-based services ran. on multiple connected computers, often over a real-time network such as the Internet. A cloud image is a file that contains the contents of an operating system (OS) plus additional software that can be instantiated on a cloud management system as one or more running virtual computing nodes, commonly called “instances.” One advantage of using cloud images is that a system may be shut down and. restored later to the exact same state. Cloud management systems such as AMAZON EC2® and IBM SMARTCLOUD® employ cloud images as a. basic unit of deployment.
[0003] A cloud-based service is simply a collection of one or more virtual machines that work together to provide some capability to a deploying organization or its clients. Benefits of cloud images in conjunction with cloud-based services may include 1) a fixed configuration that can deploy in a reliable and consistent manner; and 2) well-known optimization techniques such as copy-on-write that can lead to very fast instance deployment times and reduced storage costs.
SUMMARY
[0004] Provided are techniques for optimizing cloud-based service development, including deployment of a service under development to a test cloud, analyzing changes to nodes of the service, capturing images based upon parts of nodes that are not frequently changing and deploying the images in conjunction the non-frequently changing nodes in a non-image format.
[0005] Techniques provided include analyzing a first node, associated with a first version of a service, to extract first configuration metadata; analyzing the first node, associated with a second version, subsequent to the first version, of the service, to extract second configuration metadata; determining, based upon a comparison of the first configuration metadata and the second configuration metadata, that the first node has not been modified between the first version and the second version; generating a first image of the node for distribution in conjunction with the service in response to the determining that the particular node has not been modified; and caching the first image for use in conjunction with the service.
[0006] This summary is not intended as a comprehensive description of the claimed subject matter but, father, is intended to provide a brief overview of some of the functionality associated therewith. Other systems, methods, functionality, features and advantages of the claimed subject matter will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A better understanding of the claimed subject matter can be obtained when the following detailed description of the disclosed embodiments is considered in conjunction with the following figures, in which:
[0008] FIG. 1 is an example of one computing system architecture that, may implement the claimed subject matter.
[0009] FIG. 2 is a block diagram of an example of a Cloud Management System (CMS) that may implement the claimed subject matter.
[0010] FIG. 3 is a block diagram of one example of an element of configuration metadata used in conjunction with the claimed subject matter.
[0011] FIG. 4 is a flowchart of an example of a Test Node process that may implement aspects of the claimed subject matter.
[0012] FIG. 5 is a flowchart of an example of a Build Service process that may implement aspects of the claimed subject matter.
DETAILED DESCRIPTION
[0013] It is understood in advance that although this disclosure includes a detailed description on cloud computing, implementation of the teachings recited herein are not limited to a cloud computing environment. Rather, embodiments of the present invention are capable of being implemented in conjunction with any other type of computing environment now known or later developed.
[0014] Cloud computing is a model of service delivery for enabling convenient, on-demand network access to a shared pool of configurable computing resources (e.g. networks, network bandwidth, servers, processing, memory, storage, applications, virtual machines, and services) that can be rapidly provisioned and released with minimal management effort or interaction with a provider of the service. This cloud model may include at least five characteristics, at least three service models, and at least four deployment models.
[0015] Characteristics are as follows:
[0016] On-demand self-service: a cloud consumer can -unilaterally provision computing capabilities, such as server time and network storage, as needed automatically without requiring human interaction with the service's provider.
[0017] Broad network access; capabilities are available over a network and accessed through standard mechanisms that promote use by heterogeneous thin or thick client platforms (e.g., mobile phones, laptops, and PDAs).
[0018] Resource pooling: the provider's computing resources are pooled to serve multiple consumers using a multi-tenant model, with different physical and virtual resources dynamically assigned and reassigned according to demand. There is a sense of location independence in that the consumer generally has no control or knowledge over the exact location of the provided resources but may be able to specify location at a higher level of abstraction (e.g., country, state, or datacenter).
[0019] Rapid elasticity: capabilities can be rapidly and elastically provisioned, in some cases automatically, to quickly scale out and rapidly released to quickly scale in. To the consumer, the capabilities available for provisioning often appear to be unlimited and can be purchased in any quantity at any time.
[0020] Measured service: cloud systems automatically control and optimize resource use by leveraging a metering capability at some level of abstraction appropriate to the type of service (e.g., storage, processing, bandwidth, and active user accounts). Resource usage can be monitored, controlled, and reported providing transparency for both the provider and consumer of the utilized service.
[0021] Service Models are as follows:
[0022] Software as a Service (SaaS): the capability provided to the consumer is to use the provider's applications running on a cloud infrastructure. The applications are accessible from various client devices through a thin client interface such as a web browser (e.g., web-based email). The consumer does not manage or control the underlying cloud infrastructure including network, servers, operating systems, storage, or even individual application capabilities, with the possible exception of limited user-specific application configuration settings.
[0023] Platform as a Service (PaaS): the capability provided to the consumer is to deploy onto the cloud infrastructure consumer-created or acquired applications created using programming languages and tools supported by the provider. The consumer does not manage or control the underlying cloud infrastructure including networks, servers, operating systems, or storage, but has control over the deployed applications and possibly application hosting environment configurations.
[0024] Infrastructure as a Service (IaaS): the capability provided to the consumer is to provision processing, storage, networks, and other fundamental computing resources where the consumer is able to deploy and run arbitrary software, which can include operating systems and applications. The consumer does not manage or control the underlying cloud infrastructure but has control over operating systems, storage, deployed applications, and possibly limited control of select networking components (e.g., host firewalls).
[0025] Deployment Models are as follows:
[0026] Private cloud: the cloud infrastructure is operated solely for an organization. It may be managed by the organization or a third party and may exist on-premises or off-premises.
[0027] Community cloud: the cloud infrastructure is shared by several organizations and supports a specific community that has shared concerns (e.g., mission, security requirements, policy, and compliance considerations). It may be managed by the organizations or a third party and may exist on-premises or off-premises.
[0028] Public cloud; the cloud infrastructure is made available to the general public or a large industry group and is owned by an organization selling cloud services.
[0029] Hybrid cloud; the cloud infrastructure is a composition of two or more clouds (private, community, or public) that remain unique entities but are bound together by standardized or proprietary technology that enables data and application portability (e.g., cloud bursting for loadbalancing between clouds).
[0030] A cloud computing environment is service oriented with a focus on statelessness, low coupling, modularity, and semantic interoperability. At the heart of cloud computing is an infrastructure comprising a network; of interconnected nodes.
[0031] As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
[0032] Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard, disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
[0033] A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
[0034] Program code embodied on a computer readable medium may he transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
[0035] Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local, area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0036] Aspects of the present invention are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0037] These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0038] The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational actions to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0039] As the inventors herein have realized, there are two basic problems with the capture of cloud images from instances. Firstly, image capture is time consuming and computationally expensive. Secondly, because images are monolithic, as you make changes to the contents of an image, there may be many similar images that are expensive and complicated to manage. This issue is known as “image sprawl”.
[0040] Turning now to the figures, FIG. 1 is a block diagram of one example of computing system architecture 100 that may implement the claimed subject matter. A computing system 102 includes a central processing unit (CPU) 104 , coupled to a monitor 106 , a keyboard 108 and a pointing device, or “mouse,” 110 , which together facilitate human interaction with computing system 100 and computing system 102 . Also included in computing system 102 and attached to CPU 104 is a computer-readable storage medium (CRSM) 112 , which may either be incorporated into computing system 102 i.e. an internal device, or attached externally to CPU 104 by means of various, commonly available connection devices such as but not limited, to, a universal serial bus (USB) port (not shown).
[0041] CRSM 112 is illustrated storing an operating system (OS) 114 , a Source Control Management Client (SCMC) 116 , a Development/Test Environment Client (DTEC) 117 and a Cloud Management System (CMS) 118 , which implements aspects of the claimed subject matter. Also stored in CRSM 112 is a service, or “Service — 1,” 119 , which is used throughout the Specification, as an example of a service that is built and maintained in accordance with the claimed subject matter. Typically, SCMS 116 works in conjunction with a Source Control Management Server (not shown) residing on a separate server (not shown) since it would, be shared by many development team members. In a similar fashion, DTEC 117 would typically work in conjunction with a Development/Test Environment Server (not shown) on a another server (not shown). SCMC 116 and DTEC 117 are typical source control and build/test client utilities, respectively, and should be familiar to those with skill in the relevant arts.
[0042] CMS 118 is described in more detail below in conjunction with FIGS. 2-5 . In this example, service — 1 119 includes a number of systems, or “nodes,” i.e., a first node, version 1, or “N1_V1,” 121 and a first node, version 2, or “N1_V2,” 122 , which are versions 1 and 2, respectively, of the same node. Nodes such as N1_V1 121 and M1_V2 122 are built and maintained in accordance with the claimed subject matter. Each of nodes 121 and 122 include software packages. In this example, N1_V1 121 includes a first software package, version 1, or “SP1_V1,” 123 and a second software package, version 1, or “SP2_V1,” 125 . N1_V2 122 includes the first software package, version 2, or “SP1_V2,” 124 and the second software package, version 2, or “SP2_V2,” 126 . It should be understood that a service may include many more than two (2) nodes and that nodes may include more than two (2) software packages but, for the sake of simplicity, only two of each are shown.
[0043] Computing system 102 and CPU 104 are connected to the Internet 127 and a local area network (LAN) 128 . Internet 127 is communicatively connected to a cloud 130 , which includes a server, i.e. a ser_ 131 . Cloud 130 is illustrated storing an OS, or “OS — 2,” 134 and a version of service — 1 119 that includes N1_V1 121 , which in turn includes SP2_V2 126 and a cloud image of SP1_V1, or a SP1 — 1M 136 . Internet 127 is also coupled to a test cloud A, or “TCA” 140 , which includes a server, i.e., a ser_A 141 , an OS, or “OS — 3,” 144 , CMS 118 and N1_V2 122 . LAN 128 is coupled to a test cloud B, or “TCB,” 150 , which includes a server, i.e., a ser_B 151 , an OS, or “OS — 4,” 154 and N1_V1 121 .
[0044] Although in this example, computing system 102 and clouds 130 and 140 are communicatively coupled via the Internet 127 , they could also be coupled through any number of communication mediums such as, but not limited to, LAN 128 , direct wire of any other communication medium. In a similar fashion, computing system 102 and TCA 150 may be connected by means of different communication mediums. It should be noted there are many possible computing system configurations, of which architecture 100 , computing system 102 and clouds 130 , 140 and 150 and the various configurations of clouds 130 , 140 and 150 are only simple examples used merely for describing the claimed subject matter.
[0045] FIG. 2 is a block diagram of CMS 118 , first introduced above in conjunction with FIG. 1 , in more detail, CMS 118 includes an input/output (I/O) module 160 , a data module 162 and a node analysis module (NAM) 164 . For the sake of the following examples, logic associated, with CMS 118 is stored on data storage 112 ( FIG. 1 ) and executes on one or more processors (not shown) of computing system 102 ( FIG. 1 ). It should be understood that the claimed subject matter can be implemented in many types of computing systems and data storage structures but, for the sake of simplicity, is described only in terms of computer 102 and system architecture 100 ( FIG. 1 ). Further, the representation of backup monitor in FIG. 2 is a logical model. In other words, components 160 , 162 and 164 may be stored in the same or separates files and loaded and/or executed within system 100 either as a single system or as separate processes interacting via any available inter process communication (IPC) techniques.
[0046] I/O module 160 handles any communication CMS 118 has with other components of system 102 and architecture 100 . Data module 162 is storage for information that CMS 118 requires during normal operation. Examples of the types of information stored in data module 162 include system data 170 , node data 172 , an image repository 174 , configuration metadata 176 and operating parameters 178 . System data 170 stores information on the various systems with which CMS 118 must interact. including, but not limited to, cloud 130 ( FIG. 1 ), TCA 140 ( FIG. 1 ) and TCB 150 ( FIG. 1 ). Node data 172 stores information on services, such as service — 1 119 ( FIG. 1 ), and their related nodes and software packages that may be built and maintained in accordance with the claimed subject matter. Such information may include, but is not limited to, the identity of nodes, such as N1_V1 121 ( FIG. 1 ) and N1_V2 122 ( FIG. 1 ).
[0047] Image repository 174 stores cached images generated in accordance with the claimed subject matter. Configuration metadata 176 stores information on builds of services such as, but not limited to, current and historical information of the version number, other identifying features of individual nodes that make up a particular build of an service and the software packages and their versions installed on each distinct node type. Image repository 174 and configuration metadata 176 are described in more detail below in conjunction with FIGS. 3-5 , Operating parameters 178 includes information on various user or administrative preferences that have been set. For example, an administrator may determine a threshold corresponding to a rate of change that determines whether a particular node is created as an image.
[0048] NAM 164 analyzes builds generated in conjunction with SCM 116 ( FIG. 1 ) and DTE 117 ( FIG. 1 ) to determine a corresponding rate of change in the different parts of each particular node. For example, parts of N1_V1 121 may remain static throughout a particular number of builds, specified by a parameter stored in operating parameters 158 , and parts of N1_V2 122 may change a number of times within that particular number of builds. For example on a web app node an OS and middleware may rarely change but an an application such as a LEE WAR file might change every time, NAM 146 detects and notes these changes, NAM 146 also analyzes the generated node information to establish a plan for a next build, including whether or not any particular node should be generated as an image. The functionality of NAM 146 is described, in more detail below in conjunction with FIGS. 3-5 .
[0049] FIG. 3 is a block diagram of one example of a configuration metadata element (CME) 200 of configuration metadata 176 ( FIG. 2 ) used in conjunction with the claimed subject matter. In this example, CME 200 represents information stored in configuration metadata 176 about service — 1 119 ( FIG. 1 ). CME 200 includes a platform section 202 , an architecture section 204 , an users section 206 , a directory structure 208 and an installed packages section 210 . Platform 202 indicates that service — 1 119 executes on a particular platform, or “plat — 1” Architecture 204 indicates that service — 1 119 is associated with a particular architecture, or “arch — 1.” Users 206 indicates that the only
[0050] user in this example is “root.”
[0051] Directory structure 208 includes of number of files and directories 212 associated with service — 1 119 , including “/” 221 , “/bin” 222 , “/boot/” 223 , “/home/” 224 , “/etc/” 225 . “/etc/file — 1” 226 , “/etc/file — 2” 227 , “etc/dir — 1” 228 , “/etc/dir — 1/dir — 2” 229 and “etc/dir — 1/dir — 2/file — 2” 230 . Files and directories 212 of directory structure 208 are used only as examples of a variety of elements that might be in a directory structure.
[0052] Installed packages 210 includes examples of some installed packages 214 that might be associated with an service such as service — 1 119 . This example includes a pack — 1 241 , a pack — 2 242 , a pack — 3 243 , a pack — 4 244 and a pack — 5-2.0.35 245 . Individual files and directories 221 - 230 and installed packages 241 - 245 are used merely as examples of elements of service — 1 119 that might change at different rates throughout multiple builds and thus be handled differently by CMS 118 ( FIGS. 1 and 2 ) during a build. Processing associated with the build processes based upon the corresponding rates of in accordance with the claimed subject matter is described in detail below in conjunction with FIGS. 4 and 5 .
[0053] FIG. 4 is a flowchart of an example of a Test Node process 300 that may implement aspects of the claimed subject matter. In this example, process 300 is associated with CMS 118 and logic stored on CRSM 112 and executed on one or more processors (not shown) of CPU 104 ( FIG. 1 ) and computing system 102 ( FIG. 1 ).
[0054] Process 300 starts in a “Begin Test Node” block 302 and immediately to a “Select Nodes” block 304 , During processing associated with block 304 , nodes are selected for testing in accordance with the disclosed technology. During processing associated with block a “Record Node Data” block 306 , information about the nodes selected during processing associated with block 304 is recorded so that a determination may be made later concerning the amount of change different versions have undergone.
[0055] During processing associated with a “Deploy Nodes” block 308 , the nodes are deployed to a test cloud for development and testing. In this example, N1_V1 121 ( FIG. 1 ) is deployed to TCB ISO ( FIG. 1 ) in conjunction with OS — 4 154 ( FIG. 1 ). In a similar fashion, N1_V2 122 ( FIG. 1 ) is deployed to TCA 140 (FIG, 1 ) in conjunction with OS — 3 144 ( FIG. 1 ). Once the nodes have undergone testing, during processing associated with an “Analyze Changes” block 310 , the nodes are analyzed with respect to each other to determine the amount of change.
[0056] During processing associated with a “Change>Threshold?” block 312 , a determination is made as to whether or not the detected change is greater than a threshold amount. If not, control proceeds to a “Generate Image” block 314 . During processing associated with block 314 , a cloud image of the more recent version of the node is generated for deployment into a service environment (see N1 — 1M 134 , FIG. 1 ). During processing associated with a “Save Image” block 316 , the image generated during processing associated with block 314 is saved in image repository 174 ( FIG. 2 ). Once an image has been saved during processing associated with block 316 , or, of during processing associated block 312 , a determination is made that the changes exceed a threshold, control proceeds to a “Delete Old Images” block 318 . During processing associated with block 318 , any existing old versions of the images corresponding to the node for which an image has been generated are deleted. If control is from block 312 , any images are deleted because changes to the node have made old images obsolete. If control is from block 316 , old images are deleted because a new version has been generated. Of course, if a particular node has not changed at all, a new image may not need to be generated and the old image may not need to be deleted.
[0057] Finally, once any old images have been deleted during processing associated with either block; 318 or block 320 , if, during processing associated with block 312 , a determination is made that the detected change has exceed a threshold, control proceeds to an “End Test Node” block 329 during which process 300 is complete.
[0058] FIG. 5 is a flowchart of an example of a Build Application process 350 that may implement aspects of the claimed subject matter. In this example, process 350 is associated, with CMS 118 and logic stored on CRSM 112 and executed on one or more processors (not shown) of CPU 104 ( FIG. 1 ) and computing system 102 ( FIG. 1 ).
[0059] Process starts in a “Begin Build Service” block 352 and immediately to a “Receive Service Data” block 354 . During processing associated with block 354 , information related to a service to be deployed is retrieved from node data 172 ( FIG. 2 ). During processing associated with a “Receive Configuration (Config.) Metadata (Meta,)” block 356 , information on all nodes identified in data retrieved during processing associated with block 354 is retrieved from configuration metadata 176 ( FIG. 2 ).
[0060] During processing associated with block a “Get Node” block 358 , one particular node is selected for processing. During processing associated with an “Image Available?” block 360 , a determination is made as to whether or not the node selected during processing associated with block 358 has a corresponding image in image repository 174 ( FIG. 2 ). If so, control proceeds to a “Retrieve Image” block 362 and the corresponding image is retrieved for deployment from image repository 174 . If not, control proceeds to a “Compile Node” block 364 , During processing associated with block 364 , the selected node is compiled for deployment in atypical fashion.
[0061] During processing associated with an “Add to Build” block 366 , the image retrieved during processing associated with block 362 or the node compiled during processing associated with block 364 are added to the build for deployment. During processing associated with a “More Nodes?” block 368 , a determination is made as to whether or not there are more nodes to be processed. If so, control returns to block 358 , the next unprocessed node is retrieved and processing proceeds as described above. If not, control proceeds to an “End Build Service” block 379 during which process 350 is complete.
[0062] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be farther understood that the terms “comprises” and/or “comprising,” when used, in this specification, specify the presence of stated features, Integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0063] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
[0064] The flowchart and block diagrams h the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention, in this regard, each block, in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the Inactions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
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Techniques provide include analyzing a first node, associated with a first version of an service, to extract first configuration metadata; analyzing the first node, associated with a second version, subsequent to the first version, of the aservice, to extract second configuration metadata; determining, based upon a comparison of the first configuration metadata and the second configuration metadata, that the first node has not been modified between the first version and the second version; generating a first image of the node for distribution in conjunction with the service in response to the determining that the particular node has not been modified; and caching the first image for use in conjunction with the service.
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BACKGROUND OF THE INVENTION
This invention relates to solar air heating, and more particularly, to a method and apparatus for heating gases which selectively uses heat from the winter sun and rejects heat from the summer sun.
Solar air heaters have been known for many years. They usually have a transparent cover, a radiation absorbing surface and an insulating backing. Air is passed across the radiation absorbing surface which is heated by the sun. Typical of these solar air heaters are those described in an article entitled "Black-Painted Solar Air Heaters of Conventional Design" by Austin Whillier published on pages 31-37 of Solar Energy Vol. 8, No. 1, 1964.
Many efforts have been made to improve the efficiency of such heaters by providing selective black coatings on the radiation absorbing surface to reduce reradiation losses and by decreasing the heat losses through the transparent cover by the use of multiple glass covers. While many of these efforts have proven quite useful and, in fact, highly successful, the utilization of multiple covers simply tends to increase the cost of such heaters prohibitively. Further, the utilization of plural glass and plastic transparent covers also has a weight increasing factor.
A solar air heating system utilizing an absorber of highly polished sheet aluminum fins arranged in parallel is described by V. D. Bevill and H. Brandt, Solar Energy, Vol. 12 pp. 19-29 1968. According to Bevill et al the fins are disposed vertically - that is they were supported on their long edge being set in grooves in an aluminum base plate forming the bottom of a box horizontally positioned and having a horizontal glass cover. The solar radiation studied was at an angle of incidence less than 35°, the fins being in a fixed position. The solar radiation was reflected between adjacent highly polished fins and air was circulated between the fins. This system has proven highly desirable in many respects but has the unfortunate disadvantage of requiring an opaque cover or other shading mechanism particularly during the summer months in order to avoid unwanted and undesired heating to occur within the heater. Further, its efficiency was very sensitive to wind velocity, heat losses to ambient air being severe.
Accordingly, it is an object of this invention to obviate many of the disadvantages of the prior art solar heating apparatus.
Still another object of this invention is to obviate many of the disadvantages of prior art solar gas heating methods.
An additional object of this invention is to provide an improved solar gas heater utilizing generally horizontally disposed slats.
A still further object of this invention is to provide an improved method of absorbing and utilizing solar radiant energy using parallelly disposed heating slats.
BRIEF DESCRIPTION OF THE INVENTION
According to this invention a solar air heater is constructed having a housing defining an absorber chamber and a generally vertically disposed wall transparent to solar radiant energy, a radiant energy absorber means positioned inside the chamber generally parallel to said wall and having an assembly of generally horizontally and parallelly disposed slats adapted to absorb the radiant energy, the slats being positioned one above the other. Present also is a circulating means for passing air through the chamber and across said slats to be heated thereby. In a preferred form of the invention, one face of the slats faces the source of radiant energy (the sun) and the slats are inclined relative to the horizontal. The sun striking the exposed portion of the slats produces multiple reflections between adjoining slats, each reflection transferring additional radiant energy in the form of heat to adjacent slats.
In another preferred embodiment, the slats are curved across their width dimension. In still another embodiment the slats are bent along a longitudinal axis to define a slat having two planes. Both the bent slats and the curved slats are desirable for their additional strength and rigidity. The circulating means can direct the air longitudinally of the slats through the spacing between the several slats or transversely of the slats. The slats are positionable about their longitudinal axis to accommodate varying declination angles of the sun.
According to the method of this invention solar radiant energy is used by spacing slats that are adapted to absorb energy in a spatially stacked, generally vertically disposed array. The slats are generally parallelly positioned in the array such that at least a portion of the top face of each is exposed to the radiant energy and at least a part of the exposed portion is transverse to the direction of the energy. Multiple heat absorbing reflections thus occur between the top face of one slat and the bottom face of the next higher slat. As a final step, air is passed through the slats thereby to heat the air using the heated slats.
In a preferred method of this invention the exposed portion of said slats is positioned such that the angle of incidence of the energy thereon is less than 90°.
A particular advantage of the method and apparatus of this invention is that the winter sun is permitted entry into the spaces between the parallelly disposed slats to produce multiple reflections between adjacent slats. At each reflection, depending upon the material used, a certain percentage of the incoming energy is absorbed. Thus, with the multiple reflections, eventually a large portion of the incoming energy is received and absorbed for eventual transfer to the circulating air as heat energy which is passed across the slats. As the sun decreases its angle of declination with the oncoming of the summer months a point is reached, particularly if the slats are tilted downwardly to more fully face the sun, at which the incoming sunlight is reflected back into the sky such that little heat transfer to the slats occurs.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features that are considered characteristic of this invention are set forth with particularity in the appended claims. The invention, itself, however, both as to its organization and method as well as additional objects and advantages thereof will best be understood from the following description when read in connection with the accompanying drawings, in which:
FIGS. 1A through 1E are schematic representations of two of the horizontally disposed slats shown in FIG. 6, the schematic illustrating the effect of different sun inclination angles thereon in the ability of the slats to absorb heat energy;
FIGS. 2A through 2E are similar schematic representations in which parallel disposed reflecting slats are tilted into the sun depicting the manner in which winter sun inclinations permit the absorption of heat by the slats whereas summer sun inclinations tend to cause total reflection of the sun's energy;
FIG. 3 is a schematic representation of a cross-section of parallelly disposed, curved slats which have the feature of rejecting summer sunlight;
FIG. 4 is a schematic representation of a cross-section of parallelly disposed slats that are bent about a longitudinal axis which permits the rejection of summer sun's energy;
FIG. 5 is a pictorial elevation view of a solar air heater constructed in accordance with the preferred embodiment of this invention;
FIG. 6 is a cross-sectional view of the solar air heater illustrated in FIG. 5 taken along the section line 6--6;
FIG. 7 is a cross-sectional view of a solar air heater utilizing reflecting slats constructed in accordance with still another embodiment of this invention; and
FIG. 8 is a pictorial representation depicting a method of construction by which the slats of the solar air heater of FIG. 7 may be mounted.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The solar gas or air heater of this invention may perhaps best be understood by referring to FIGS. 5 and 6 first. These figures depict the construction of a solar air heater 10 in accordance with this invention, which is generally boxlike in shape to enclose a cavity or chamber 36 having a heat exchange unit 38 as will be described. The solar air heater has two end chambers or plenums 12 defined by end walls 14, which may be a wall or part of a wall of a house or other structure to be heated or may be of lightweight material lending portability to the device, and inner walls depicted by the dashed lines 16 which direct the air to and from the heat exchange unit 38. The heater has a bottom wall 18 and a back wall 20 along with a top wall 22. The various walls may be formed of any suitable rigid material such as metal or preferably hard-pressed asbestos, that is capable of withstanding the heat to which the unit is typically subjected (typically 200° F.) and is a poor heat conductor, with walls 14 and 20 being separate or integral.
Suitable ducts 24 provide access and egress from the plenum chambers 12. The exhaust duct (or the inlet duct) has a fan 25 which aids in circulating the air through the heat exchange unit 38. Thermal insulating material 26 is disposed against the back wall 20. This insulating material may be of any suitable type such as polyurethane foam, glass wool and the like which has low heat conductivity. The front of the solar air heater is covered by a transparent cover or window 30 which is transparent to the sun's radiant energy. This window 30 thus completes the enclosure of the heat exchange unit 38. In addition to the outer cover 30 there may be provided an inner separator 32 which is also transparent to the sun's radiant energy. Desirably this inner separator 32 and the window 30 should be resistive to thermal radiation, have a high resistance to heat and undergo no long term discoloration as a result of exposure to the sun's energy or heat. Among the suitable materials for this inner separator and/or window 30 are glass and polyvinyl fluoride film such as that sold under the registered trademark "TEDLAR" by E.I. DuPont deNemours Co., Wilmington, Delaware. Suitable transparent spacers 34 may be provided to maintain a space or separation between the window 30 and inner separator 32 and also to reduce the convection heat losses by the air circulating therein. These spacers 34 should not contact the inner separator 32 if heat conduction losses are to be avoided. Alternatively, the window and/or inner separator may be made of "PLEXIGLAS" (a registered trademark of Rohm and Haas Company) sheets, typically of a thickness less than one-sixteenth of an inch to reduce weight and costs. PLEXIGLAS is particularly suitable in that it is transparent to the sun's radiant energy and is relatively rugged. A particularly suitable material for this purpose may be that sold by Rohm & Haas Company of Germany under the trademark "ROHAGLASS". This material is an integral ribbed, double sheet structure that provides both the window 30 and inner separator 32 together with spacers 34.
The insulation 26 on the one hand, together with the inner separator 32 define an absorber chamber 36 in which the collector or radiant energy absorber 38 is disposed in a vertical array. The absorber 38 is constructed of a plurality of generally horizontally positioned slats 40 which are disposed in a stacked array with each slat being spaced vertically from its adjoining slats as by a pair of vertical spacer supports 42 which may be connected adjustably to the top and bottom walls 22 and 18, respectively. In the embodiment illustrated in FIG. 6, each slat 40 is rotatably connected at its ends, as by spaced pin and socket mountings 43 to each of the supports 42. By making one (or both) of the supports 42 movable or adjustable in a vertical sense and one fixed, the slats 40 are preferably tiltable about their longitudinal axes so as to vary their angle of inclination relative to the horizontal as will be described. Alternatively, the supports 42 may be fixed so that the slats 40 within the absorber chamber 36 are at a fixed angle relative to the horizon or sun.
In operation, the vertically disposed array 38 is attained by positioning the solar air heater 10 with the transparent window 30 facing the sun in the south (when in the northern hemisphere). The sun's radiant energy passes through the transparent window 30 and the transparent inner separator 32 and impinges upon the exposed portion (the front portion) of the several slats. This energy strikes the slats which preferably are constructed of a polished aluminum or other suitable material capable of radiant energy absorption which as a low infrared emissivity. Typically, the slats may be 2 inches in width and spaced vertically one-half to one inch apart. In any event, the ratio between the spacing between the slats' vertical spacing and the slats' width should be one to four or more. Aluminum is particularly preferred because of its infrared emissivity which is low and approximately 15% of the radiant energy of the sun striking it is absorbed on each incidence. The slats are inclined such that the radiant energy impinges on the top surface of a slat and is reflected up to the bottom surface of the next higher slat, thence down again and so on to provide multiple reflections. This radiant energy, by producing multiple reflections between adjoining slats 40, is absorbed by the slats and converted to heat. Air circulating downward through the inlet plenum chamber 24 as denoted by the arrow 44 and upward from the outlet plenum chamber 24 as denoted by the arrow 46, passes through the absorber chamber 36 between the slats along their longitudinal axis thereby extracting heat from the slats by convection such that the exit air is warmer.
At first glance, the heat exchange resembles the usual venetian blinds, but there are very essential differences.
The solar air heater's slats must be highly refective and preferably should not be coated with any color or coating, (except those few coatings which have total transparency for the long infrared radiation, such as certain silicone lacquers).
When regular venetian blinds transmit light for the purpose of absorbing the light inside the rooms, the slats of the blind must be turned to admit light from the sun between the slats. In solar air heaters, the slats are turned at an angle to the sun's rays, so that a high number of reflections occur between the slats. At each reflection some portion, typically 15%, of the sun's radiant energy becomes absorbed, heating the slats, so that these become heated near their exterior surface and do not have to rely on thermal conductivity in the aluminum body of the slats. In this way, the slats can be made of very thin aluminum decreasing the weight (and cost) of the solar air heater.
The end profile of the slats can be bent, curved, or it could have multiple stiffening bends which have surfaces designed to facilitate multiple reflections. The slats can be formed of rather thin sheet aluminum of sufficient rigidity to support the length of the slat. This rigidity can be increased by the bent or curved end profile. In this way the solar heat collector can be made much lighter in weight, saving material and costs.
The degree of energy absorbed by the slats will be a function of their positioning relative to the sun as noted. This effect may be more easily understood by reference to FIGS. 1A through 1E. In FIGS. 1A through 1E the slats 40 are depicted as being horizontally disposed in front of the insulating material 26. In FIG. 1A with the winter sun in an extreme north latitude having an angle of inclination of 20°, the sun's radiant energy will reflect upon the lower plate 40 at the point 50 thence upwardly, reflecting off the bottom surface of the upper plate 40 at the point 52 thence to the insulation 26. With the first incident reflection, using polished aluminum, roughly 15% of the radiant energy is absorbed. With the second incident at the point 52, another 15% of the remaining energy, i.e., 15% of 85% of the sun's radiant energy is absorbed. This heat energy is temporarily stored in the plates and transferred as described to the circulating air.
As may be seen in FIG. 1B, if the winter sun is at the inclination of 30°, which is a typical angle for the winter sun at noon for latitude north 40°, with the slats having the 1:4 ratio noted between spacing and width, three reflections denoted by the points 54 will occur. Thus, an additional amount of energy may be seen to be absorbed. As the sun's angle of inclination increases to say 45° as is depicted in FIG. 1C and then to 60° in FIG. 1D a still greater number of multiple reflections occur, so that still more heat energy is absorbed using the horizontally disposed plates. With the typical summer sun, 75° inclination at 40° north latitude, a very large number of reflections occur so that the degree of heat absorbed is quite high. While this may not be necessary or desirable in the case of summer sun, the horizontally disposed plates are a relatively stable configuration.
It must be remembered that the increased number of reflections makes up for the fact that as the angle of the sun's inclination increases, a smaller portion of the sun's radiant energy due to the sun's relationship actually impinges upon the vertical face of the solar air heater. Thus, the greater number of multiple reflections makes up for this loss so that the solar air heater becomes more efficient with the increase in the sun's inclination to make up for what would otherwise be a heat reduction. This obviates the necessity for relatively expensive servo systems such that the solar air heater may follow the sun and be at an optimal position thereto at all times.
In accordance with another embodiment of this invention, the slats 40 of FIG. 6 making up the heat exchange unit may be mounted at a fixed angle of inclination α or adjusted to such inclination by the movable support arrangement 42. A slat angle of inclination of α = 30° is depicted in FIGS. 2A through 2E, inclusive. This has the unique advantage in that an increased number of reflections occur when the angle of the sun's inclination, as depicted by the vector 56, is 20° by the resulting increase in number of reflections on the top and bottom surfaces of the adjoining slats 40 over that which occurs with the same sun inclination with the horizontally disposed slats. As may be seen in the several figures, the number of reflections increases as the sun's angle of inclination increases thereby compensating, as previously described, for the decreased radiation striking the vertical face of the solar air heater. A point is reached (FIG. 2D) when the sun's inclination reaches 60° such that the sun is no longer able to be reflected into the void or space between the slats 40 and, instead, is reflected directly back. As the inclination increases still further, as depicted by the vector 56 in FIG. 2E, to 75° (typical summer sun), the solar energy is, in fact, reflected away from the solar air heater. Thus, during the extreme heat of the summer when in all probability the solar air heater is not normally used, it is not unduly burdened by unwanted heat energy being absorbed therein.
The adjustable feature, which is depicted in FIG. 6, is particularly advantageous since the angle of inclination of the slats may be adjusted to optimize the heating effect for any given angle of sun inclination. All the while, the heat absorber is vertically positioned as against the side wall of a house or building. Thus, no special design is needed to accommodate the solar air heater.
Still another embodiment of this invention is illustrated in FIG. 3 in which the slats are depicted as having a curved cross-section 58 along their width dimension. These curved slats 58 are substantially parallel to each other and the outer or edge portion 60, which forms the front or exposed edge or side of the vertically disposed array, is inclined relative to the horizontal at an angle beta. This angle beta may be varied utilizing the adjustable mounting supports 42 depicted in FIG. 6. As may be seen, with this 30° inclination, multiple reflections 62 occur between adjacent top and bottom faces of adjoining slats 58. The array still has the ability to reject summer sun and is strengthened by the curvature.
In still another form of the invention the slats may be formed to have a bend 64 along their longitudinal axis such that the slats 66 have two planar portions 68 and 70 each lying in different intersecting planes. These slats 66 with the longitudinal bend thereby simulate the curved slats 58 of FIG. 3. These slats may have an inclination angle which may be varied. This angle is depicted by the greek symbol gamma (γ). Thus, with a sun inclination of say 30° it is again seen that multiple reflections 71 occur between the inner adjoining faces of adjoining plates. In fact, the operation is quite similar to that described in conjunction with the embodiment of FIG. 3.
These slats having the longitudinal bend may be fixedly secured within the absorbing chamber 36 by utilizing the channel-type fixed mountings as depicted in FIG. 8 instead of the adjustable mounting. As seen in FIG. 8, the slats 68 are introduced into slots 70 formed in the uprights 72 of U-shaped metal channels 74. By selecting the angle of the longitudinal bend to be slightly different than that of the angle of the slot 70, a friction fit may be produced such that the slots may be secured by friction and no welding or other means of securing the slots in position is required, although these other means may be used if desired. The friction or interference fit is preferred as cheaper and facilitating slat replacement.
Another alternative embodiment of this invention is depicted in FIG. 7. In this instance the slats are depicted purely by way of illustration as having a bend along their longitudinal axis. It is to be understood, of course, that any of the other configured slots, either planar, curved, having multiple longitudinal bends, or otherwise as is described hereinbefore, may be employed. In this instance, the heat absorbing chamber 36 is constructed similarly to the chamber previously described in connection with FIG. 6 with suitable insulation at the rear portion thereof. The transparent face wall 30 through which the sun's radiant energy enters is depicted as a single face wall for simiplicity of illustration. In this instance, the slats 68 are formed in a vertical array an positioned such that the top of the array 38 is tilted forwardly toward the transparent cover 30. Air is circulated into the chamber from the bottom through a suitable duct 76 and outwardly at the top through a second duct 78 as depicted by the respective arrows 80 and 82. The ducts 80 and 82 encompass the entire horizontal width of the heat absorbing chamber 36 such that the air moves upwardly within the heat absorbing chamber as depicted by the arrow 84 and thence flows back across the width of the slats 68, to continue its upward journey at the back portion of the heat absorbing chamber, as depicted by the arrow 86, thence out through the exhaust duct 78. This flow pattern has one advantage over that depicted in FIG. 6 in that the flow resistance is somewhat less. Here again, although the fixed positioned slats 68 are illustrated, it is preferred that adjustable slats mounted in a manner similar to that in FIG. 6 be used.
Thus, according to the method of this invention and utilizing the apparatus of FIG. 7, the inlet air to be heated moves upwardly, thence backwardly across the width of the slats thereby removing the heat from the slats by convection, thence upwardly and out from the heat exchange chamber. A desirable feature of this method is that the vertical array of slats be tilted forwardly to facilitate this type of air flow. Slats having a flat, curved, or angular cross-section may be used.
There has thus been described a rather unique apparatus and method for solar air heating. This method utilizes multiple reflections from the surfaces of horizontal slats disposed in a vertical array and has a particular advantage in that by proper angular positioning of the slats the summer sun's heat may be rejected from the heater.
It is obvious that many embodiments may be made of this inventive concept, and that many modifications may be made in the embodiments hereinbefore described. Therefore, it is to be understood that all descriptive material herein is to be interpreted merely as illustrative, exemplary and not in a limited sense. It is intended that various modifications, which might readily suggest themselves to those skilled in the art, be covered by the following claims, as far as the prior art permits.
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A solar air heater is vertically disposed and composed of a plurality of parallel, horizontally disposed slats resembling a venetian blind. The slats are positioned with their upper faces facing the sun and at an acute angle relative to the horizontal such that the winter sun will produce multiple heat absorbing reflections between adjacent slat surfaces, whereas the summer sun will be reflected back, if desired, so as to impart little or no heat to the heater. Air is circulated through the heater between the slats, thereby becoming heated as it absorbs heat from the slats. This heated air is then sent into a structure, such as a room of a house, via air ducts or the like to heat the structure or is sent to such other areas as desired, the solar air heater being attached to or forming a part of the structure that is to receive the heat produced by its use.
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BACKGROUND
1. Technical Field
The present disclosure relates generally to self loading firearms and, more particularly, to a multi-block gas regulator for use with self-loading firearms
2. Description of the Related Art
Adjustable gas regulators have been utilized on self loading firearms since the 1940's. Some early examples are the Soviet SVD and Belgium FAL, while the Adams Arms, Sig Sauer 516 and the Ruger SR-556 are some recent designs.
Early on gas regulators were developed to enable discharge gas pressure to be adjusted on a host firearm. The use of gas regulators was necessitated by ammunition that produced inconsistent pressures that led to excessive wear and or malfunctions of a firearm's operating system.
More recently with the increased use of silencers, the role of gas regulators took on a new priority in the form of managing back pressure. Back pressure is created by a silencer forcing more discharge gas into the rifles operating system. The increase in the volume of discharge gas passing through the operating system of a firearm resulted in increased fouling, felt recoil, accelerated wear of the firearms components and a plethora of operational related malfunctions.
With the early designs like the Belgian FAL, the discharge gas was regulated by allowing excess gas to be exhausted into the atmosphere. However, such regulation was not practical with firearms utilizing a silencer because when the discharge gas entered the oxygen rich atmosphere, the gases flashed and produced a report that nullified the silencing effect of the silencer. Furthermore, the regulator did not provide preset gas settings. Other disadvantages of such systems included requiring a tool to adjust the gas settings and the inability to rapidly adjust the gas flow while the weapon is fielded.
Modern designs like Adams Arms have made some improvements over earlier designs in the following ways: 1) restricting the amount of discharge gas allowed to escape into the atmosphere. 2) equipping their regulators with preset gas adjustments; and 3) providing a means to change gas settings in the field without requiring the use of tools.
The problems with existing systems are numerous. Adams Arms is the only current retro fit piston system that is capable of regulating gas flow to the firearms operating system. However the Adams Arms system is not equipped to precisely regulate gas as would be appropriate to optimize a firearm's performance. Furthermore, the Adams Arms gas regulation system is limited to three positions, i.e., partial gas, full gas, and off. Because the system uses a single large aperture for full gas and partially occludes the aperture to achieve partial gas, the caliber and type of ammunition compatibility are unduly restricted. The Adams Arms single aperture design lacks efficiency by excluding a means to precisely meter gas flow. The gas regulator is not easily manipulated under adverse conditions, especially if gloves are worn. In addition, the gas regulator can be accidentally released while moving between settings and there are no options for a low profile gas regulator that would allow the use of an uninterrupted extended hand guard.
The present disclosure offers many advantages over the prior art. More specifically, the presently disclosed gas regulator provides four positions of adjustment including reduced gas flow, normal gas flow, adverse gas flow, and extra high or no gas flow settings. Each position of adjustment has a precisely sized gas port to optimize performance with or without a silencer and provide the widest range of caliber and ammunition type compatibility. A spring loaded adjustment knob positively locks the regulator in position while its method of actuation and size facilitate rapid manipulation under adverse conditions and while wearing gloves. The gas regulator works by restricting the flow of gas from the host weapons barrel and not by venting excess gas into the atmosphere. The present disclosure offers an alternative low profile gas regulator that may be concealed under the hand guard providing for an uninterrupted extended hand guard for mounting accessories, In addition, the gas regulator cannot be accidentally released while in use yet it can be easily retro fitted to existing gas operated firearms. Moreover, the gas regulator may be quickly and easily disassembled for routine maintenance, and can be configured for use with both indirect gas impingement, e.g. piston op-rod, or direct gas impingement, e.g. original AR type, operating systems.
SUMMARY
An adjustable gas regulator for use with a gas operated firearm is disclosed which includes a gas block configured to receive a barrel of a firearm and defining a gas block bore. A gas port is defined within the gas block bore and is positioned to communicate with a gas port aperture of a firearm. A gas regulating cylinder is dimensioned to be rotatably received within the gas block bore. The gas regulating cylinder defines a plurality of cylinder gas ports spaced about the periphery of the cylinder. The gas regulating cylinder is rotatably positioned within the gas block such that the gas regulating cylinder is selectively rotatable to position any one of the cylinder gas ports in communication with the gas port of the gas block bore. In one embodiment, an adjustment knob is secured to one end of the gas regulating cylinder. The adjustment knob is rotatably fixed in relation to the gas regulating cylinder such that rotation of the adjustment knob effects corresponding rotation of the gas regulating cylinder.
In one embodiment, the adjustment knob includes interlocking structure configured to releasably retain the adjustment knob in a plurality of rotatably fixed positions in relation to the gas block. The adjustment knob may include at least one position stop and the gas block may support structure defining a plurality of notches dimensioned to receive the at least one position stop to rotatably maintain the adjustment knob and the gas regulating cylinder in rotatably fixed positions with respect to the gas block. In one embodiment, the adjustment knob is movable axially from a first position wherein the at least one position stop is received in at least one of the plurality of notches to a second position wherein the at least one position stop is disengaged from the at least one of the plurality of notches, wherein in the second position of the adjustment knob, the adjustment knob and the gas regulating cylinder are rotatable in relation to the gas block. A spring may be positioned to urge the adjustment knob to the first position.
In one embodiment, a bushing is fixedly positioned within the gas block bore and the plurality of notches are formed in one end of the bushing.
In an alternate embodiment, the plurality of notches are formed in one end of the gas block.
The plurality of notches may include four notches and the at least one position stop may include two position stops. Each of the plurality of notches may be spaced 90 degrees from an adjacent notch about its periphery of the gas block or bushing.
In one embodiment, the gas block is a Picatinny-type gas block. Alternately, the gas block may be a low profile gas block.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the presently disclosed multi-block gas regulator are disclosed herein with reference to the drawings wherein:
FIG. 1 is an exploded view in perspective of the presently disclosed multi-block gas regulator including with a Picatinny rail type gas block, and removable four position gas regulating cylinder;
FIG. 2 is an exploded view in perspective of the presently disclosed multi-block gas regulator including a low profile gas block, and four position gas regulating cylinder;
FIG. 3 is a perspective view from the front of the bushing and adjustment knob of the multi-block gas regulator shown in FIG. 1 ;
FIG. 4 is a front view of low profile gas block and the adjustment knob of the multi-block gas regular shown in FIG. 1 ;
FIG. 4A is a front view of the adjustment knob shown in FIG. 4 ;
FIG. 4B is a side view of the adjustment knob of FIG. 4 ;
FIG. 5 is a side view of the multi-block gas regulator as shown in FIG. 1 in an assembled state as it would be installed on a firearm;
FIG. 6 is a side view of the multi-block gas regulator shown in FIG. 2 illustrating how the low profile gas block is fully concealed by the firearm's hand guard;
FIG. 7 is a side view of the fully assembled multi-block gas regulator illustrating internal details of the gas regulating system;
FIG. 8 is a side view of the presently disclosed multi-block gas regulator shown in FIG. 1 , illustrating how the Picatinny type gas block with removable four position gas regulating cylinder shown in FIG. 1 can be configured with a gas tube so as to be utilized by a direct gas impingement firearm; and
FIG. 9 is a side view of the presently disclosed multi-block gas regulator illustrating how the low profile gas block with four position gas regulating cylinder shown in FIG. 2 can be configured with a gas tube so as to be utilized by a direct gas impingement firearm.
DETAILED DESCRIPTION OF EMBODIMENTS
Embodiments of the presently disclosed multi-block gas regulator will now be described in detail with reference to the drawings wherein like reference numerals designate identical or corresponding elements in each of the several views.
The detailed description set forth below in connection with the appended drawings is intended as a description of selected embodiments of the disclosure and is not intended to represent the only forms in which the present embodiments may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the selected embodiments. However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of this disclosure.
Exemplary embodiments of the present disclosure are shown in FIGS. 1-9 . Looking first at FIGS. 1 , 2 , and 5 , the multi-block gas regulator 13 is shown in an exploded view, with dashed lines indicating the order and way of assembly. The primary parts of the multi-block gas regulator 13 include a Picatinny-type gas block 6 A, a gas regulating cylinder 5 A, a bushing 3 , an adjustment knob 2 , a compression spring 1 , a split pin 4 , a piston 7 , and a take down pin 11 . In an alternative embodiment shown in FIG. 2 , the gas block 6 A can be replaced by a low profile gas block 6 B which will be discussed in further detail herein below. The gas block 6 A forms a rail mounting surface 14 on a top surface of gas block 6 A for attaching accessories, e.g., sights, lasers, etc. Two bores extend through the gas block 6 A including, a gas regulating cylinder bore 15 and a barrel bore 16 . The gas regulating cylinder bore 15 is configured to receive the gas regulating cylinder 5 A and the barrel bore 16 is configured to receive a barrel of a firearm 17 as shown in FIG. 5 . The gas regulating cylinder 5 A or 5 B has a piston bore 19 which is configured to slidably receive a piston 7 . FIG. 5 shows the multi-block gas regulator as it would be assembled on a firearm with additional parts including an op-rod ( 8 ), a return spring 9 and a bolt carrier 10 .
Referring to FIGS. 1 , 2 , and 7 , a barrel 17 of a rifle defines a gas port aperture 22 which communicates with the gas block gas port 18 ) within gas regulating cylinder bore 15 of gas block 6 A or 6 B. Gas block gas port 18 communicates with the gas regulating cylinder 5 A or 5 B.
As discussed above, gas block 6 A includes barrel bore 16 which is dimensioned to receive barrel 17 of a rifle. Clamping screws 20 are provided to fixedly secure gas block 6 A to barrel 17 . Referring also to FIG. 5 , gas block 6 A defines a retaining pin hole 24 which is aligned with a retaining pin groove 25 formed along bushing 3 . A retaining pin 11 is dimensioned to be received through retaining pin hole 24 in gas block 6 A and along retaining pin groove 25 in bushing 3 to secure bushing 3 in an axially and rotatably fixed position within gas block 6 A. The regulating cylinder 5 A is configured with three gas ports 33 , 34 , 35 of various sizes spaced apart, e.g., 90 degrees, about its periphery.
Bushing 3 and adjustment knob 2 are configured with a thru-bore 30 and 30 A, respectively, to receive the narrow end of the regulating cylinder 5 A. Bushing 3 has four index notches 29 - 29 C ( FIG. 4 ) positioned 90 degrees apart on its periphery. Index notches 29 - 29 C are positioned to selectively interlock with position stops 28 that are positioned 180 degrees apart on the periphery of adjustment knob 2 . Alternately, other configuration of stops and notches on knob 2 and bushing 3 may be provided to release secured knob 2 to bushing 3 . Bushing 3 and adjustment knob 2 are secured to the regulating cylinder 5 A with split pin 4 . Split pin 4 traverses U-notches 32 of the adjustment knob 2 and is affixed within split pin bore 31 . Adjustment knob 2 is maintained in interlocked relation with bushing 3 under compressive force of compression spring 1 which is captured between a shoulder or rim (not shown) defined at one end of adjustment knob 2 and split pin 4 . Spring 1 urges adjustment knob 2 towards bushing 3 to position stops 28 in selected ones of notches 29 - 29 C to rotatably secure knob 2 in relation to bushing 3 . The adjustment knob 2 has a position aperture or indicator 36 that may be selectively aligned with any one of index notches 29 - 29 C of bushing 3 to provide a visual indication of the selected gas setting of the multi-block gas regulator as will be described in further detail below.
As illustrated in FIG. 5 , adjustment knob 2 is positioned forwardly of hand guard 21 A and gas block 6 A such that it is easily accessible to an operator. Because of the position of adjustment knob 2 and the type of interlocking engagement provided between adjustment knob 2 and, bushing 3 , single handed manipulation or operation of adjustment knob 2 from either side of hand guard 21 A, is easily effected.
FIG. 6 , is a side view of the multi-block gas regulator 13 A shown in FIG. 2 illustrating the low profile gas block 6 B fully concealed by the firearm's hand guard 21 A. FIG. 6 also illustrates how the adjustment knob 2 is positioned forward of the hand guard 21 A allowing easy access to the adjustment knob 2 .
Referring to FIG. 7 , when a round is fired, a bullet 26 is propelled by discharge gases 27 located behind bullet 26 muzzleward, in the direction indicated by arrow “A”. When the bullet 26 passes over the gas port aperture 22 of barrel 17 of a firearm, a portion of the discharge gases 27 is directed through gas port aperture 22 and into the gas regulating cylinder passage 22 A of gas block 6 A. As the discharge gases 27 enter the gas regulating cylinder 5 A, the gases exert a force that actuates a firearm's operating system. U.S. patent application Ser. No. 12/909,278 titled “Convertible Gas Piston Conversion System” discloses a gas operating system such as shown in FIG. 6 and is incorporated herein in its entirety by reference.
Referring to FIGS. 1 , 3 , and 7 , gas flow into a firearm's operating system is traditionally set by the manufacturer and is determined by the size of the gas port aperture 22 created in the barrel 17 of the firearm. The multi-block gas regulator 13 of the present disclosure adjustably regulates the amount of gases permitted to flow into the firearm's operating system by selectively positioning one of gas ports 33 - 35 in communication with gas port aperture 22 . More specifically, when adjustment knob 2 is rotated, split-pin 4 , which is positioned through U-notches 32 of adjustment knob 2 and through split-pin bore 31 of regulating cylinder 5 A, is also rotated to effect corresponding rotation of regulating cylinder 5 A. Position aperture or indicator 36 is selectively positionable, by rotating adjustment knob 2 , to be aligned with any one of index notches 29 - 29 C. More specifically, when the adjustment knob 2 is positioned to align indicator 36 with index notch 29 , regulating cylinder 5 A is positioned to align gas port 33 in communication with gas port aperture 18 of gas block 6 A which communicates with gas port aperture 22 of barrel 17 of a firearm. In one embodiment, gas port 33 is dimensioned to restrict the flow of discharge gas 27 to an optimum level to run a silencer. With further rotation of adjustment knob 2 to align position aperture 36 with index notch 29 A, gas port 34 is positioned in communication with gas port aperture 18 which allows an optimal flow of discharge gas 27 to cycle the host firearm without a silencer and under normal conditions. With further rotation of adjustment knob 2 to align position aperture 36 with index notch 29 B, gas port 35 is positioned in communication with gas port aperture 18 which allows an extra flow of discharge gas 27 to cycle the host firearm without a silencer and under adverse conditions. Lastly a further rotation of adjustment knob 2 to align position aperture 36 with index notch 29 C takes gas port 33 , 34 and 35 out of communication with gas port aperture 18 shutting off the flow of discharge gas 27 to the host firearm operation system. Although the presently disclosed multi-block gas regulator is disclosed to have four distinct gas settings, it is envisioned that two or more gas settings may be provided, e.g., three, four, five, six, etc.
Referring to FIGS. 1 , 3 , and 7 , the rotational position of regulating cylinder 5 A within gas block 6 A, and thus the gas settings, are maintained by an interlocking mechanism defined by the four index notches 29 - 29 C of bushing 3 and adjustment knob's 2 two position stops 28 . Pulling muzzleward on the adjustment knob 2 moves adjustment knob 2 muzzleward against the urging of spring 1 to release the position stops 28 from the index notches 29 - 29 C allowing rotation of the regulating cylinder 5 A, thus changing the gas setting. Aligning the position aperture 36 with any one of the index notches 29 - 29 C and releasing the adjustment knob 2 again interlocks the position stops 28 within the index notches 29 - 29 C preventing rotation of the regulating cylinder 5 A, thus securing the selected gas setting. More specifically, when position aperture 36 is aligned with a selected index notch 29 - 29 C by rotating adjustment knob 2 and, thereafter, released, spring 1 urges adjustment knob 2 towards bushing 3 to locate position stops 28 into selected index notches 29 - 29 C to releasably lock adjustment knob 2 and regulating cylinder 5 A at a rotatably fixed position. Because regulating cylinder 5 A is rotatably fixed to adjustment knob 2 by split-pins 4 , regulating cylinder 5 A is maintained in a rotatably fixed position within gas block 6 A, 6 B.
Referring to FIG. 4 , low profile gas block 6 B is configured with four index notches 29 - 29 C, which correspond to the index notches on bushing 3 . The adjustment knob 2 and position stops 28 of adjustment knob 2 interface with the four index notches 29 - 29 C of the low profile gas block 6 B in the same way the notches 29 - 29 C of bushing 3 interface with the position stops 28 of adjustment knob 2 to provide the same means for selectively adjusting and maintaining the gas settings.
Referring to FIGS. 8 and 9 , the multi-block gas regulator may be configured with a gas tube 21 for utilization with a direct gas impingement operating system, e.g. AR-15/AR-10 family of firearms. More specifically, in FIGS. 8 and 9 , the piston 7 , op-rod 8 and return spring 9 in FIG. 5 are replaced by a gas tube 21 . Referring to FIGS. 5 , 7 , 8 , and 9 , the multi-block gas regulator 37 and 38 directs discharge gas 27 through the regulating cylinder 5 A to act upon a piston 7 causing the firearm's action to cycle. In comparison the multi-block gas regulator 37 A and 38 A in FIGS. 8 and 9 directs discharge gas 27 through the regulating cylinder 5 A and gas tube 21 into a bolt carrier gas key 39 causing the firearm's action to cycle. Otherwise all the operational characteristic of the multi-block gas regulator 37 , 38 and the gas tube configured multi-block gas regulator 37 A 38 A are identical.
Persons skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. It is envisioned that the elements and features illustrated or described in connection with one exemplarly embodiment may be combined with the elements and features of another without departing from the scope of the present disclosure. As well, one skilled in the art will appreciate further features and advantages of the system based on the above-described embodiments. Accordingly, the present disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.
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A multi use retro fit capable adjustable gas block designed to interface with an autoloading gas operated firearm is provided to replace existing gas blocks. The adjustable gas block optimizes gas flow into the host firearms operating system. The adjustable gas block has a spring loaded adjustment knob that releases when pulled forward allowing it to rotate. By rotating the adjustment knob the gas flow is increased or decreased based on one of four provided gas settings. Setting one is optimal for using a silencer, setting two is optimal for normal operations, setting three is optimal for adverse conditions, and setting four either turns the gas flow off optimizing sound reduction and providing for manual operation, or provides an extra high gas setting for the host firearm. The system works by precisely metering gas entering the operating system and not by exhausting excess gas into the atmosphere. The adjustable gas regulator may be configured with a piston operating system or a direct gas impingement operating system, e.g. gas tube, as is the case with the standard AR-15/AR-10 family of firearms.
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FIELD OF THE DISCLOSURE
[0001] The present disclosure is directed to an automated mix in-cup apparatus and the related method of operation. The disclosure relates generally to the field of mixing consumable material. The apparatus is effective, fast, easy to operate, safe, and clean.
BACKGROUND OF THE DISCLOSURE
[0002] In a commercial food environment, it is often important to prepare items as quickly as possible. This objective runs counter to the mandate that all food preparation devices remain as sanitary as possible. That is, in the rush to deliver an item to a customer, it is possible that best practices regarding sanitation are not observed. It is also understood that human error increases as a person more quickly repeats a repetitive task. In other words, the person preparing the food or drink may “get sloppy” as the food or drink preparation is accelerated.
[0003] A conventional blender requires that the food/drink components are separately loaded into a blender jar. The jar is closed and placed on a blender base. The machine is activated to blend the contents, which are then placed into another receptacle. The blender and/or blender base is cleaned between consecutive blending operations.
[0004] Other commercial food preparation and drink delivery units include drink and ice dispensers and mixers for frozen drinks or confections. Drink and ice dispensers can be manually operated by a customer, as found in many ‘fast food’ establishments, or they can include the automated filling of various cup sizes.
[0005] Commercial mixers for frozen drinks or confections typically involve a user (i.e., employee) loading a metal cup with the beverage ingredients onto a machine. The cup is positioned so that a mixing blade is located in the cup. The user then activates the machine in order to spin the blade. In this conventional machine, it is possible to remove the cup while the mixing blade is still spinning, which results in the beverage/confection splashing onto the machine and/or user. To achieve a more even mix, a user may also manually move the cup up-and-down during the mix cycle. However, this practice increases the chances that the beverage or confection will splash out of the cup. Basically, the operation becomes less sanitary and less safe as the operator attempts to more quickly complete the task. The mixed material must be transferred to another receptacle.
[0006] Machines for automatically accomplishing the mixing operation have also been envisioned. For the automated units, there is still the question of cleaning the blade and apparatus used in the mixing operation. It is important that a flavor from one mix cycle does not contaminate the next mix cycle, which might be for a different flavor. In addition, the drink or confection must be cleaned from the machine regularly to avoid build up and contamination on the machine. It is thought that the operation of known automated machines is relatively slow and complex.
[0007] There remains a need for an apparatus for mixing consumable material in-cup, and a method of operating the same, that is fast, effective, safe, clean, and easy to operate. An automated mix in-cup apparatus and the method of operating the same as disclosed below addresses at least one of these or other needs.
SUMMARY OF THE DISCLOSURE
[0008] The present disclosure is directed to an automated mix in-cup apparatus adapted to mix consumable material. An ‘in-cup mixer’, ‘mix in-cup’ or ‘blend in-cup’ apparatus is understood to be a mixer where the consumable contents are not transferred to another vessel after the mix cycle and prior to consumption. Conventional mixers and blenders use dedicated mixing vessels and then all or part of the mixed material is transferred to a serving vessel (glass, Styrofoam cup, etc.).
[0009] Among other advantages, the automated mix in-cup apparatus disclosed herein is thought to be fast, clean, easy to operate, safe, and effective. The automated mix in-cup apparatus for mixing consumable material includes a frame supporting a stepper motor to move a carriage up and down on the frame. The carriage supports a mixing motor, a shield prop, and a combined splash shield and lid. The frame comprises a vertically aligned stand and a horizontal, cup-supporting leg. An optional cup-receiving holder is positioned on the leg of the frame.
[0010] In one embodiment, movement of the carriage is accomplished via the stepper motor and a lead screw. The lead screw passes though the carriage, and the carriage is supported on the lead screw via a nut. The stepper motor rotates the lead screw, also known as a translation screw, to translate the radial motion imparted by the stepper motor into a linear movement for the carriage. Rotation of the lead screw either raises or lowers the carriage on the frame. One or more guide rails pass through the carriage to keep the carriage aligned on the frame.
[0011] The mixing motor is attached to the carriage, and a rotatable mixing blade extends downwardly from the mixing motor. The mixing motor moves along with the carriage. The mixing blade is reciprocally moveable along with the mixing motor and carriage. When engaged, the mixing motor is operable to rotate the mixing blade in order to mix the consumable contents of the cup.
[0012] The horizontal portion of the frame may comprise a flat floor to support a cup or a cup-receiving holder. The floor may include liquid nozzles (small diameter apertures) from a manifold to eject a fluid upwardly from the floor. A drain aperture might also be employed in the floor as a liquid outlet. The drain is preferably proximate the cup-receiving position.
[0013] In another embodiment, the horizontal portion of the frame further comprises a liquid well comprising a recessed floor and a sidewall. The well could further include a liquid inlet manifold having at least one nozzle fluidly connecting the manifold and well. The well might further include a drain to serve as at least one liquid outlet for the well. In this embodiment, the optional cup-receiving holder is positioned above the floor of the well. The cup is positioned in the well or on the cup-receiving holder above the floor of the well. The cup-receiving holder may be selectively removed from the apparatus for cleaning.
[0014] The splash shield includes at least one sidewall, a closed lid or top, and a lower opening. The lid and shield might be integral parts or the shield might be secured to the lid via known fasteners. The splash shield and lid surround the mixing blade. The blade is connected to the mixing motor via a shaft that extends through an aperture in the shield's top end. A seal can be employed about the shaft in the lid aperture to prevent a fluid escaping upwardly from the shield. The seal is in close proximity to the shaft and may contain an internal helix groove. The helical groove on the inside surface of the seal directs any liquid between the shaft and seal downwardly.
[0015] The subject splash shield, mixing blade, and mixing motor are all reciprocally movable along a shared axis via the movement of the carriage on the lead screw. However, the splash shield can be moved independently of the mixing blade and motor via the shield prop, as described below.
[0016] Once engaged, the apparatus automatically moves the mixing blade, mixing motor, and splash shield from a home position to a mixing position. In the mixing position, the mixing blade is located within the dimensions of the cup. The shield rests on the cup, and the lid of the shield closes the cup. During a mix cycle, the blade can move up and down through the consumable material without displacing the shield.
[0017] The mixing motor, mixing blade, and splash shield return to the home position. The user removes the cup, and the apparatus moves the carriage to a cleaning position whereby the shield comes into contact with the frame, such as at the well floor, to selectively encase the cup-receiving position and optional cup-receiving holder on the frame. The blade can be positioned so as to pass through the cup-receiving holder during a cleaning cycle.
[0018] In one embodiment, a pulley system acts as a cord a cord management system for a power cord connected to the mixing motor. The power cord, which might also enclose sensor wires, is fixedly secured to the carriage at a first end and is fixedly secured to the frame at a second end. The carriage moves up and down on the frame. As a cord management system, the pulley system includes one stationary and one moveable, spring-biased pulley to manage slack in the power cord as the carriage moves up and down. As the carriage moves down on the frame, the moveable pulley is lifted by the tension placed on the power cord. As the carriage moves up on the frame, a spring biases the moveable pulley down to take up slack in the power cord.
[0019] In use, the machine starts at a first home or open position. A user places a cup with consumable material on the cup-receiving holder and activates the apparatus. The stepper motor rotates the lead screw in order to lower the carriage. The downward movement of the carriage lowers the mixing motor, mixing blade, and splash shield to a mixing position. As a result, the shield is lowered around the cup until the lid contacts and closes the open top of the cup. Similarly, the mixing blade enters the interior space of the cup.
[0020] In this mixing position, the shield at least partially isolates the cup from the user. The lid also prevents the material in the cup from exiting the cup during a mix cycle. Once the apparatus is in the mixing position, the motor is activated to rotate the mixing blade thereby causing the consumable material to be mixed. The speed of the blade may be variable, and a speed sensor can be included so as to output motor speed feedback to a control board. In addition, the blade may move up and down within the cup during the mix cycle without displacing the splash shield.
[0021] After the mix cycle is completed, the shield and blade automatically retract to an open or home position so as to allow access to the cup. The cup is then removed. A cleaning cycle is then manually or automatically activated. The carriage is again lowered. In the cleaning position, the shield comes into contact with the frame to create a sealed, enclosed space. For the cleaning cycle, the blade can be positioned at various distances from the floor of the frame/well, including beneath the level of the cup-receiving holder.
[0022] Fluid is injected into the interior of the shield via the inlet manifold so as to contact the shield and blade during the cleaning cycle. The fluid is used to rinse the shield and blade. The blade may rotate during the cleaning cycle to increase fluid distribution or force. The rinse fluid is removed via the drain. In this manner, the automated mixing of the material and subsequent cleaning of the apparatus can be achieved. The cleaning cycle is fast and effective. The blade is isolated from the user during the mixing and cleaning operations. The cleaning operation is thought to remove all food or drink material and to prevent any flavor contamination between mix cycles.
[0023] In at least one embodiment, it is also envisioned that a number of sensors could be employed. The sensors are used to electronically determine the position of the motor, blade, and/or shield and to act as interlock mechanisms to disengage the mixing motor if a user displaces the shield during the mixing or cleaning cycles. In other words, the feedback from the sensors is used to automatically prevent the rotation of the blade unless the splash shield is properly positioned. In one embodiment, the failure to remove a cup from the cup-receiving position prior to initiating the cleaning cycle would also prevent the movement of the mixing blade to the blade's cleaning position. The blade or blade shaft would contact the cup. In response, the unit would return the shield to the home position.
[0024] Further features and advantages of the present disclosure will become apparent to those of skill in the art from the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The features and objects of the subject mix in-cup apparatus and related method will be better understood from the following detailed description taken in conjunction with the drawings wherein:
[0026] FIG. 1 is a perspective view of the housing for a combined fluid or ice dispensing and mixing unit wherein the mixing apparatus is envisioned as the apparatus disclosed herein;
[0027] FIG. 2 is a perspective view of the automated mix in-cup apparatus as disclosed herein wherein a mixing blade and a splash shield are shown in an elevated or home position;
[0028] FIG. 3 is a side cut-away view of the same wherein a well, a cup-receiving holder, and a drain are further illustrated;
[0029] FIG. 3A is a side view of a seal member as further disclosed herein;
[0030] FIG. 4 is a perspective, semi-transparent view of one embodiment of the subject apparatus wherein a mixing blade and splash shield are shown in an mixing or down position so that the shield is in the well and at least partially encloses the opening of a cup;
[0031] FIG. 5 is a side cut-away view of the same;
[0032] FIG. 5A further illustrates a cord management pulley system as disclosed herein;
[0033] FIG. 6 is a perspective, semi-transparent view of an embodiment of the subject apparatus wherein the splash shield is in a mixing or down position and the blade is in a mixing position so as to engage the contents of a cup;
[0034] FIG. 7 is a side cut-away view of the same;
[0035] FIG. 8 is a perspective, semi-transparent view of an embodiment of the subject apparatus wherein the splash shield and blade are in a cleaning position;
[0036] FIG. 9 is a side cut-away view of the same;
[0037] FIG. 10 is a top-down view of the well and the cup-receiving holder as disclosed herein in at least one embodiment;
[0038] FIG. 11 is a top-down cut-away view of the a water inlet manifold and the drain as disclosed herein;
[0039] FIG. 12 is an exploded view of the selectively removable cup-receiving holder, a liquid well, and a manifold cover as found in one embodiment disclosed herein;
[0040] FIG. 13 is a perspective view of the subject apparatus further illustrating a selectively removable cup-receiving holder as found in one embodiment disclosed herein
[0041] FIG. 14 is a close-up, semi-transparent view of the splash shield in the well and a related interlock safety mechanism; and
[0042] FIG. 15 is a three quarter front view of one embodiment of the subject apparatus illustrating sensors located on the apparatus.
DETAILED DESCRIPTION
[0043] The present disclosure is directed to an automated mix in-cup apparatus and the method of using the same. In general, the automated mix in-cup apparatus is thought to be more effective, safer, faster, cleaner and easier to operate than known devices. The apparatus and method are described and illustrated in terms of various embodiments. Of course, the present disclosure is not limited to the embodiments disclosed herein but also includes variations and equivalent structures that would be apparent to one of skill in the art, having studied the subject disclosure.
[0044] Turning now to the drawings, FIG. 1 illustrates a combined commercial fluid/ice dispensing and mixing unit 2 . Unit 2 comprises an outer housing to cover both the dispensing and mixing machinery. Unit 2 may also include a cabinet 6 accommodating a plurality of fluid containers 8 fluidly connected to a dispenser. An ice or frozen slurry dispenser and/or hopper may also be included in the unit.
[0045] The overall operation of unit 2 comprises a user selecting the cup 4 , which may be selected from a single size or a plurality of differently sized cups, and placing cup 4 on unit 2 proximate to a dispensing mechanism (not illustrated or described further herein). The dispensing mechanism is actuated to at least partially fill cup 4 from fluid containers 8 and/or a frozen fluid dispenser. The fluid containers 8 could contain various flavors of consumable drink mix. The cup would also at least partially be filled with ice or other frozen consumable material from unit 2 .
[0046] One or more automated mix in-cup apparatuses 10 are located next to the dispensing apparatus for mixing/blending drinks such as smoothies, milkshakes, ice coffee drinks, or the like. After the step of dispensing a fluid into the cup, the user positions cup 4 containing the selected flavor and frozen material at a cup-receiving position on mix in-cup apparatus 10 . Mix in-cup apparatus 10 is then engaged to commence an automated mixing operation of the cup contents, as explained further below. The user does not contact the apparatus 10 other than to select mix cycles or otherwise actuate the switches or buttons necessary to begin the operation of the unit.
[0047] With respect to FIGS. 2-14 , there is illustrated one or more embodiments of the mix in-cup apparatus and the method of operation of the same as described herein. The apparatus moves between three operational positions, as detailed further below with specific reference to the figures and labeled elements.
[0048] In general, the first position is the open or “home” position where a mixing blade, a mixing motor, and a splash shield are elevated above a cup-receiving position so as to allow a user access to the cup-receiving position. In the mixing position, the splash shield is lowered until it engages and closes cup 4 . The shield is held on the cup by gravity. While the shield always surrounds the sides and top of the mixing blade, the shield also surrounds the sides of cup 4 and closes the top of cup 4 in the mixing position. The mixing blade is positioned inside cup 4 when the apparatus is in the mixing position. During a mix cycle, the blade may move up and down within the cup independent of the movement of the splash shield.
[0049] In a cleaning position, the cup is first removed from the cup-receiving position, and the shield is again lowered until it contacts a floor. The floor and shield act to create a sealed interior space. In the cleaning position, the blade is moved into a position that may be below the cup-receiving position. A user cannot access the mixing blade in the cleaning or mixing positions without manually displacing the shield.
[0050] Turning to FIGS. 2 and 3 in further detail and with specific reference to the labeled elements, there is illustrated a mix in-cup apparatus 10 in accordance with at least one embodiment of this disclosure. The automated mix in-cup apparatus 10 for mixing consumable material includes a frame 12 supporting a stepper motor 13 . Frame 12 in this embodiment is generally an L-shaped, substantially vertical structure with sufficient width to support mechanical components as described below. Frame 12 could in turn be mounted to the structure of the combined unit 2 and be largely enclosed behind a housing. It is also envisioned that mix in-cup apparatus 10 might instead serve as a standalone device for mixing consumable material in cup 4 .
[0051] FIGS. 2 and 3 illustrate the home position of apparatus 10 . As illustrated, the horizontal portion of the L-shaped frame 12 supports cup 4 at a cup-receiving position. The stand portion of frame 12 supports a vertically aligned lead screw 15 connected to stepper motor 13 . Stepper motor 13 is positioned at the top of frame 12 . The distal end of lead screw 15 is mounted in a bearing (not illustrated).
[0052] One or more guide rails 16 are vertically aligned on frame 12 and are parallel to lead screw 15 . Lead screw 15 and guide rails 16 pass through a carriage 17 . A nut (not illustrated) under carriage 17 on lead screw 15 retains carriage 17 in place on lead screw 15 . As stepper motor 13 rotates lead screw 15 , the nut moves up and down on the screw. As a result, carriage 17 moves up and down relative to frame 12 . Guide rails 16 further support carriage 17 and maintain the alignment of carriage 17 as it moves. Overall, activating stepper motor 13 rotates lead screw 15 , and lead screw 15 translates the rotational movement into the linear up-and-down movement of carriage 17 .
[0053] In one embodiment, as explained further below, a pulley system acts as a cord management system for a power cord 19 connected to carriage 17 . Power cord 19 , which might also enclose sensor wires, is fixedly secured to carriage 17 at a first end and is fixedly secured to frame 12 at a second end. To account for the movement of carriage 17 , the pulley system includes one stationary pulley 18 and one moveable, spring-biased pulley 21 .
[0054] Moveable pulley 21 is at least partially placed within a pulley housing that slides within a vertical track defined by frame 12 . Moveable pulley 21 includes an axle mounted to the sliding housing. A spring 23 is secured to the housing a proximate end. Distal end of spring 23 is attached to a point on frame 12 beneath the pulley housing so as to maintain a tension force on the pulley housing. As carriage 17 moves down on lead screw 15 , moveable pulley 21 is lifted by the tension placed on power cord 19 . That is, the downward force on carriage 17 overcomes the tension force of spring 23 . As carriage 17 is lifted on lead screw 15 so as to move up relative to frame 12 , spring 23 biases moveable the pulley housing downwards so that pulley 21 move down within the frame's track. In this manner, any slack in cord 19 is controlled by the pulley system.
[0055] Carriage 17 supports a mixing motor 14 , a shield prop 70 , and a splash shield 50 . Any suitable type of electric motor may be employed as mixing motor 14 , as would be known or used in the mixing art. A mixing motor housing 54 surrounds and supports mixing motor 14 and housing 54 , in turn, is secured to carriage 17 . In this manner, carriage 17 supports motor 14 . Mixing motor 14 is axially aligned above cup 4 when cup 4 is in the cup-receiving position. The horizontal portion of the frame defines a floor to support cup 4 or an optional cup-receiving holder 40 may be positioned on frame 12 at the cup-receiving position. In an embodiment where frame 12 defines a fluid-receiving well, holder 40 is at least partially placed in the well. With the holder, a cup never contacts a drain or floor of the apparatus, which is thought to be more sanitary.
[0056] A rotatable mixing blade 20 extends vertically downwardly from mixing motor 14 via a shaft 22 . Blade 20 is used for mixing a consumable material in cup 4 . Motor 14 is operable to rotate mixing blade 20 and shaft 22 . Blade 20 moves relative to frame 12 when mixing motor 14 is raised or lowered via carriage 17 . Shaft 22 extends from mixing motor 14 at a fixed length. As such, blade 20 is reciprocally moveable along a shared axis with mixing motor 14 .
[0057] In one embodiment, frame 12 further comprises a liquid well 30 sharing a vertical axis with cup 4 , mixing motor 14 , shaft 22 , and splash shield 50 . Well 30 is a recess in the horizontal portion of the L-shaped frame 12 including a floor 32 and a sidewall 34 . In this embodiment, floor 32 is considered to be a part of frame 12 . Well 30 may be a plastic molded part inserted into frame 12 .
[0058] A liquid inlet manifold 36 is integral to or connected to frame 12 , and manifold 36 includes at least one nozzle fluidly connecting the manifold to the exterior of frame 12 (see also FIGS. 10 and 11 ). In the illustrated embodiments where an optional recessed well 30 is employed, manifold 36 is integral to or connected to well 30 . A cleaning liquid, which might be water or a combination of water and a known cleaning agent, is selectively ejected from manifold 36 . A drain 38 acts as at least one liquid outlet. In the embodiment containing the well, drain 38 is integral to or connected to well 30 . In either embodiment, a drainpipe would connect to the drain so that the cleaning fluid is removed from apparatus 10 .
[0059] The optional cup-receiving holder 40 is positioned to support a cup above frame 12 , such as above floor 32 of well 30 . Holder 40 may be selectively removable from the apparatus for cleaning, as further described below (see also FIG. 14 ).
[0060] Splash shield 50 may consist of an opaque, semi-transparent or transparent material. In the cup-receiving position, such as when cup 4 is placed on holder 40 , cup 4 is axially aligned beneath shield 50 .
[0061] Shield 50 comprises a shield lid 52 and a cylindrical sidewall 56 depending from lid 52 . Shield 50 defines an open bottom end 60 into which cup 4 and/or cup-receiving holder 40 can be placed. Shield 50 is suspended from motor housing 54 by a shield prop 70 . Prop 70 includes two guide rods 72 and upper stop plate 74 . In a home position, stop plate 74 rests atop mixing motor 14 or mixing motor housing 54 with guide rods 72 securely fixed to shield lid 52 .
[0062] As carriage 17 moves to a mixing position, shield lid 52 engages the open top of cup 4 so as to close the lid. Shield sidewall 56 at least partially surrounds cup 4 at the cup-receiving position. In the mixing position, the downward movement of shield 50 is limited by the height of cup 4 , and shield 50 rests atop cup 4 . However, carriage 17 may continue to move downward along lead screw 15 after shield 50 engages cup 4 . The continued downward motion of carriage 17 causes motor housing 54 to move along shield god rods 72 . The upper stop plate separates from mixing motor 14 and motor housing 54 . Carriage 17 can continue downwards until motor housing 53 engages the top of lid 52 .
[0063] Moving carriage 17 upwards will not displace shield 50 until mixing motor 14 and/or motor housing 54 engage upper stop plate 74 . Once engaged, the continued upward movement of carriage 17 lifts stop plate 74 . Guide rods 72 , which are fixed at a first end to plate 74 and at a second end to shield 50 , then lift shield 50 . For aesthetic purposes, an outer housing 53 can selectively nest over motor housing 54 . Outer housing 53 is supported atop lid 52 . As motor housing 54 moves away from shield 50 , outer housing 53 encases guide rods 72 and shaft 22 between motor housing 54 and lid 52 . As the motor housing 54 is brought into closer proximity to lid 52 , outer housing 53 nests over motor housing 54 .
[0064] Splash shield 50 surrounds blade 20 on all sides and covers the top of blade 20 . Shaft 22 extends through an aperture 62 in the shield's top end. A seal 63 is employed to prevent the escape of a fluid up and through lid 52 . One embodiment of seal 63 is illustrated in FIG. 3A . Seal 63 is in the lid aperture 62 through which shaft 22 passes. Seal 63 reduces or prevents fluid from passing around shaft 22 upwardly through the shield's top end. Shaft 22 can move independently of shield 50 so seal 63 allows for the linear movement of shaft 22 into and out of shield 50 . The inside face of seal 63 in contact or close proximity with shaft 22 includes a helical groove 64 . Groove 64 permits and encourages the downward flow of fluid were any fluid to enter seal 63 .
[0065] FIGS. 2 and 3 illustrate motor 14 and shield in the home position whereby a user can access cup 4 and the cup-receiving position. In this home position, mixing motor 14 cannot be activated, as further described below.
[0066] Turning then to FIGS. 4 and 5 , there is illustrated the embodiment of FIGS. 1 and 2 but where carriage 17 has been moved downwards to the mixing position. In the mixing position, as briefly referenced above, shield 50 comes to rest on a cup 4 . In the absence of a cup, shield 50 would rest on frame 12 . In this illustrated embodiment, shield 50 does not contact frame 12 or floor 32 of well 30 due to the height of the cup. In the mixing position, cup 4 is closed by lid 52 and is at least partially surrounded by shield 50 .
[0067] In one embodiment, the connection of shield sidewall 56 to closed top end 58 forms a frustoconical shape or portion 59 . That is, the connection between sidewall 56 and lid 52 is sloped as if to form a cone. However, the cone tip is truncated.
[0068] Conical portion 59 creates an effective seal on cup 4 despite the use of cups that might be of different diameters. Conical portion 59 also serves to center cup 4 on the cup-receiving position or holder. Where the conical portion engages a cup disproportionally on one side, the slope of lid 52 translates the downward motion of shield 50 into a lateral motion to better position cup 4 within shield 50 .
[0069] FIG. 5A further illustrates the pulley-based cord management system. A portion of frame 12 , which helps to define a vertical track, is removed to better illustrate the cord management system. Moveable pulley 21 is secured via an axle to the moveable pulley housing. The pulley housing slides within the vertical track defined by frame 12 .
[0070] The downward movement of carriage 17 places tension on cord 19 . This tension exceeds the spring bias provided by spring 23 . As a result, pulley 21 moves up within frame 12 . As carriage 17 is lifted on lead screw 15 so as to move up relative to frame 12 , spring 23 biases pulley 21 , via the pulley housing, downwards. In this manner, any slack in cord 19 is controlled by the pulley system.
[0071] With respect to FIGS. 6 and 7 , it is evident that blade 20 and motor 14 may continue to move down relative to frame 12 even after shield 50 comes into contact, and is stopped by, cup 4 . Prop 70 is fixed to shield 50 by guide rods 72 . Motor 14 slidably moves along guide rods 72 . As carriage 17 continues to move mixing motor 14 closer to shield 50 , upper stop plate 74 moves away from mixing motor 14 . In this manner, mixing motor 14 can be reciprocally moved up and down without displacing shield 50 during the mix cycle. The ability to move blade 20 up and down during a mix cycle increases the quality and consistency of the blended product.
[0072] Following the mix cycle, which can comprise a pre-programmed sequence of blade movements and variable blade speed changes, stepper motor 13 is actuated to rotate lead screw 15 to lift carriage 17 . The motor engages the stop plate 74 . As a result, shield 50 and blade 20 are withdrawn from cup 4 . Cup 4 is then removed.
[0073] Turning now to FIGS. 8 and 9 , apparatus 10 or a user then engages a cleaning cycle. Carriage 17 is positioned, via the stepper motor and lead screw, in a cleaning position. In the cleaning position, shield 50 brought into contact with frame 12 (such as well 30 ) to create an enclosed space about the cup-receiving position. Cup-receiving holder 40 would be encased by shield 50 and well floor 32 , for example.
[0074] As further illustrated in FIGS. 8 and 9 , with cup 4 removed, motor 14 can be lowered past the lowest mix position. As a result, blade 20 and/or shaft 22 extend below the cup-receiving position. For example, blade 20 can pass through the cup-receiving holder 40 . During the cleaning operation or cycle, it would again be possible to reciprocally move blade 20 up and down without displacing shield 50 .
[0075] In the cleaning operation, and with reference to FIGS. 10 and 11 , fluid enters a manifold 36 via pipe 35 . The fluid is transmitted to the space enclosed by shield 50 via manifold 36 and fluid nozzles 37 . The fluid will strike blade 20 , which can be rotated during the cleaning cycle to further disperse the fluid. The cleaning operation rinses the interior of shield 50 (including shield lid 52 ), cup-receiving holder 40 , blade 20 , and shaft 22 . Cleaning fluid exits the frame via the drain 38 , which is tied to an outlet pipe. The cleaning operation is automatic and requires little to no user involvement. As such, the automated mix in-cup apparatus is self-cleaning, which permits a user to fill another cup during the cleaning operation.
[0076] FIG. 12 illustrates the underside of well 30 with manifold 36 in an exploded view. A bottom plate 39 of manifold 36 is removed to reveal one embodiment of the interior of manifold 36 . Holder 40 is illustrated as being removed from well 30 .
[0077] Turning to FIG. 12 , cup-receiving holder 40 includes an open ring 42 upon which cup 4 rests. Ring 42 provides an aperture through which blade 20 passes when carriage 17 is in the cleaning position.
[0078] As briefly noted above, holder 40 may be selectively removable from frame 12 . Holder 40 could include one or more hollow posts 44 that engage vertical posts 46 on frame 12 . For instance, vertical posts 46 might be integral to well floor 32 . Vertical posts 46 nest within hollow posts 44 of the holder in order to frictionally retain holder 40 in place. A user could lift holder 40 off frame 12 to independently clean holder 40 , if necessary. Removing holder 40 provides the means to further clean the holder and/or the drain and frame that are located beneath holder 40 .
[0079] Overall, apparatus 10 is easy to operate, safe, and fast in that shield 50 and mixing blade 20 automatically move into and out of the mix position. A user is provided one-handed operation in that they merely need to place the cup before the mix cycle and remove the cup after the mix cycle. There is no need to manually manipulate the cup, the shield, or any other components of the apparatus besides cup 4 . Nevertheless, a user may mistakenly attempt to access or manipulate the splash shield or to otherwise access the cup during a mix cycle.
[0080] Turning now to FIG. 14 , there is illustrated a close-up view of shield 50 in the mixing position. In the illustrated embodiment, a magnetic strip 80 is integrated into or otherwise secured to sidewall 56 of shield 50 . Corresponding shield sensors 82 on frame 12 (e.g., in well 30 ) are operable to detect magnetic strip 80 . In the mix and cleaning positions, mixing motor 14 will not rotate blade 20 unless shield sensors 82 detect magnetic strip 80 . A control unit will disengage mixing motor 14 once strip 80 is displaced. As such, a user cannot lift shield 50 to access cup 4 without disengaging mixer motor 14 .
[0081] Additional sensors provide feedback to the control unit, as further illustrated in FIG. 15 . A home sensor 84 is used to determine if carriage 17 is properly returned to the home position after each mix and cleaning cycle. Home sensor 84 is operable to detect a magnet 86 located on carriage 17 . Stepper motor 13 runs until home sensor 84 detects magnet 86 or until there is a time-out condition. For example, if carriage 17 is obstructed, stepper motor 13 will run for a predetermined period of time that is longer than it takes for carriage 17 to return to the home position. If the magnet 86 is not detected within that time period, stepper motor 13 is deactivated and apparatus 10 would be reset.
[0082] Once home sensor 84 detects magnet 86 , stepper motor 13 reverses lead screw 15 until magnet 86 is no longer detected. Carriage 17 is then raised a second time until magnet 86 is detected by home sensor 84 . This provides an optional calibration mechanism so that the position of carriage 17 is calibrated prior to a mix or cleaning cycle.
[0083] A cup sensor 88 also works in conjunction with magnet 86 and the control unit. The failure to detect magnet 86 at cup sensor 88 indicates to the control unit that shield 50 is not in the cleaning position. As referenced above, in the cleaning position, shield 50 contacts frame 12 (e.g., well floor 32 ). Shield 50 creates an enclosed interior space to capture the cleaning fluid during the cleaning cycle. With the cup in place, shield 50 does not reach the frame or well floor. As a result, shield 50 will not properly rest against frame 12 or well floor 32 . The shield will not create an enclosed interior space so that the cleaning fluid will not be fully contained during the cleaning cycle. Cup sensor 88 prevents the initiation of the cleaning cycle where a user leaves the cup in place.
[0084] In addition, carriage 17 moves blade 20 to a cleaning position that is below the blade's “mixing position” and below the cup-receiving portion of holder 40 . If a user forgets to remove cup 4 , blade 20 will move downwardly until it contacts the floor of the cup. The floor will resist the further movement of blade 20 on shaft 22 . The extra load on the stepper motor causes it to stall. As a result, carriage 17 will not be in the proper position for cup sensor 88 to detect magnet 86 on carriage 17 .
[0085] The method of using the subject apparatus provides for one-handed operation that is fast, safe, clean, easy to use, and effective. In use, a user places a cup with consumable material at the cup-receiving position, such as on the cup-receiving holder, and activates the apparatus via a switch, button, touchpad, or the like. The apparatus automatically lowers the carriage to the mixing position. In the mixing position, the shield lid closes the top of the cup, and the mixing blade is positioned within the cup and consumable material.
[0086] The mixing motor is automatically activated to rotate the mixing blade thereby causing the consumable material to be mixed. The speed of the blade may be variable, and the blade may move up and down within the cup during the mix cycle without displacing the splash shield.
[0087] After the mix cycle is completed, the carriage is returned to the home position whereby the splash shield and mixing blade are lifted from the cup. The user can access and remove the cup from the cup-receiving position.
[0088] A cleaning cycle is then manually or automatically activated. The splash shield, which still surrounds the blade, is again lowered into contact with the frame. The splash shield and frame (such as well floor 32 ) create an enclosed entire space. The cup-receiving position and/or cup-receiving holder are encased by the splash shield and frame. The blade can be positioned at various distances from the frame including beneath the level of the cup-receiving holder. Mixing blade could be moved during the cleaning cycle without displacing the splash shield.
[0089] The cleaning cycle is initiated, and fluid is injected into the interior of the shield via an inlet manifold. The fluid contacts and cleans the shield (including the lid), blade, cup-receiving position, and optional cup-receiving holder. The mixing motor can be engaged to rotate the mixing blade during the cleaning cycle to increase fluid distribution or force. The rinse fluid is removed via the drain. In this manner, the automated mixing of the material and subsequent cleaning of the apparatus can be achieved. A user may select the flavors to be dispensed for the next order while the mix in-cup apparatus mixes a previous order and executes a self-clean operation. The mixing blade is isolated from the user during the mixing and cleaning operations. An attempt to displace the splash shield during the mixing or cleaning cycles deactivates the mixing motor.
[0090] While the disclosure has been described with reference to specific embodiments thereof, it will be understood that numerous variations, modifications and additional embodiments are possible, and all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the disclosure.
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The present disclosure describes an automated blend in-cup apparatus and the related method of operation. The disclosure relates generally to the field of mixing consumable material. More specifically, the disclosure relates to a mixer that is automatically operable to lower a mixing blade into a cup or vessel that contains material to be blended/mixed. A shield is automatically lowered to at least partially isolate the cup. The apparatus further comprises a well with an inlet manifold and a drain and a fixed but removable cup-receiving holder. The shield can include a magnetic portion that is detected by a first sensor on the apparatus. A safety interlock prevents the actuation of the mixing blade in the event that the magnetic portion is not proximate to the first sensor. Overall, the apparatus is effective, fast, easy to operate, safe, and clean.
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RELATED APPLICATIONS
[0001] Applicant claims the benefit under 35 U.S. Code 119( e ) of U.S. Provisional Application SER. NO. 60/477,274, filed Jun. 9, 2004 on the present invention, and incorporates the disclosure thereof herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to latches and levers, specifically ejector latches and ejector levers which may be adapted for use to secure and release computer-type boards in racks and cabinets, such as large boards known as peripheral component interconnect (PCI) boards. These boards are used to hold such electronic components as processor circuits, banks of switches, banks of transducers, transformers and other components and modules. Such PCI boards are generally larger than PC boards (personal computer boards) and can be generally square or rectangular in shape; and are generally sized from six (6) inch to ten (10) inches on a side. Compared to the much larger boards, previously used in the computer, the switching circuit, and the telecommunications industries, these boards have become known as compact PCI boards. It important to be able to easily insert such a module carrying PCI board with a positive snap-in connection and positive snap-out release. Moreover, it is important to have an insertion aid and/or a pull-out aid, such as a handle or a hold. This snap-in and snap-out operation has been implemented with ejector latches.
[0003] However, these latches must also comply with the general industry standards for this type of latch, including the standards for mounting on a faceplate on the front of a board, and the engagement with the chassis mounted flange, which acts as combination guide block and keeper. These standards are defined as a subset of IEEE1101.1 and IEEE 1101.10 specifications known as Compact PCI (PICMG 2.0) standards. Many inject/eject latches are in the marketplace and meet these standards. Examples are those sold by manufacturers such as Rittal, Schroff, Elma and Bivar. As manufactures are using higher frequency circuits on compact PCI boards, electromagnetic compatibility (EMC) is becoming an increasing concern. The existing prior art ejector latch configuration requires a large cutout in the aluminum faceplate normally mounted to the outside edge of a compact PCI board. This large cutout often is a source of electromagnetic radiation. Furthermore, such prior art compact PCI board latches often do not have a low profile and generally have a limited degree of movement and mechanical leverage.
[0004] [0004]FIG. 1 shows a typical example of a prior art compact PCI board 21 with a pair of prior art inject/eject latches 23 mounted on its outboard edge faceplate 25 . Chassis connectors 27 have wire leads 29 into the board 21 . Each latch 23 includes a base/alignment pin block 31 that carries a larger leading guide pin 33 and a smaller seating guide pin 35 .
[0005] [0005]FIG. 2 shows a perspective side view of the prior art pin 23 of FIG. 1 showing the single structure combination housing 37 having a claw-shaped end pawl 37 a and a thumb handle 37 b. The base/alignment pin block 31 is a casting with a number of openings and shoulders. A spring biased release button 39 is shown in Fig.3, which is a longitudinal cross-sectional view of FIG. 2 taken as shown in FIG. 2. The spring 41 biases the thumb release button away from the pawl 37 a to have a projection shoulder 39 a extend through the opening in the back of the housing 37 to prohibit the rotation thereof and to keep the pawl 37 a locked in position.
[0006] This prior art device has a high profile and its faceplate mounting with relatively large cutout results in a relatively large amount of EMF signal leakage (electromagnetic frequency radiation).
[0007] The IEEE Compact PCI specification defines the location, with respect to a chassis, of the faceplate in its fully inserted and fully extracted positions, where fully extracted is defined as being loose for removal. It also defines the area of the chassis to which a latch is to interact when inserting and extracting (ejecting) a board.
[0008] An object of this invention is to meet these IEEE requirements for a latch for Compact PCI board installations, which allows for more efficient EMC shielding.
[0009] A second object of this invention is to provide a latch that needs a smaller cutout in the PCI board faceplate.
[0010] An third object of this invention is to provide such a latch that has a low profile when folded closed.
[0011] A further object of this invention is to provide such a latch with a greater degree of rotation and a two-phase operation.
[0012] An even further object of this invention is to implement such a two-phase operation by having the ejector successively operating first in a rotary motion and then secondly in a linear motion.
SUMMARY OF THE INVENTION
[0013] The objects of the present invention are realized in a low profile Compact PCI board latch, having a fold-down handle that operates with a greater degree of rotation, and has a separate alignment guide block, which facilitates its mounting to the board's faceplate and thereby requires a smaller faceplate aggregate cutout area thereby reducing EMF leakage and enhancing EMC compatibility.
[0014] The invention is an inject/eject latch, for mounting on the outside of a PCI board faceplate. This latch engages and disengages a chassis keeper, whereof the chassis environment, including the shape, position and size of the chassis keeper, is specified by IEEE standards for Compact PCI boards. The latch includes a claw-shaped pawl that engages and disengages from a flange-type keeper under a two-phase motion, whereof each motion is a movement, such as a rotation, about a separate and distinct point.
[0015] This pawl includes an elongate arm extension and an abutment shoulder with which fold-down latch handle operates. The fold-down handle rotates through 90 degrees from its flat, folded-down position to the upright standing position facing outwardly from the faceplate.
[0016] The latch has a base that is mounted to the outside face of the compact PCI board's faceplate with its entire structure being outboard of the PCI board faceplate. A separate alignment guide block mounts to inside face of the faceplate to extend inwardly towards the chassis connectors. The latch, including its base and the separate alignment guide block are mounted to the faceplate with but two screws. The two-phase operation of the pawl permits the faceplate to extend further beyond the outside edge of the board than with solely rotational movement pawls. This increases the EMF shielding and enhances EMC levels for the latch and faceplate combination.
[0017] The latch housing has two juxtaposed plates each carrying facing guide openings and facing pivot openings. A one-piece handle is assembled to ride on and pivot between the juxtaposed housing faces. A claw-shaped pawl is acted upon by the handle to first rotate into a small rectangular cutout opening and then to translate longitudinally into a flange-shaped keeper on injecting. A reverse path of motion of longitudinally withdrawing from the flange-shaped keeper and then rotating is carried out on ejecting.
[0018] A spring-biased, plate-shaped catch with a small projecting hook acts as a locking device in the folded-down position. Releasing the catch permits the latch's handle to be rotated upwardly.
[0019] From the fully inserted configuration/position, the user first rotates the spring loaded catch which in turn releases the handle from the base and permits it to be rotated outwardly from the board's faceplate. As the handle is rotated though the first 75 degrees, it pivots around the end of a central slot in the base halves (juxtaposed base plates). Slots in the end of the handle contact pins on the pawl. The pawl rotates around a pin and ejects the faceplate/board structure from the chassis connector by moving the board outwardly above the chassis keeper flange. A further 15 degree rotation of the handle causes the handle to pivot around the end of semi-circular slots in the base halves (juxtaposed base plates). The first slots now drive the pawl pins down vertical portions of “L”-shaped slots in the base plates, causing the pawl to disengage from the chassis keeper flange with a longitudinal movement. The board is now free to be removed (pulled) from the chassis. The ends of the pins on the pawl have a tear-drop shape which prevents them from beginning the vertical travel before the extraction rotation is completed (the full 75 degrees of rotation).
[0020] Insertion reverses the motion and sequence of operation of extraction. The insertion and the extraction is a two-step process. With extraction, the process uses first one pivot location for the handle acting on the pawl extension to provide the extract motion, and then uses a second pivot location for the handle to provide the linear disengagement movement. With injection the order sequence is reversed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The features, advantage and operation of the present invention will become readily apparent and further understood from a reading of the following detailed description with the accompanying drawings, in which like numerals refer to like elements, and in which:
[0022] [0022]FIG. 1 is a side view of a prior art Compact PCI board with prior art inject/eject latches positioned on the faceplate;
[0023] [0023]FIG. 2 is a perspective view of the prior art inject/eject latch of FIG. 1;
[0024] [0024]FIG. 3 is a longitudinal cross-sectional view of the prior art latch of FIG. 2 taken as shown in FIG. 2;
[0025] [0025]FIG. 4 is a perspective view of the latch of the present invention assembled on the faceplate of a Compact PCI board and engaging a chassis keeper;
[0026] [0026]FIG. 5 is a perspective view of the latch of the present invention assembled on the faceplate of a Compact PCI board with the board removed, the view is from the bottom of the latch, i.e., the inboard face of the faceplate;
[0027] [0027]FIG. 6 is a bottom/inboard view of the PCI board faceplate showing a detail of the two mounting screw holes and the faceplate extension permitted by the unique operation of the latch of the present invention;
[0028] [0028]FIG. 7 is a perspective view of the left sidewall of the base for the latch of FIGS. 5-6 showing the inside face thereof;
[0029] [0029]FIGS. 7 a - 7 e are outside, inside, top, claw-end, and thumb handle end views, respectively, of the left sidewall shown in FIG. 7;
[0030] [0030]FIG. 8 is a perspective view of the right sidewall of the base for the latch of FIGS. 5-6, showing the outside face thereof, with the left sidewall and right sidewall of the base having, respectively, inside face cavities, projections, ramps and journals being mirror images;
[0031] [0031]FIGS. 8 a - 8 e are outside, inside, top, claw-end, and thumb handle end views, respectively, of the left sidewall shown in FIG. 8;
[0032] [0032]FIG. 9 is a perspective view of the thumb handle member for the latch of FIGS. 5-6;
[0033] [0033]FIGS. 9 a - 93 are left side, right side, top, claw-end and thumb grasping-end views, respectively, of the handle of FIG. 9;
[0034] [0034]FIG. 10 is a perspective view of the claw-shaped pawl with elongate arm for the latch of FIGS. 5-6;
[0035] [0035]FIGS. 10 a - 10 e are left side, right side, top, claw-end and thumb/catch-end views, respectively, of the pawl of FIG. 10;
[0036] [0036]FIG. 11 is a perspective view of the catch for the latch of FIGS. 5-6;
[0037] [0037]FIGS. 11 a - 11 e are left side, right side, top, catch tang-end, and free-end views, respectively, of the catch of FIG. 11;
[0038] [0038]FIG. 12 is a perspective view of the alignment pin block for the latch of FIGS. 5-6;
[0039] [0039]FIGS. 12 a - 12 e are left side, right side, faceplate side, inboard side, and outboard views, respectively, of the alignment pin block of FIG. 12;
[0040] [0040]FIG. 13 shows the latch of the present invention in the fully closed and locked position;
[0041] [0041]FIG. 14 shows the latch in the unlocked position with the catch depressed;
[0042] [0042]FIG. 15 shows the latch with the handle rotated to about the 75 degree position whereby the ejection step is about completed; and
[0043] [0043]FIG. 16 shows the latch with the handle fully rotated to about 90 degrees and the latch fully open and free of the chassis keeper.
DETAILED DESCRIPTION OF THE INVENTION
[0044] The present invention is fold-down low profile inject/eject latch which meets IEEE standards for compact peripheral interconnection (PCI) boards. Such compact PCI boards have been standardized to have aluminum faceplates at their outermost edges. These faceplates primarily provide EMF shielding. The operation of this latch permits a construction/structure which yields enhanced EMC (electromagnetic compatibility) by permitting increased shielding and reduced EMF emissions past an IEEE standards PCI board faceplate. The design and operation of the present latch invention permits a reduction in the cumulative openings and the aggregate area of the openings through the board's faceplate, including the addition of lateral extensions to the faceplate outboard its side edges, which lateral extensions are a part of and within the scope of the present invention.
[0045] The invention creates a motion control of the pawl and handle that is created by separately and sequentially pivoting about two different pivot points. The fold-down handle of the latch swings through an arc of 90 degrees from a position parallel to the faceplate to one upstanding perpendicular to the faceplate. The sequential dual pivot point motion, coupled with an elongate slot, enable the pawl to transcribe two separate motions as it disengages from the chassis, the first being a pivoting eject motion against the keeper, and the second being a longitudinal withdrawal motion to release from the keeper. During the first 75 degrees of eject motion, the handle's rotation pivot point is located close to the pawl pin which the handle bears against. This short-coupled lever action is important to have during the first 75 degrees of eject motion of the handle's swing so as to maximize the mechanical advantage for ejecting from the printed circuit board/housing connectors with the least amount of effort on the handle during extraction sequence.
[0046] During the next 15 degrees of handle rotation (75-90 degrees), the handle pivot shifts to a second pivot point so as to pull on the pawl structure, and then to cause it to undergo a sliding translation away from the chassis keeper flange, thus freeing the board by completely disengaging the latch. Very light loads are present during this portion of the latches movement.
[0047] Ejection therefore, becomes a two-step process. The first step is rotating the handle to rotate the pawl to eject the board from its connectors. The second step is further rotating the handle to horizontally (laterally) translate (pull) the pawl out of engagement with the chassis keeper flange. This operation, and the resulting process is reversed for the injection process.
[0048] [0048]FIG. 4 is a perspective top-wise view of the two-phase operation latch 43 of the present invention, mounted according to the IEEE standards to the outside of a PC board faceplate. The claw-shaped pawl 47 engages a flange-type keeper 49 . In the closed position, as seen in FIG. 4, the latch 43 presents a low-profile, with its thumb-end handle 51 folded down parallel with the faceplate 45 . A flat plate shaped catch 53 is mounted to pivot underneath the free end of the handle 51 . The latch has a base (or housing) 55 comprised of two juxtaposed plates 55 mounted to either edge of the faceplate 45 , FIGS. 4 and 5. These base plates 55 support the pawl, which operates there between, and the handle 51 . These base plates 55 engage the faceplate end projecting tabs 57 which each carry a square (or rectangular) slot 59 into which a respective foot 61 on each base plate 55 seats.
[0049] The outboard extension of the faceplate 45 comprising the projecting tabs 57 , the interlocked base plate feet 61 , and the rectangular pawl opening 63 , FIG. 5, are new with the present invention and a part hereof. This added structure extends the faceplate shielding further than previously available and enhances EMC by providing greater EMF shielding. The claw portion of the pawl 47 has a solid bar upper lip 65 and a bifurcated lower lip 67 . This bifurcated lower lip 67 creates a pair of parallel projecting feet, which engage the adjacent openings 69 in the chassis keeper plate shown in FIG. 4.
[0050] The faceplate 45 , FIG. 6, previously terminated in a square shoulder 71 which was spaced from the edge of the chassis keeper flange 49 , and slightly inboard of the spacing 73 provided for the operation of a pawl.
[0051] This invention has added an extension 57 a and associated structure onto the end of the faceplate, this being the solid portion 57 a and a pair of outboard side tabs 57 extending there from. The rectangular (or square) slots 59 , which receive the feet 61 of the latch's left side and right side base plates 55 , each open onto the outboard edge of each tab 57 .
[0052] The left base plate 55 is shown in perspective view in FIG. 7 and carries on the inside wall facing the opposite or right side base plate 55 , that side being its mirror image. There is an L-shaped cam slot 75 near the pawl end thereof and above the foot 61 , FIGS. 7 a - 7 e. Adjacent this L-shaped slot is an oval-shaped pivot opening 77 with the rearward portion slightly cocked upward. Above the oval-shaped pivot opening 77 , and also being rearward towards the handle end of the plate 55 , is a arc shaped slot 79 traversing and arc distance of about 90 degrees about the oval-shaped pivot opening 77 .
[0053] A French curve-like ramp surface 81 projects from the inward face of each base plate, to extend rearward of the arc shaped slot 79 , beginning just about below the edge of the oval-shaped pivot opening 77 and extending to a rearward positioned top planer surface 83 with a tapered leading edge 85 . This planer surface 83 which is formed on a shoulder structure has a ramped surface and a flat surface and carries a pair of holes 87 for assembly pins. A partial-cylindrical spacer 89 projects outwardly from the inner face of the curve-like surface ramp 81 . A further, longitudinally extending slot 91 extends adjacent the planer surface 83 and below the projecting cylindrical spacer 89 .
[0054] The right base plate 55 , shown in FIG. 8 and in the respective various views FIGS. 8 a - 8 e, are each respective mirror images of the left base plate, shown in FIG. 7, and the respective side, top, and end views FIGS. 7 a - 7 e. The only departure from this mirror imaging is the pair of assembly pins 93 which extend inwardly from the inner face of the right respective planer surface 83 structure.
[0055] The thumb handle 51 is shown in detail in the perspective view, FIG. 9, and in the. respective side, top, and end views FIGS. 9 a - 9 e. Thumb handle 51 has a thumb engaging flat gripping portion 94 and a pawl engaging portion. The pawl engaging portion comprises the two parallel extending C-shaped (round) pawl engaging pickup plates 95 . Each pickup plate 95 has a curved outer edge and an outwardly projecting center pivot pin 97 , which engages the oval-shaped pivot opening 77 , in an adjacent, respective right and left side base plate 55 . A second, rearward positioned cam pin 99 engages the arc shaped slot 79 , in a respective side base plate 55 , and controls the degree of pivoting of the handle 51 and its gripping portion, from the horizontal to the vertical, for traversing 90 degrees of rotation.
[0056] The pickup plates 95 each have a pickup slot 101 . Each slot 101 has a curved bottom and parallel faces. The pickup slots 101 are paired to engage a respective projecting pin on the pawl 47 which will be discussed below. A pivot boss 103 is positioned on the bottom face of the thumb gripping portion 93 slightly inboard of the free end thereof, thereby providing a structure for the catch plate 53 to pivot on.
[0057] The claw-shaped pawl 47 is shown in FIG. 10 in a perspective view, and in a side, top and end views, respectively, in FIGS. 10 a - 10 e. This pawl has the upper lip 65 and lower bifurcated lip 67 at one end and an elongate bar-shaped body extending rearward there from. Approximate the claw end 105 of the pawl is a pair of tear-drop shaped pivot pins 107 , each with a cam lobe 107 a at the end thereof, to form a tear-drop end shape. These pivot pins 107 extend outwardly from each side of the pawl 47 and are the pivot stub shafts thereof.
[0058] The elongate body 105 of the pawl 47 has paired opposite sidewall bump-ins 109 , each of which ride-against a respective partial cylindrical spacer 89 . Cam pins 111 , one on each side of the rearward end of the pawl body 105 mate with a respective one of the rearward facing longitudinal cam slots 91 in a respective side base plate 55 .
[0059] The stub shafts 107 ride in the L-shaped cam slots 75 of a respective side base plate 55 . This L-shaped slot 75 allows the pawl 47 to first rotate and lift the latch 43 and attached faceplate 45 upward, and then forces the pawl to retract horizontally rearward (traverse the horizontal leg of the “L) once the full length of the upward leg of the “L” has been traversed.
[0060] The tear-drop shaped stub shafts 107 are also simultaneously engaged with the pickup slot 101 of the handle 51 pickup plates 95 . The creates the movement of the pawl 47 when the handle 51 is moved. The L-shaped slot 75 and the rear horizontal slot 91 provide the primary direction of motion. The elongation of the oval-shaped pivot opening 77 and the cam lobe 107 forming the tear-drop shaped stub shafts 107 refine the motion.
[0061] The catch plate 53 is shown in FIG. 11 in a perspective view, with the top, side and end views, respectively shown in FIGS. 11 a - 11 e. This catch plate 53 has paired outside journals 113 though which a shaft (not shown) extends to mount the catch plate 53 on the paired catch pivot bosses 103 on the handle 51 . A projection 115 on the circumference of each outside journal 113 limits the movement thereof. The inside face of the catch plate 53 carries a circular cavity 117 for holding a compression spring 119 shown in FIG. 13. This spring acts to bias the catch plate 53 away from the bottom of the flat thumb gripping portion 94 of the handle 51 .
[0062] A transversely projecting hook 121 extends from the inboard edge of the catch plate 53 towards the bottom face of the handle 51 . This hook 121 engages the very rearward edge 92 , seen in FIGS. 7 b, 8 b, of each of the right and left side base plates 55 shown in FIGS. 7 b and 8 b, to hold the handle 51 in a fixed position with regards to the base plates 55 and fixed parallel to the faceplate 45 . Pushing against the catch 53 to depress the spring 119 moves the hook 121 and permits the handle 51 to rotate.
[0063] The separate alignment pin block structure 58 , FIG. 5, is shown in detail in the perspective view of FIG. 12. The back, side and end views, respectively, of this alignment pin block 58 are shown in FIGS. 12 a - 12 e. This block 58 has a bracketed back plane 123 with a plurality of rectangular through-holes 125 and two mounting tabs 127 each with a screw hole 129 . A larger tapered lead guide pin 131 , with successive diameters each leading into with a tapered shoulder, extends from the larger of the two tabs 121 . A cylindrical stub pin 133 , which acts as the smaller seating pin, extends from the smaller of the two tabs 121 .
[0064] [0064]FIG. 13 shows the latch 43 in the closed and locked position. FIG. 14 shows the latch 43 after it has been unlocked by moving the catch 53 to have its hook 121 release the base 55 . FIG. 15 shows the latch after the handle 51 has been rotated to about 75 degrees of rotation. This is the transition for the pawl 47 to change over from rotational motion to rearward, horizontal, longitudinal motion. This occurs at the point where the lower bifurcated lip 67 has fully lifted the board 21 out of its connector socket. FIG. 16 shows the handle 51 fully rotated to the 90 degree position and the pawl 47 with its chassis 49 engaging upper and lower lips 65 , 67 free of the chassis flange 49 .
[0065] Referring to FIGS. 13-16, from the fully inserted configuration (closed) FIG. 13, latch is moved to the unlocked position, FIG. 14, then to the board ejected position, FIG. 15, and finally to the fully open position, FIG. 16. Reinsertion of a board reverses the process.
[0066] In operation, the pawl 47 undergoes two distinct motions, those being first rotating against a portion of the chassis to eject the PCI board (by ejecting the face plate 45 ), then sliding out of the way to disengage itself from the chassis frame 49 . The handle 94 accomplishes this two-motion pawl operation in one 90 degree rotational stroke of the handle 94 , utilizing a “short-coupled” mechanical advantage during the pawl's rotation and ejection during the first 75 degrees of handle rotation, and then with a longer-coupled lever action during the remaining 15 degrees of handle rotation, whereby the pawl is more rapidly disengaged by its longitudinal sliding away from the chassis engagement position.
[0067] The secondary catch hook 121 keeps the handle positively locked in the closed position until it is released. The catch 53 must be operated to release the hook 121 to in turn release the handle 94 for its operation.
[0068] The compound operation of the latch is accomplished because the handle and pawl pivot about two separate pivot points, one being a real pivot point and the second being a “virtual” pivot point.
[0069] For unlocking, ejecting and withdrawing a compact PCI board, the user first rotates the spring-loaded catch 53 , which releases the hook 121 from the base side plate 55 and allows the handle 51 to be rotated. As the handle 51 is rotated through 75 degrees, it pivots around the position “A” of the central elongate slot 77 in the base plates 55 . Slots “B” in the end of the handle 51 contact (ride on) the pins at position “C” on the pawl. The structure of the device thereafter allows a longitudinal movement of the handle away from the pivot position “C” by the sliding along the slots “B” of the handle 94 . The elongation of slots 77 and 91 permits this withdrawal of the pawl 47 from the chassis. The total amount of rotation of the pawl 47 from the closed position to the fully open position is about 15 to 20 degrees. This permits a small pawl opening 63 in the faceplate extension 57 a thereby minimizing EMF leakage and enhancing EMC compatibility.
[0070] The pawl rotates around the pin at position “D”, i.e., the cam pins 111 engaging the respective longitudinal slots 91 , and ejects the faceplate 45 and its attached PCI board from the chassis 49 . This ejection operation is under the leverage of the entire length of the pawl arm from pivot pin 107 to cam pin 111 . A further 15 degree rotation of the handle causes it to pivot around the end of the arc slots at position “E”, these being the arc slots 79 in the base halves, i.e., base plates 55 .
[0071] The pawl pins 107 first move along the horizontal leg of the L-shaped slots 75 , then down the vertical leg of these slots 75 . In this regard, slots “B” drive the pawl pins “C” down the vertical portion of the L-shaped slots 75 in the base halves 55 , causing the pawl 47 to retract in order to disengage from the chassis 49 and allowing the PCI board to then be removed from the chassis. The ends of the pins “C” have a tear-drop shape, lobe 107 a, which prevents them from beginning the vertical travel before the extraction rotation is completed.
[0072] Insertion of the PCI board take an opposite sequence of operation and a reversal in travel paths. In the fully closed and the unlocked positions, FIGS. 13, 14, the handle 94 is close to the chassis 49 and the round pickup plates 95 of the handle are off of the curved ramp surface 81 of the base plates 55 . When the latch is in the fully open position, FIG. 16, the handle not only rotated, but has also laterally translated to have moved away from the chassis 94 and the round pickup plates 95 abut the curved ramp surfaces 81 .
[0073] Many changes can be made in the above-described invention without departing from the intent and scope thereof. It is therefore intended that the above description be read in the illustrative sense and not in the limiting sense. Substitutions and changes can be made while still being with the scope of the appended claims.
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A latch for a Compact PCI board, which incorporates inject and eject and engage and disengage functions, has a low profile shape, whereof a fold-down handle operates through a total arc of 90 degrees. Enhanced electromagnetic compatibility (EMC) is provided, by more efficient EMC shielding and by reduced electromagnetic force (EMF) radiation pass-through. The latch, in its inject/eject operation, undergoes a two-phase motion, which utilizes a rotary motion to insert/extract the board from electrical connection, and utilizes a linear motion to engage/disengage the latch pawl from the chassis (keeper). A separate alignment pin block, normally carrying a lead guide pin and a seating guide pin, is independent of the structure for the base of the latch. This permits the alignment pin block to be mounted to the inside of the faceplate and the latch to be mounted to the outside of the faceplate. By so doing, the cumulative (aggregate) area of the opening(s) through the faceplate is reduced, which thereby increases the EMC (electromagnetic compatibility) of the design by reducing EMF radiation pass-through.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of European application No. 07019293.5 filed Oct. 1, 2007, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The invention relates to an arrangement with a mounting rack and at least one assembly provided with a housing encapsulation and mounted on the mounting rack, wherein the mounting rack and the assembly have contacting means which are thermally connected to each other. In addition, the invention relates to an assembly which is suitable for use in a mounting rack of this kind.
BACKGROUND OF THE INVENTION
Higher performance electronic components are increasingly used in assemblies for automation technology thus necessitating measures for dissipating the heat from the assemblies. For this, it is usual to employ heat sinks in these assemblies, in particular because fans for heat dissipation are not desired in automation technology.
Known from the Siemens Catalog ST 70, Edition 2007, pages 5/2 and 5/112 is an automation device comprising a plurality of assemblies and a mounting rack. The mounting rack is provided to accommodate the assemblies and to supply them with an operating voltage, wherein the assemblies may be plugged into slots in a rear panel bus by means of which the assemblies are connected to each other. Each slot in the mounting rack has on one edge three spring contacts arranged in parallel and provided with a ground potential which are electrically connected to a connector of a plugged-in assembly. Due to the ageing of the spring contacts and the associated deterioration in the elasticity of the spring contacts or due to contamination of the spring contacts, there is an increase in the contact or transfer resistance between the spring contacts and the corresponding connector of the respective plugged-in assembly. This results in an increase in the electrical power loss at the contact point and in addition the thermal power loss from the assembly is only poorly dissipated by the rear panel bus resulting in an increase in the temperature in the assembly. If a critical temperature is reached in the assembly, its operation can be disrupted and this has a detrimental impact on the technical process to be controlled.
SUMMARY OF THE INVENTION
The present invention is based on the object of providing an arrangement of the type mentioned in the introduction with which the quality of the heat dissipation is identified at the correct time. The object is also to specify an assembly which is suitable for an arrangement of this kind.
This object is achieved in respect of the arrangement and in respect of the assembly with the measures disclosed in the claims.
The invention is based on the concept of determining before start-up or before the actual operation of the arrangement whether good thermal conductivity is ensured between the contacting means of the assembly and the contacting means of the mounting rack as an “external” heat sink. In cases when, contrary to a desired heat conduction within the framework of a defined heat input, the temperature in the housing encapsulation of the assembly increases too rapidly, attention is drawn to the fact that the contacting means cannot dissipate the heat sufficiently and the thermal contacting is poor. In such a case, corresponding measures can be taken before the actual operation, for example such as exchanging the assembly and replacing it with another one.
In one embodiment of the invention, it is provided that the contacting means of the assembly and of the mounting rack have a planar design which means that the thermal contacting is simple to produce.
In a further embodiment the invention, the contacting means have a surface-enlarging, for example saw-tooth-shaped, design. This measure achieves a very good thermal connection.
BRIEF DESCRIPTION OF THE DRAWINGS
The following describes the invention, its embodiments and advantages in more detail with reference to the drawing, which depicts an exemplary embodiment of the invention.
FIG. 1 shows components of an assembly and a mounting rack and
FIG. 2 components of an automation device.
DETAILED DESCRIPTION OF THE INVENTION
Reference is made first to FIG. 2 which depicts components of an automation device which is known per se. A mounting rack 1 comprises an aluminum rack 2 , two bus boards 3 mounted on this rack 2 and a plastic rack 4 through the openings 5 of which connectors 6 of the bus boards 3 project toward the terminal side of the mounting rack 1 . In the exemplary embodiment depicted, only one assembly 7 of the automation device provided with a housing encapsulation is shown which is mounted on one of the connectors 6 . The aluminum rack 2 is provided with two grounding bars 8 on which the electrically conductive spring contact parts 9 are mounted and which are guided through further openings 10 of the plastic rack 4 . These contact parts 9 come into contact with contacting means of the plugged-in assembly 7 causing this assembly 7 to be connected to the ground potential, wherein in addition the thermal power loss of the assembly 7 is dissipated via these contacting means to the grounding bar 8 . Further components of the assembly 7 , such as for example a printed circuit board provided with a plurality of electronic components, are of no significance for the invention and will therefore not be explained in any more detail.
To check the quality of the heat dissipation between the contacting means of the plugged-in assembly 7 on the mounting rack 1 and the grounding bar 8 , it is provided that a heating element, a temperature sensor and an evaluation unit are arranged in the housing encapsulation of the assembly 7 . Hereby, the heating element increases the temperature in the housing encapsulation cyclically or in accordance with predefinable times, the temperature sensor detects the temperature increase and the evaluation unit checks the heat conduction between the contacting means on the basis of the thermal energy supplied by the heating element and the temperature increase or the rate of temperature rise. In this context, reference is made to FIG. 1 which depicts components of an assembly and a mounting rack.
An external heat sink in the form of a grounding bar 11 of a mounting rack is provided to dissipate the heat formed in a housing encapsulation of an assembly 12 . Obviously, it is possible for the mounting rack itself to serve as a grounding bar or for the mounting rack itself to be designed to dissipate the heat of the assembly 12 . The assembly 12 is provided with a contacting means 13 , wherein a side surface 14 of this contacting means 13 is thermally connected to a part of a surface 15 of the grounding bar 11 . It can now occur that the side surface 14 of the contacting means 13 of the assembly 12 swiveled onto the mounting rack is not in sufficient thermal contact with the side surface 15 of the grounding bar 11 , for example because the contact surfaces are dirty or because a swivel mechanism (not shown here) of the assembly 12 is defective. In order to identify a poor thermal connection between the contacting means 11 , 13 of this kind at the correct time, before the operational control of the automation device, for example, a heating element 16 supplies a defined amount of thermal energy to the contacting means 13 , wherein a temperature sensor 17 detects a temperature increase effected thereby in the housing encapsulation or of the contacting means 13 . An evaluation unit 18 connected to the temperature sensor 17 and the heating element 16 knows for example from a default setting, the degree to which with a good or sufficient contacting of the assembly 7 to the grounding bar 11 the temperature in the housing encapsulation can increase due to the thermal energy supplied or how rapid the temperature rise can be in order to ensure trouble-free operation within the framework of a process control. In the event that, contrary to the correct heat conduction within the framework of a defined supply of thermal energy, the temperature in the housing encapsulation of the assembly rises too rapidly or the temperature exceeds a threshold value, it brings attention to the fact that the contacting means 13 are not dissipating the heat sufficiently via the grounding bar 11 and the thermal contacting is poor. In this case, for example, the contacting means 13 should be checked; it may be necessary to exchange the assembly and replace it with a new assembly.
It is obviously possible, also to check the quality of the heat dissipation during the control of a technical process. In this case, the “normal” thermal power loss of the assembly should be taken into account during the operational control, wherein corresponding default settings have to be stored in the evaluation unit 18 .
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The invention relates to an arrangement with a mounting rack and at least one assembly provided with a housing encapsulation and mounted on the mounting rack, wherein the mounting rack and the assembly have contacting means which are thermally connected to each other. Suitable measures are provided with which the quality of the heat dissipation is identified at the correct time.
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[0001] The invention relates to self-contained room air humidifiers. More particularly, the invention relates to mist generating room air humidifiers of the wall mount configuration as described in provisional patent application No. 60/659,668 filing date Mar. 08, 2005.
BACKGROUND OF THE INVENTION
[0002] Self-contained room air humidifiers are used to introduce water, and other additives, to air in an enclosed environment, such as a room. Mist generators or mist sources, such as steam boilers, atomizers, nebuliziers and ultrasonic vibrators have been used to present water in the form of droplets to a passing air flow.
[0003] Self-contained room air humidifiers are typically constructed in compact housings. Also, self-contained room air humidifiers in the past have injected the mist of water particles into the room environment for subsequent evaporation. Many droplets produced by the mist generator and introduced to the room environment to be humidified do not completely evaporate before contacting and wetting objects in the room or the room structure. Other configurations of the existing art utilize integral evaporation chambers to give the moisture time to be absorbed before discharge into the room environment. This configuration typically works best at lower relative humidity levels. At higher levels of room humidity, the mist is not completely evaporated in the absorption chamber and will be visible on the discharge of the room humidifier. Additional variations of this type of existing art add electric heaters to warm the air stream to enhance evaporation. The additional energy required by the electric heaters greatly off set any advantage gained from using a non-steam mist generator. In addition, this configuration requires floor space, which is extremely valuable in commercial and industrial environments.
SUMMARY OF THE INVENTION
[0004] It is an object of the invention to provide a self-contained wall mounted room air humidifier that prevents moisture fall out in the humidified room by mixing the discharged humidified air with dry un-humidified room air.
[0005] It is a further object of the invention to provide a self-contained room air humidifier that is constructed for wall mounting to minimize required floor space for the self-contained room air humidifier.
[0006] It is yet another object of the invention to provide a self-contained wall mounted room air humidifier that can be positioned in a variety of room locations including against a wall to avoid obstruction to intended room activity with out exposing the wall or other room structure to moisture damage.
[0007] It is still another object of the invention to provide variable levels of humidification without exposing room objects to moisture damage.
[0008] These and other objects of the invention are achieved by preferred embodiments of a self-contained wall mounted room air humidifier that receives air from the room environment and mixes the humidified discharge air with an un-humidified bypass air stream drawn from the room environment to cause complete evaporation of the mist before impinging on room objects or room structure.
[0009] The self-contained wall mounted room air humidifier includes a housing having an inlet for receiving air from the room environment and an outlet for discharging humidified air back into the room environment. A mist generator is disposed in said housing for producing a mist to humidify the air received through the inlet from the room environment. A fan, or multiple fans, moves air past the mist generator and also provides the bypass mixing air.
[0010] According to a preferred embodiment of the invention, the housing of the self-contained wall mounted room air humidifier has a drain connection for disposing of excess water that may be generated by the mist generator, but not discharged into the room environment.
[0011] In the preferred embodiment of the invention, the housing is constructed of stainless steel to prevent corrosion and enhance the appearance of the self-contained wall mounted room air humidifier.
[0012] The self-contained wall mounted room air humidifier includes controls to start and stop the fan(s), operate sump pumps if needed, and interface with the primary room environment humidity control system.
[0013] The preferred embodiment of the invention has a mixing chamber within the housing where the inlet air provided by the fan(s) is mixed with the mist provided by the mist generator. This mixing enhances the evaporation of the mist into the air drawn from the room environment by the fan(s). The air and mist are mixed using a counter flow arrangement, which causes turbulence and increased contact of the air and water mist. The humidified discharge air is mixed with the un-humidified bypass air external to the humidifier housing. The un-humidified bypass air is discharged below the humidified air and provides a horizontal layer of dry room air that mixes with and carries the humidified air into the room until it is completely evaporated.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0014] The invention is directed to a self-contained wall mounted room air humidifier that provides for complete evaporation of the water mist within the room environment. The preferred embodiments of the invention discussed in this specification are arranged to minimize the area required by the self-contained wall mounted room air humidifier, while at the same time providing protection from water damage to the room contents.
[0015] The room environment, as used through out this specification and the claims, refers to the area to be humidified by the self-contained wall mounted room air humidifier. This area can include office and computer space, lab areas and industrial processing areas, and does not have to be completely enclosed from other areas of the structure.
[0016] The self-contained wall mounted room air humidifier is designed to be used primarily with water, and further water that has been purified using reverse osmosis or de-ionizing equipment. The purification of the water is important because this process reduces the concentration of the dissolved minerals in the water to a point where the evaporation of the water will not leave any mineral residue in the space that is humidified.
[0017] Referring to FIGS. 1 & 2 , a preferred self-contained wall mounted room air humidifier includes a housing 1 having an inlet 4 for receiving air from the room environment and passing the air flow through a mixing chamber 10 , for complete mixing of the mist and room air before discharge through an outlet 2 back into the room environment. The room air is drawn into the humidifier housing inlet 4 by the fan(s) 5 . The room air is divided into two air streams by the internal baffle 6 . Some of the air flows out of the by-pass air slot 8 to mix with the humidified room air discharged from the discharge opening 2 . The remainder of the air passes into the mixing chamber 10 where it is mixed with the mist. The internal baffle 6 allows just enough air into the mixing chamber 10 to carry the moisture out of the humidifier into the room environment from the humidifier outlet 2 . The mist is moving in a downward direction and the air passing under the internal baffle 6 is moving in an upward direction. The counter flow enhances the mixing of the air and mist and serves as a centrifugal separator because the larger water droplets in the mist cannot reverse direction and subsequently fall into the humidifier sump 11 to be drained away by the drain connection 9 .
[0018] The mist source 12 is provided within the housing 1 . The self-contained wall mounted room air humidifier 1 can include any of a variety of mist generators or mist sources. While the preferred embodiment disclosed utilizes one or more high pressure atomizing nozzles 12 for atomizing the water, the self-contained wall mounted room air humidifier can use other mist generators, such as steam generators, ultrasonic nebulizers or air/water atomizers.
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A mist generating, self contained wall mounted room air humidifier ensures substantially complete evaporation of the mist introduced to an air flow drawn from a room environment by preferably providing a bypass air stream of un-humidified room air to cause complete and immediate evaporation.
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This application is a continuation of application Ser. No. 09/559,993, filed on Apr. 27, 2000, now abandoned, which is a continuation of application Ser. No. 09/074,517, filed on May 8, 1998, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for bleaching pulp. More specifically, the present invention relates to a method of bleaching pulp using ozone in which the ozone is more effectively dispersed and dissolved in a low consistency pulp.
2. Brief Description of the Prior Art
During the past 10-15 years the bleaching of pulp in the Kraft Process has undergone many changes. These changes were mainly prompted by environmental concerns of the quality of the effluent being discharged from paper mills. Of main concern was the bleach plant effluent, which contained polychlorinated dibenzodioxines and dibenzofurans among other compounds. The measurement of AOX was used as an indicator of the concentration of these compounds and the test was quickly adopted as a standard for legislation.
It was soon determined that the chlorine used in bleaching was a factor in high AOX values, while values could be reduced by lowering the quantity of chlorine used. Chlorine dioxide was substituted for chlorine and reduced AOX values was the result. A typical bleaching sequence became C/D.Eo.D.E.D. with at least 50% of the chlorine being replaced by chlorine dioxide on an equivalence basis. Some paper mills have eliminated chlorine entirely by using D.Eo.D.E.D. or O.D.Eo.D.E.D. sequences.
Ozone is a powerful bleaching agent used in many bleach plants throughout the world to bleach Kraft Pulp and recycled fibers. It has recently been discovered that ozone can replace chlorine dioxide and achieve the same brightness and pulp quality. It has been found that 1 kg of ozone can essentially replace 2 −4 kgClO2 . This results in lower cost bleaching sequences such as O.Z/D.Eop.D.E.D, O.D/Z.Eop.D.X.D, D/Z.Eop.D.E.D. and others. The use of ozone (O 3 ) can become more attractive, however, if a more efficient and cost effective method can be found to better disperse and dissolve O 3 into an existing bleaching sequence. The usual method of bleaching with ozone comprises dispersing ozone into a medium consistency pulp using a pump, mixer and retention tube. This is carried out at a pressure of 150 psig and requires a compressor to add the ozone.
Medium consistency pulp generally contains a cellulose fiber suspension of from 8-15%, that when exposed to high shear forces acquires fluid properties that permits it to be pumped. High shear mixers enable gases to be dispersed and dissolved in medium consistency pulps.
A typical medium consistency ozone bleaching process generally consists of pumping pulp to a mixer where ozone is added. The gas dispersion in the pulp is then sent to a vertical retention tube where at least 90% of the ozone dissolves and reacts during a hydraulic residence time of 3060 secs. If the ozone utilization is low, then a second mixer may be added. On discharge from the retention tube, gas is separated from the pulp and the excess ozone in the gas is sent to an ozone destruct unit.
To achieve high utilization of ozone in medium consistency bleaching, a pump and mixer(s) are used that are driven by high HP motors and the power requirement can reach 0.5-1.0 HP/ton pulp/day. Typically pulp is bleached with an ozone charge of about 5 kg ozone/ton pulp, and this is added in a single stage. If higher charges of ozone are required then more than a single stage is necessary, e.g. 10 kg/ton requires two stages. The limiting factor in ozone addition is the volume of gas that can be dispersed and dissolved in the pulp with high ozone utilization. For medium consistency processes it has been found that a high utilization of ozone can be achieved if the volume ratio of gas in the total fluid mixture does not exceed 30%. For ozone generated at a concentration of 10% w/w and operating at a pressure of 150 psig, the maximum charge added is 5 kg of ozone/ton of pulp. If the ozone concentration is raised to 12% this charge can be raised to 6 kg/ton with the same ozone utilization.
An alternative to medium consistency pulp technology is that of using high consistency pulp. In this process fibers are dewatered to a consistency of 25-40% by passing medium consistency pulp through a press. As well as dewatering the fibers, the pulp is compressed and then fluffed in order to have good contact between gas and fibers. The pulp is then introduced into a reactor where it is contacted with ozone for a period of 1-3 minutes at a pressure of 5 psig. After ozonation, the pulp is degassed and diluted with wash water before passing on to a washing stage.
When this process was first started there were reports of uneven bleaching, but with improved reactor design this was overcome. An advantage of this process is that it does not require high concentrations of ozone, as using 6.0% w/w works very well. However the high consistency process is not widely accepted because of the mechanical complexity of the equipment and the high power requirement for dewatering the pulp.
Another possible technique for bleaching pulp involves low consistency pulp. Low consistency pulp employs a cellulose fiber suspension of 1-5% that has a viscosity greater than water, but can be pumped using conventional pumps without the need of a high shearing effect. Chlorination is generally carried out in a low consistency process and in many processes chlorine dioxide is also added to low consistency pulp slurries. However there has been little discussion of ozonation at low consistency.
Laboratory studies have been carried out on ozonating pulp in bubble columns using pulp slurries around 0.5% concentration. This method worked well, but with columns of a height of 25 m, the gas residence time was very short and ozone utilization low. Furthermore, ozone concentrations in the gas applied were low, 2-3% w/w.
This low concentration required large volumes of gas to obtain the desired ozone charge. The low concentration also led to low mass transfer rates. The net effect of this was poor ozone utilization, and this together with the dilute pulp slurry has made the consideration of using ozone with low consistency pulp commercially unattractive.
Up to this point, therefore, there has been no commercial process devoted to ozone bleaching of low consistency pulp. While some laboratory studies have been carried out at consistencies of about 0.5% using unpacked columns and adding the ozone by a diffuser at the bottom, such a process is not considered to be practical for commercial use. Furthermore, there are reports that O 3 consumption increases due to decomposition in water. Also the favored technology for bleaching uses medium consistency pulps and there have been no reported attempts to carry out low consistency ozone bleaching on an industrial scale.
Low consistency pulp, however, is easier to pump. Dispersing ozone onto it, because of its low viscosity, would therefore require less power. This can be done before or after a low consistency D stage or a medium consistency D stage. In the latter case this is carried preferably out in a downflow tower and at the bottom of the tower the pulp is diluted to low consistency in order to pump it to the next process step.
Hence if ozone can be effectively and efficiently dispersed and dissolved in low consistency pulp, the use of low consistency technology with ozonation offers a low cost method which can be used to retrofit an existing bleaching process.
Therefore, it is an object of the present invention to provide a novel process and apparatus for bleaching pulp using ozone.
Another object of the present invention is to provide a method for more effectively and efficiently dispersing and dissolving ozone into low consistency pulp so as to make low consistency pulp bleaching technology with ozone viable.
Still another object of the present invention is to provide an efficient process and apparatus for bleaching employing low consistency technology, whereby ozone is used as the bleaching agent.
These and other objects of the present invention will become apparent to the skilled artisan upon a review of the following disclosure, the Figures of the Drawing, and the claims appended hereto.
SUMMARY OF THE INVENTION
In accordance with the foregoing objectives, there is provided a novel process and apparatus for bleaching pulp with gaseous mixtures comprising ozone. The process of the present invention comprises first preparing a slurry of cellulosic pulp of a low consistency, i.e., a consistency of fibers of from about 1-5 weight %. Ozone is then mixed with the pulp slurry using high shear mixing. This high shear is preferably created using a mixer designed for medium consistency pulp bleaching, i.e., a mixer generally used for medium consistency pulps. Such high shear (high-intensity) mixers are well known in the art. Using the high shear mixing has been found to allow the ozone to be effectively and efficiently dispersed and dissolved into the low consistency pulp, even while the pulp mixture remains at low pressure. The ozone is then maintained in contact with the cellulosic fibers for a time sufficient to bleach the fibers, before separation occurs.
The process of the present invention offers one the energy benefits of using low consistency technology, in combination with the benefits of using ozone to bleach the cellulosic pulp. The ozone bleaching step of the present invention can be combined in an overall bleaching process with other bleaching steps. For example, the ozone bleaching step can be used either before or after a chlorine dioxide bleaching step. The ozone bleaching step can also be followed by a different bleaching step, e.g., with hydrogen peroxide.
Another advantage of the present invention is that when ozone is compressed at higher pressures, it breaks down to oxygen (O 2 ). Thus, if a lower pressure can be used, more ozone should be available. Ozone also has a short half-life before converting to oxygen, therefore, the present invention with its short mixing time helps ensure more ozone is available for bleaching purposes.
In another embodiment, there is provided a system for a reactor for bleaching pulp at low consistency with ozone. The reactor comprises a high shear mixer wherein ozone is dispersed into a pulp slurry having a consistency in the range of from 1 to 5 wt %, and a retention tube connected to the mixer which operates at a pressure of from 20 to 60 psig, and wherein the ozone bleaches the pulp in the pulp slurry.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 of the Drawing depicts a reactor for bleaching pulp at low consistency with ozone, which uses a pressurized ozone generator.
FIG. 2 of the Drawing depicts a reactor for bleaching pulp at low consistency with ozone employing an ozone compressor.
FIG. 3 of the Drawing depicts a low consistency ozone bleaching process carried out before a chlorine dioxide bleaching step.
FIG. 4 of the Drawing depicts an alternative low consistency ozone bleaching process carried out before a chlorine dioxide bleaching step.
FIG. 5 of the Drawing depicts a low consistency ozone bleaching process wherein the ozone bleaching step is carried out after a chlorine dioxide bleaching step.
FIG. 6 of the Drawing depicts an alternative low consistency ozone bleaching process using an ozone bleaching step that is carried out after a chlorine dioxide bleaching step.
FIG. 7 of the Drawing graphically depicts the D/Z delignification efficiency for various reactor/mixers at low consistency (2.5-3.5 wt %).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The ozone employed in the process of the present invention can be of any source. Preferably, the ozone is generated on-site using an ozone generator, to thereby produce ozone from oxygen at a concentration in the range of from about 5 to 20 wt %, more preferably in the range of from about 10 to 20 wt %, and most preferably in the range of from about 10 to 15 wt %. Ozone generators are well known, and are generally operated at a pressure in the range of from about 20-60 psig, and more preferably in the range of from 30-40 psig.
The ozone/oxygen mixture is preferably introduced into the high shear mixer through a valve, which can be used to control the flow of the gas mixture into the high shear mixer. The ozone/oxygen gas mixture can be compressed, if so desired, prior to introduction into the high shear mixer. The ozone compressor generally operates at a pressure ranging from 20-150 psig, and more preferably in the range of from 30-40 psig.
The high shear mixer can be any high shear mixer well known to the art of pulp bleaching. Such mixers are described, for example, in Pulp Bleaching—Principals and Practice by Carlton W. Dence and Douglas W. Reeve, TAPPI Press, 1996, pages 549-554. In high shear (high intensity) mixers, the pulp and ozone gas mixture are mixed by passage through zones of intense shear. They induce microscale mixing in the entire volume and not only in specific locations as in a continuous stirred reactor. The high shear is created by imposing high rotational speeds across narrow gap, generally between the rotor blades and reactor casing, through which the pulp suspension flows. Although there are design differences among the high shear mixers conventionally known, they all attempt to fluidize the suspension in the mixture working zone. The high shear rate insures flock disruption and good fiber scale mixing.
The present invention employs a high shear mixer, and many different high shear mixers used for pulp bleaching are known. Some of those known include the Ahlstrom Ahlmix, the Ahlstrom MC pump, the Beloit-Rauma R series, the Ingersoll-Rand Hi-Shear and the Impco Hi-Shear mixer from Beloit Corporation. Others include the Kamry MC, the Kamry MC Pump (Pilot) the Sunds SM and Sunds T mixers. The Quantum mixer is also an acceptable high shear mixer. All such mixers are known in the art and are generally used to mix medium consistency pulp suspensions.
Mixers can be compared based on energy applied (MJ/ton of pulp) and power dissipation (W/m 3 ). J. R. Bourne in Chem. Eng. Sci., 38(1):5 (1983) states that all devices operated at the same power unit volume will generate the same rate of micromixing. This assumes energy applied equals energy dissipated, which is not true for all mixers. The distribution of power throughout the suspension is as important as its total. Examples of different mixers and the energy and power values for a given pulp consistency are as follows:
Consistency
Power Dissipation
Energy
Mixer Type
(wt %)
(W/m 3)
(MJ/ton)
Hand Mixing
3
2 × 10 4
120
CSTR
2-3
600
5-9
Quantum (high
5
4.5 × 10 5
63
shear) Mixer
High Shear
10
1.8 × 10 6
180
Using the measured energy dissipation rate and a correlation for the apparent viscosity of a pulp suspension given by Bennington in “Mixing Pulp Suspensions”, PhD. thesis, The University of British Columbia, Vancouver, B.C., 1988, τ is 0.02 sec. for a 10% consistency in a typical high shear mixer. In a CSTR operating at 3% consistency, τ=0.4 sec., but varies locally with the mixer. τ represents the mean lifetime of turbulent eddies.
The pulp suspension of the present invention that is provided to the high shear mixer is of low consistency. This means that the amount of pulp contained in the suspension ranges from about 1 to 5 wt %. More preferably, the amount of pulp in the suspension ranges from 2 to 4 wt %. Preferably, the temperature of the pulp slurry entering the mixer is in the range of from about 20-80° C., more preferably from about 40-60° C. The ozone charge added to the pulp is in the range of from about 2-10 kg/ton, more preferable from about 5-6 kg/ton.
Once in the high shear mixer, the ozone and pulp suspension are mixed in the high shear mixer in the range of from about 0.01 seconds to 10 seconds, and more preferably in the range of from about 0.1 seconds to 4 seconds. Once the mixing has taken place, the pulp suspension is then passed to a bleaching or reactor station, which is preferably a retention tube, wherein the residence time ranges from about 1 to 10 minutes, more preferably from about 2-5 minutes. It is in the retention tube that the bleaching of the pulp actually takes place by the ozone. Because of the use of the high shear mixer, and the short time in which it takes to dissolve the ozone, as well as the low pressures under which the mixing and retention tube can operate, more ozone is available to do the bleaching of the low consistency pulp. Accordingly, the present invention provides surprising results with regard to excellent bleaching.
Referring to FIG. 1, there is illustrated a reactor for bleaching pulp at low consistency with ozone by using a pressurized ozone generator. It consists of a medium consistency mixer where ozone is dispersed in the low consistency pulp followed by a retention tube operating at a pressure between 20-60 psig where ozone gradually dissolves and bleaches the pulp.
Air is introduced by line 1 into an air separation unit 2 where oxygen is separated from air. Oxygen passes by line 3 into an ozone generator 4 and is converted to ozone, and this passes through line 5 into a control valve 6 that automatically regulates the gas flow by gas flowmeter 7 . Ozone gas is introduced to the mixer 9 by an inlet line 8 and is dispersed into the low consistency pulp. Pulp slurry passes through line 20 into pump 21 where it is pumped into the mixer 9 and mixed with the ozone-oxygen mixture.
The pulp slurry-gas mixer passes into the column 23 that is held under pressure by a back pressure valve 24 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 24 into line 25 .
The pulp slurry-gas mixture flows into a separator vessel 26 where gases are separated from the pulp and flow through line 27 into an ozone destruct unit 28 , where the ozone is destroyed and the remaining gases leave through line 29 . The pulp slurry leaves the separator through line 30 and flows into pump 31 where it is pumped to the next stage through line 32 .
FIG. 2 illustrates a reactor for bleaching pulp at low consistency with ozone by using an ozone compressor. It comprises generally of a medium consistency mixer where ozone is dispersed in the low consistency pulp, followed by a retention tube operating at a pressure between 20-60 psig where ozone gradually dissolves and bleaches the pulp.
Air is introduced by line 100 into an air separation unit 102 where an oxygen rich stream is separated from air. Oxygen passes by line 103 into an ozone generator 104 and is converted to ozone and this passes through line 105 into an ozone compressor 110 where the gas mixture is compressed. From here it flows to a control valve 106 that automatically regulates the gas flow by gas flowmeter 107 . Ozone gas is introduced to the mixer 109 by an inlet line 108 and is dispersed into the low consistency pulp. Pulp slurry passes through line 120 into pump 121 where it is pumped into the mixer 109 via line 122 and mixed with the ozone-oxygen mixture.
The pulp slurry-gas mixture passes into the column 123 that is held under pressure by a back pressure valve 124 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 124 into line 125 . The pulp slurry-gas mixture flows into a separator vessel 126 where gases are separated from the pulp and flow through line 127 into an ozone destruct unit 128 , where the ozone is destroyed and the gases leave through line 129 . The pulp slurry leaves the separator through line 130 and flows into pump 131 where it is pumped to the next stage through line 132 .
FIG. 3 illustrates a low consistency ozone bleaching process in accordance with the present invention that includes an ozone bleaching stage before a chlorine dioxide bleaching stages. This uses a pressurized ozone generator to compress ozone before adding it to a mixer. This method avoids the use of a compressor to add compressed ozone to the mixer.
In the process, pulp of medium consistency is pumped through line 252 into a storage tank 251 . The pulp flows down the tank into a dilution zone 250 where it is diluted to a low consistency with dilution water added through nozzles 246 and 247 . Agitators 248 and 249 ensure that mixing is complete. The pulp slurry of consistency about 3% passes through line 220 into pump 221 where it is pumped into the mixer 209 and mixed with the ozone-oxygen mixture. Air is introduced by line 201 into an air separation unit 202 where oxygen is separated from air. Oxygen passes by line 203 into a pressurized ozone generator 204 and is converted to ozone and this oxygen-ozone mixture passes through line 205 into a control valve 206 that automatically regulates the gas flow by gas flowmeter 207 . The ozone-oxygen gas mixture is introduced to the mixer 209 by an inlet line 208 and is dispersed into the low consistency pulp.
The pulp slurry-gas mixture passes into the column 223 , that is held under pressure by a back pressure valve 224 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 224 into line 225 . The pulp slurry-gas mixture flows into a separator vessel 226 , where gases are separated from the pulp and flow through line 227 into an ozone destruct unit 228 , where the ozone is destroyed and the resulting gases leave through line 229 . The pulp slurry leaves the separator 226 through line 230 and flows into pump 231 , where it is pumped through line 232 into a mixer 234 where chlorine dioxide is added through line 233 before flowing by line 235 into the bottom of the bleaching tower 236 . The pulp rises to the top of the tower and overflows through line 237 into line 238 to a washer 239 . The pulp is washed with wash water added through line 240 and the washed pulp leaves the washer through line 241 . The dilution water separated from the pulp is collected in storage tank 242 , where it is removed through line 243 by pump 244 and is pumped through line 245 to the nozzles 246 and 247 , where it is added to the dilution zone 250 of the storage tank 251 .
FIG. 4 illustrates a low consistency ozone bleaching process involving an ozone bleaching stage in accordance with the present invention that is carried out before a chlorine dioxide bleaching stage. The process uses a compressor to compress ozone before adding it to the mixer.
In the figure, pulp of medium consistency is pumped through line 352 into a storage tank 351 . The pulp flows down the tank into a dilution zone 350 where it is diluted to a low consistency with dilution water added through nozzles 346 and 347 . Agitators 348 and 349 ensure that mixing is complete. The pulp slurry of consistency about 3% passes through line 320 into pump 321 where it is pumped through line 322 into the mixer 309 and mixed with the ozone-oxygen mixture. Air is introduced by line 301 into an air separation unit 302 where oxygen is separated from air. Oxygen passes by line 303 into an ozone generator 304 and is converted to ozone, and this oxygen-ozone mixture passes through line 305 into an ozone compressor 310 where it is compressed. From here it flows to a control valve 306 that automatically regulates the gas flow by gas flowmeter 307 . The ozone gas mixture is introduced to the mixer 309 by an inlet line 308 and is dispersed into the low consistency pulp.
The pulp slurry-gas mixture passes into the column 323 , which is held under pressure by a back pressure valve 324 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 324 into line 325 . The pulp slurry-gas mixture flows into a separator vessel 326 where gases are separated from the pulp and flow through line 327 into an ozone destruct unit 328 , where the ozone is destroyed and the gases leave through line 329 . The pulp slurry leaves the separator through line 330 and flows into pump 331 where it is pumped through line 332 into a mixer 334 where chlorine dioxide is added through line 333 before flowing by line 335 into the bottom of the bleaching tower 336 . The pulp rises to the top of the tower and overflows through line 337 into line 338 to a washer 339 . The pulp is washed with wash water added through line 340 and the washed pulp leaves the washer through line 341 . The dilution water separated from the pulp is collected in storage tank 342 . It is removed through line 343 entering pump 344 and is pumped through line 345 to the nozzles 346 and 347 , where it is added to the dilution zone 350 of the storage tank 351 .
FIG. 5 depicts a low consistency ozone bleaching process stage in accordance with the present invention that is carried out after a chlorine dioxide bleaching stage. The process uses a pressurized ozone generator to produce compressed ozone before adding it to a mixer. This method avoids the use of a compressor to add compressed ozone to the mixer.
Pulp of medium consistency is pumped through line 452 into a storage tank 451 . The pulp flows down the tank into a dilution zone 450 where it is diluted to a low consistency with dilution water added through nozzles 446 and 447 . Agitators 448 and 449 ensure that mixing is complete. The pulp slurry, now of low consistency about 3%, passes through line 420 into pump 421 that discharges through line 422 into a mixer 424 where chlorine dioxide is added through line 423 . The pulp slurry-chlorine dioxide mixture passes through line 425 into the bottom of tower 426 , where it flows upwards consuming chlorine dioxide and bleaching the pulp. It overflows from the tower 426 in line 427 flowing into pump 428 , which discharges into mixer 409 where the oxygen-ozone mixture is added.
Air is introduced by line 401 into an air separation unit 402 where oxygen is separated from air. Oxygen passes by line 403 into an ozone generator 404 and is converted to ozone and this passes through line 405 into a control valve 406 that automatically regulates the gas flow by gas flowmeter 407 . Ozone gas is introduced to the mixer 409 by an inlet fine 408 and is dispersed into the low consistency pulp. The pulp slurry-gas mixture passes into the column 429 , which is held under pressure by a back pressure valve 430 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 430 into line 431 . The pulp slurry-gas mixture flows into a separator vessel 432 , where gases are separated from the pulp and passed through line 433 into an ozone destruct unit 434 , in which the ozone is destroyed and the resultant gases leave through line 438 . The pulp slurry leaves the separator through line 436 and flows into pump 437 , where it is pumped to the washer 439 through line 460 . The pulp is washed with wash water added through line 440 and leaves through line 441 . The washings are collected in tank 442 and leave through line 443 entering pump 444 and discharges via line 445 through nozzles 446 and 447 into the dilution zone 450 of the medium consistency storage tank 451 .
FIG. 6 illustrates a low consistency ozone bleaching process in accordance with the present invention that is carried out after a chlorine dioxide bleaching step. The process uses a compressor after the ozone generator to compress ozone before adding it to a mixer.
Pulp of medium consistency is pumped through line 552 into a storage tank 551 . The pulp flows down the tank into a dilution zone 550 where it is diluted to a low consistency with dilution water added through nozzles 546 and 547 . Agitators 548 and 549 ensure that mixing is complete. The pulp slurry, now of consistency about 3%, passes through line 520 into pump 521 and discharges through line 522 into a mixer 524 where chlorine dioxide is added through line 523 . The pulp slurry-chlorine dioxide mixture passes through line 525 into the bottom of tower 526 , where it flows upwards consuming chlorine dioxide and bleaching the pulp. It overflows from the tower in line 527 flowing into pump 528 and discharges into mixer 509 where the oxygen-ozone mixture is added. Air is introduced by line 501 into an air separation unit 502 where oxygen is separated from air. Oxygen passes by line 503 into an ozone generator 504 and is converted to ozone, and this passes through line 505 into a compressor 510 where the gas is compressed. The oxygen-ozone mixture passes through control valve 506 , which automatically regulates the gas flow by gas flowmeter 507 . The ozone gas mixture is introduced to the mixer 509 by an inlet line 508 , and is dispersed into the low consistency pulp.
The pulp slurry-gas mixture passes into the column 529 , which is held under pressure by a back pressure valve 530 . The ozone-oxygen mixture dissolves and reacts with the pulp slurry before exiting through valve 530 into line 531 . The pulp slurry-gas mixture flows into a separator vessel 532 , where gases are separated from the pulp and flow through line 533 into an ozone destruct unit 534 , wherein the ozone is destroyed and the resultant gases leave through line 535 . The pulp slurry leaves the separator through line 536 and flows into pump 537 where it is pumped to the washer 539 through line 538 . The pulp is washed with wash water added through line 540 and leaves through line 541 . The washings are collected in tank 542 and leave through line 543 entering pump 544 and discharges via line 545 through nozzles 546 and 547 into the dilution zone 550 of the medium consistency storage tank 551 .
The invention will be illustrated in greater detail by the following specific example. It is understood that the example is given by way of illustration and is not meant to limit the disclosure or the claims to follow. All percentages in the examples, and elsewhere in the specification, are by weight unless otherwise specified.
EXAMPLE 1
It has been found that most pulps bleach well giving increased brightness with little strength loss for an ozone charge of 5 kg of ozone/ton pulp. Taking this is as the basis of a design for a reactor, and assuming ozone is generated at a concentration of 12% w/w, the oxygen requirement is estimated as follows:
O 2 required=100*5/12=41.7 kg/ton of pulp.
This produces a mixture of O 2 +O 3 =5 kg O 3 +36.7 kg O 2 .
The volume of the gases at a pressure of 760 mms Hg, and temperature of 0° C. is 2.76 m 3 O 3 +30.40 m 3 O 2 .
Total gas volume=33.16 m 3 /ton of pulp.
If this is to be dispersed and dissolved in a pulp slurry having a consistency of 3%, volume of pulp slurry=100/3 m 3 /ton of pulp=33.3 m 3 /ton of pulp.
This consists of 1.0 m 3 pulp+32.3 m 3 of dilution water.
Hence it is required to dissolve and disperse 33.16 m 3 of gas in 33.3 m 3 of pulp slurry.
The ratio of gas to pulp slurry=33.16:33.3=about 1:1.
If all the O 3 dissolved in the dilution water, the solubility of the O 3 would have to be 5 kg/32.3 m 3 , or 155 g/m 3 .
If this reaction takes place at 50° C., the solubility of 12% w/w O 3 in water is as follows:
Total Pressure
Partial Pressure O 3
Solubility O 3
(psia)
(psia)
(g/m 3 )
14.7
1.22
13.2
24.7
2.05
22.2
164.7
13.67
147.9
If this is compared to dispersing ozone in medium consistency pulp having a consistency of 10%:
Volume=1.0 m 3 pulp+9.0 m 3 dilution water=10.0 m 3 pulp slurry.
If 5 kg O 3 ton of pulp is dispersed and dissolved in the dilution water, O 3 applied=5 kg/9 m 3 =555 g/m 3 .
The gas to liquid ratio at a pressure of 760 mms Hg and 0° C. is 33.16:9, which is 3.7:1.
At a pressure of 150 psig, this ratio becomes 0.33:1
If this medium consistency equipment disperses ozone satisfactorily at a ratio of 0.33:1 for medium consistency pulp, it will be able to do the same for low consistency. Hence to reduce the gas:slurry ratio from 1:1 to 0.33, the gas volume must be reduced by a ratio of 1/0.33 m 3 . This corresponds to a pressure of 30 psig.
Based on the above calculations, it was decided that medium consistency equipment can be used for dispersing ozone into low consistency pulp at a pressure of 30 psig. This was confirmed by testing carried out in the Laboratory as follows:
Laboratory Studies
Trials were carried out in a Quantum Mark-5 Laboratory Mixer/Reactor. This was originally designed and operated with medium consistency pulp. For each run 90 grams of pulp having Kappa No=25.5 was used and a first bleaching stage at a temperature of 40° C. with a constant chlorine dioxide dosage of 14.5 kg/ton was carried out. Following this, 4.0-5.5% w/w ozone-oxygen mixture was then introduced at a pressure of 50-70 psig at a temperature of 40° C. During the ozone addition, the pulp was mixed for 5 seconds at high intensity using a Quantum mixer followed by subsequent intermittent mixing at a lower intensity (using a CSTR) for 5 minutes. The results are shown in Table 1 below:
TABLE 1
O 3 Charge
O 3 Consumed
O 3 Reacted
Retention Time
Pressure
(kg/t)
(kg/t)
(%)
(mins)
(psig)
2.4
2.2
93.0
5
46
4.0
3.9
95.0
5
55
6.1
5.8
95.1
5
52
7.3
7.0
95.9
5
65
This illustrates that equipment designed for dispersing gases in medium consistency pulp can also be used successfully for O 3 bleaching of low consistency pulp with high ozone utilization.
EXAMPLE 2
Tests were carried out on a Pilot Plant that was originally designed to use ozone to bleach a medium consistency pulp slurry. It consists of a pump that pumps the pulp into a pressurized high shear mixer. Ozone of concentration 12% w/w is compressed and added to the pulp slurry at the inlet of the mixer. The ozone gas mixture is dispersed in the pulp slurry where it reacts with the lignin. The slurry-gas mixture discharges into a column where the remaining ozone is consumed.
Results for a Softwood Pulp having Kappa No 31, carried out at temperature 40° C. and a pulp consistency of 3.5%, are shown in Table 2 below:
TABLE 2
Ozone
Ozone
Pressure
Ozone
Ozone
Charge
Pressure
Bottom
Consumed
Consumed
to pulp
inlet Mixer
Tower
in Mixer
top Tower
(kg/t)
(psig)
(psig)
(%)
(%)
6.3
30
20
87
99
6-3
90
80
94
99
6-3
110
100
99
99
These results demonstrate that a Mixer designed for dispersing ozone into a medium consistency pulp slurry can be used successfully for a low consistency pulp slurry and that it is possible to operate at lower pressures with good results.
EXAMPLE 3
Two runs of an ozone stage were performed on a brown stock kraft pulp at low consistency in a Pilot plant using a high intensity mixer. The runs were made to verify if the ozone stage efficiency (degree of delignification) and the consumption were equivalent for low and medium consistency pulp. The pulp used was a softwood kraft with an initial kappa number of 30.8 and ISO brightness of 27.9%.
In each run, the washed pulp was received at 33% consistency and diluted to 3.8% consistency in an agitated feed tank. Pulp slurry was then preheated to 40° C. with the injection of steam in the feed tank. At that temperature, concentrated (98%) sulphuric acid was added to the tank to adjust the pH of the pulp suspension to 2.5 before the ozone stage. Pulp slurry was pumped directly to the hopper of the positive displacement pump. This pump introduced pulp in the high pressure section of the pilot plant, where ozone gas was mixed with the pulp in a Impco high intensity mixer. The flow of the pulp into the high pressure section and the ozone charge and concentration were kept constants.
After compression, the ozone gas stream was introduced into the pulp suspension trough a sintered metal sparger (20 micron porosity) located between the feed pump discharge and the Impco high intensity mixer inlet. The residence time in that mixer was approximately 0.05 second. The conditions for each run are described in Table 3.
The pulp was sampled approximately 1 meter from the ozone injector point after passing through the high intensity mixer. Gas samples were removed at the exit of the high intensity mixer, at the medium consistency pulp sampling point and at the top of the tower. Each gas sample was analyzed for residual concentration by gas chromatography. The ozonated pulp for the second run was analyzed for kappa number (CPPA standard, G.18) and ISO brightness (CPPA standard, E.1). The results are shown in Table 4 below.
The efficiency of delignification was approximately 1 kappa number drop per kg ozone. This observation is comparable to the efficiency observed at medium consistency and demonstrates the successful and efficient use of a high shear mixer with ozone and low consistency pulp.
TABLE 3
Z-stage conditions
Conditions
First Run
Second Run
Consistency, %
3.8
3.8
Temperature, ° C.
40
40
pH
2.4
2.4
Ozone charge, % o.d. pulp
0.551
0.566
Ozone concentration, %
12.85
13.21
Pressure
30
90
Residence time, min
6.4
6.4
TABLE 4
Results
First Run
Second Run
Results
Bottom
Top
Bottom
Top
Ozone residual, % on o.d. pulp
0.072
0.001
0.037
0.001
Ozone consumed, % on o.d. pulp
0.479
0.550
0.530
0.565
Kappa
27.0
24.1
Brightness ISO, %
31.4
32.2
Viscosity, CP
25.3
23.3
Initial kappa: 30.8 and brightness % ISO: 27.9, 39.5 CP
EXAMPLE 4
The performance of continuously stirred tank reactors (CSTR) of different types was compared to a high shear mixer for delignification efficiency in a D/Z process at low consistency. The performances were compared on the basis of OXE (oxidation equivalent, with 1 OXE=quantity of substance which receives 1 mole electrons when the substance is reduced. ClO 2 =74.12 OXE/Kg and O 3 =125.00 OXE/Kg). All of the CSTRs considered were similar in setup in terms of ozone pressure, concentration and duration.
The various reactors/mixers run, with the results are as follows.
CRL: (D/Z)Ep, SKP, initial kappa No. 23.3, final kappa No. 3.6, 14.0 kg ClO 2 ton for 6.3 kg O 3 /ton
AL: (D/Z)Eop, SKP, initial kappa No. 24.0, final kappa No. 7.9, 8.0 kg ClO 2 /ton, 6.33 kg/O 3 /ton
ECONOTECH: (D/Z)Ep, SKP, initial kappa No. 23.3, final kappa No. 3.6, 14.0 kg ClO 2 /ton, 6.0 kg O 3 /ton
CTP: (D/Z)Ep, SKP, initial kappa No. 25.4, final kappa No. 5.1, 15.0 kg ClO 2 /ton, 5.3 kg O 3 /ton
QUANTUM: (D/Z)Ep, SKP, initial kappa No. 25.5, final kappa No. 4.5, 10.0 kg ClO 2 /ton, 4.0 kg O 3 /ton
ROBIN: (D/Z)Ep, SKP, initial kappa No. 25.4, final kappa No. 9.0, 9.3 kg ClO 2 /ton, 8.1 kg O 3 /ton
The delignification efficiency for the various reactors is graphically depicted in FIG. 7 . The results clearly demonstrate the superiority of using a high shear mixer in connection with ozone at low consistency, as compared to other reactors which are conventionally used with low consistency pulp.
While the invention has been described with preferred embodiments, it is to be understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and the scope of the claims appended hereto.
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Provided is a process for bleaching pulp with ozone. The process involves preparing a slurry of cellulosic pulp having a consistency in fibers of from 1-5 weight %. Such a low consistency slurry is then mixed with ozone under high shear conditions. The ozone is then maintained in contact with the cellulosic fibers to effect bleaching of the fibers. The present process offers the advantages of bleaching using a low consistency slurry, with the added advantages of employing ozone.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to the induction of stock activity in paper forming.
2. Description of the Prior Art
Stock activity in the early part of a Fourdrinier table is critical to the production of a good sheet of paper. Generally, stock activity can be defined as turbulence in the fiber-water slurry on the forming fabric. This turbulence takes place in all three dimensions. Activity plays a major part in developing good formation by impeding stratification of the sheet as it is formed, by breaking up fiber flocs, and by causing fiber orientation to be random. Typically, the beneficial effect of stock activity is inversely proportional to the consistency of the sheet. That is, the effect of activity is typically enhanced if dewatering of the sheet is retarded while the activity is generated. Also, at higher sheet consistency, activity becomes more difficult to induce because the sheet becomes set and because water, which is the media in which activity takes place, becomes scarcer. Moreover, stock activity quality is inversely proportional to water removal from the sheet.
There are a number of conventional methods to promote activity. These methods are often associated with affecting rates of water removal. A table roll causes a large positive pressure pulse to be applied to the sheet resulting from water under the forming fabric being forced into the incoming nip formed by the roll and forming fabric. This positive pulse has a positive effect on stock activity by causing flow perpendicular to the sheet surface. Table rolls also generate a large negative pressure (vacuum) pulse from the exiting nip formed by the roll and forming fabric, which while enhancing activity, tends to greatly enhance sheet drainage. Moreover, table rolls are generally limited to relatively slow machines because at high speeds, the pulse amplitude becomes excessively large. Foils are also used to promote and control activity and drainage. A vacuum pulse is generated by the nip formed by the forming fabric and conventional foil as the fabric passes over the foil. Activity is generated by using a number of consecutively placed foils, encouraging a positively reinforced activity in the stock. Another type of foil (sometimes referred to as a "posi-blade") incorporates a positive incoming nip to generate a positive and negative pressure pulse. The amplitude of the pressure pulse is determined in a large part by the angle formed by the fabric and the incoming edge of the foil.
Often Fourdrinier tables are mechanically shaken to promote stock activity, especially on slower, narrower machines. While the shaking might enhance formation, mechanical restraints limit shake frequency and amplitude to the degree that it is not effective on machines producing at speeds over 1000 feet per minute and it is undesirable even on slow machines because of the mechanical wear on the machinery. An example of such shaking is disclosed in U.S. Pat. No. 1,623,157 to Berry entitled "Paper Making Machine". While the shaking might be a good way to enhance formation, it is undesirable because it is difficult and expensive to control and maintain, and generally punishing on the equipment on and around the Fourdrinier table. For papermaking in general, most activity inducing systems have the disadvantage of causing excessive drainage.
Similarly, U.S. Pat. No. 2,727,442 entitled "Apparatus for the Manufacture of Paper" to Hayes discloses an electromechanical vibrating element attached to a transverse vessel holding water, wherein the forming fabric or "Fourdrinier wire" is passed across the transverse vessel while the sheet metal floor of the vessel is being mechanically vibrated. This, however, would not appear to result in uniform turbulence across the width of the forming fabric.
U.S. Pat. No. 5,306,394 entitled "Turbulence Roll for a Web Former" to Meinander discloses an unpowered drainage roll, driven by the passing forming fabric, which includes a plurality of discs to impart vibratory movement to the inclined forming fabric during the dewatering process.
U.S. Pat. No. 4,789,433 entitled "Skimming Blade with Wave Shaped Troughs for a Papermaking Machine" to Fuchs discloses a skimming blade for removing water above a dewatered surface with is inclined and having a plurality of troughs.
Some further prior art U.S. patents in this general area include the following:
______________________________________5,089,090 4,055,640 1,839,1585,080,760 3,598,694 1,670,8844,532,009 2,128,269 695,7534,306,934 2,124,028 568,211 2,095,378 2,092,798______________________________________
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of this invention to create stock activity in a Fourdrinier table in order to make high quality paper.
It is therefore a further object of this invention to induce activity in stock in a Fourdrinier table without creating excessive mechanical vibration in the mechanical components of the table.
It is therefore a still further object of this invention to induce activity in stock in a Fourdrinier table uniformly across the width of the forming fabric.
These and other objects are achieved by providing a Fourdrinier table and associated apparatus which uses motive force for the stock activity originating independently from the stock and the forming fabric. The motive force is coupled to the stock hydraulically via a water-filled cavity over which the forming fabric passes, the cavity being bounded on a lower side by a non-permeable or semi-permeable membrane which receives the motive force. The membrane allows energy to be transmitted to the forming fabric and paper stock while simultaneously reducing or eliminating the amount of water drained from the stock.
Subsequent high-capacity drainage devices may be used to freeze the formation created by the activity generator.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention will become apparent from the following description and claims, and from the accompanying drawings, wherein:
FIG. 1A is a schematic illustrating the hydraulic coupling concept of the present invention.
FIG. 1B is a schematic illustrating the hydraulic coupling concept of the present invention using a lobed roller.
FIG. 2 is a side schematic view of the apparatus of the present invention.
FIG. 3 is a side schematic view of the apparatus of the present invention with two activity inducing stations.
FIG. 4 is a side schematic view of the apparatus of the present invention, using two rolls in a tandem activity unit.
FIG. 5 is a side schematic view of the apparatus of the present invention, including the papermaking environment.
FIG. 6 is a side schematic of the apparatus of the present invention, shown with an inclined membrane bounding the lower surface of the water filled cavity.
FIG. 7 is a side schematic of the apparatus of the present invention, shown with the forming fabric being free of clearance from the membrane.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that FIG. 1A illustrates the present apparatus 10 wherein motive force originating independently from the stock 100 and the forming fabric 12, and coupled to the paper stock 100 hydraulically via liquid 102, is used to provide for mechanical induction of the stock activity.
More specifically, a membrane or fabric 14 is stretched between stationary elements 16, 18 across the apparatus 10 for the full width of the forming fabric 12. The end walls of the membrane which are needed to hold the activity transmission water do not add stiffness to the membrane 14. Thus, the membrane 14 can vibrate uniformly across the whole width of the machine. Membrane or fabric 14 is caused to vibrate vertically under the forming fabric 12 carrying the stock 100. The tension of membrane or fabric 14 is controlled such that its resonant vibrational modes are controlled. In this regard, the membrane is tunable to correspond to the preferred frequency of activity of the stock. The resonant state of the membrane is determined (given a material and geometry of the membrane) by its tension and span. Thus, by controlling tension and span, the membrane can be made to suit particular papermaking conditions. The membrane is tensioned in the machine direction only, like a papermaking fabric. Cross-machine tension is determined by Poissons effects. The activity can be profiled across the machine by varying and controlling its tension differentially across the membrane. The membrane 14 is coupled hydraulically to the stock 100 via the forming fabric 12 by flooding the cavity 20 formed between membrane 14 and forming fabric 12 with liquid such that only incompressible media at very close to or at atmospheric pressure exists between membrane 14 and stock 100. In some applications, cavity 20 may be eliminated since the water carried inside the thickness of forming fabric 12 will provide the hydraulic coupling. However, at least a small cavity 20 is preferred to minimize or eliminate the wear of membrane 14 due to direct contact with forming fabric 12. The liquid in cavity 20 can be introduced independently or liquid from the process can be allowed to fill the cavity at start-up. Of course, the most likely liquid to be used in cavity 20 is water. It may also be possible to drain water slowly from cavity 20 between membrane 14 and forming fabric 12, as long as the coupling between the membrane 14 and forming fabric 12 is not compromised and activity is maintained.
While the membrane 14 may be such that it is impermeable to water, and therefore drainage from the stock 100 does not occur through membrane 14, in certain applications, the membrane 14 may be permeable to a desired degree to allow for drainage. Permeability can be differentially varied in the machine direction to blend activity and drainage for optimum papermaking. The desired stock activity is induced by the vibration of membrane 14 closely coupled to the stock. Again, some drainage from cavity 20 may be possible, as long as the close coupling is maintained.
Additionally, the membrane 14 can have a variable tension in the machine direction (typically no tension in the cross-machine direction) so as to tune the vibrations of the membrane 14.
As shown in FIG. 7, the membrane 14 can also be free of clearance of forming fabric 12.
Also, the length of the membrane may be modified to control a number of factors including frequency of activity and dwell time during which the forming fabric 12 is subjected to excitation.
The forming fabric 12, while having many of the characteristics of the membrane 14, is permeable to water. While it is possible with proper attention to span, tension and the resulting resonant frequency of forming fabric 12 to excite the forming fabric 12 directly without the use of membrane 14, this may result in undesired drainage through forming fabric 12.
Several methods are available to excite membrane 14. As shown conceptually in FIG. 1B, a roll 22 of irregular diameter with protrusions 24 can be oriented across a full width of membrane 14, perpendicular to the direction of travel of forming fabric 12, and made to contact membrane 14 and rotated such that protrusions 24 (i.e., the irregularities in the profile of roll 22) cause membrane 14 to be excited vertically. As roll 22 extends across the entire width of membrane 14 and has a constant profile thereacross, the excitation resulting from the rotation of roll 22 is evenly distributed across the apparatus 10 of the papermaking machine. Similarly, as the protrusions 24 are symmetric and regularly spaced circumferentially about the rotational axis of roll 22, frequency of excitation is easily controlled by the rotational speed of roll 22. Amplitude of excitation depends on the extent of the irregularity of roll 22, alternately viewed as the amplitude of protrusions 24, and position of the centerline of the roll 22 relative to the membrane 14. While the roll 22 conceptually illustrated in FIG. 1B has four lobes, the technique is applicable to any number of lobes.
FIG. 2 illustrates an embodiment where roll 22, journaled for rotation about horizontal axis 23, has many lobes or protrusions 24, and on which lobes or protrusions 24 are designed such that the displacement of membrane 14 is controlled by the profiles of lobes or protrusions 24. The vertical position of horizontal axis 23 of roll 22 is adjustable so as to allow variation in the amplitude of vibration imparted from roll 22 to membrane 14, such as may be required for different stock or paper products and as may be required for differences in the profile of roll 22. The horizontal position (in the machine direction) of horizontal axis of roll 22 is likewise adjustable.
As shown in FIG. 6, the vertical position of the ends 15, 17 of membrane 14 is adjustable so as to allow for an inclination of membrane 14 (the inclination in FIG. 6 is illustrated as exaggerated) which may have a variable permeability. Slope could be in either direction depending on paper characteristics and drainage/activity objectives.
As further seen in FIG. 2, foil 26 has a lead-in surface 28 leading to the location of membrane 14 and cavity 20. Lead-in surface 28 has a corrugated or sinusoidal shape. This sinusoidal shape has a wavelength corresponding to the wavelength of oscillation of membrane 14, so that the sinusoidal shape of lead-in surface 28 of foil 26 will complement the oscillation of membrane 14. While this may appear to be similar to the "Wonderfoil" of Kallmes, disclosed in U.S. Pat. No. 4,687,549, typically used in combination with a "Sheraton Roll", the function of the pattern of the present invention is entirely different. The function of the pattern of the present invention is to increase the kinetic energy of the suspension and to enhance the activity generated by the oscillation of membrane 14.
Alternative methods of exciting membrane 14 employ an independent actuator, such as a hydraulic or electromechanical actuator (not shown). Such a device would offer easy control of excitation amplitude as well as frequency but would be somewhat more complicated to install than roll 22. The actuator device would also have to be coupled evenly across the apparatus 10 to equal the action of roll 22. However, point excitation of membrane 14 by an actuator or series of actuators may present the opportunity to create activity variations at locations of the membrane 14 in the cross-machine direction which, under some circumstances, can be desirable.
After contacting foil 26 and roll 22, forming fabric 12 contacts member 40, which may, for example, be a drainage device, and includes lead-out surface 42 extending away from the location of membrane 14 and cavity 20. Lead-out surface 42 has a sinusoidal-shaped profile similar to that of lead-in surface 28 of foil 26.
Member 40, along with the sinusoidal lead-in and lead-out surfaces 28, 42, if used as a drainage device, can be implemented by many kinds of suction boxes, including a conventional blade drainage box or a submersible drainage box, an example of which is disclosed in U.S. Pat. No. 5,242,547 entitled "Submerged Drainage System for Forming and Dewatering a Web on a Fourdrinier Fabric" to Corbellini et al.
FIG. 3 shows an embodiment of the invention with a first apparatus 10 including foil 26, roll 22 driven by a rotational drive mechanism (not shown) and member 40 as described hereinabove, followed by a conventional gravity foil 60, followed in turn by a second apparatus 10' including corresponding primed elements. The rotational drive mechanism (not shown) which drives roll 22 is configured in any number of ways as appropriate as is well known in the prior art. Forming fabric 12 is configured in a loop about breast roll 80 and supported on a lower portion of the loop by idlers 84. Subsequent papermaking stations 200 are downstream from apparatus 10, gravity foil 60 and apparatus 10'.
Head box 86 provides paper stock 100 to forming fabric 12 after forming fabric 12 reaches an upright horizontal orientation downstream of breast roll 80. Forming fabric 12 is stabilized by forming board 88 and the paper stock 100 is distributed over substantially the width of forming fabric 12. As previously described, activity is induced in the stock by rolls 22, 22' which results in a random orientation of the stock and an improved quality of paper.
FIG. 4 is similar to FIG. 2 except that second roll 22' is placed to be immediately downstream from roll 22 so that rolls 22 and 22' are exciting a single membrane 14, cavity 20, forming fabric 12 and associated paper stock 100.
FIG. 5 shows the apparatus 10 of FIG. 2 in a papermaking environment, including gravity foil 60, breast roll 80, idlers 84, head box 86, and forming board 88, similar to the environment of FIG. 3.
As previously described, in order to use apparatus 10, the user fills cavity 20 between forming fabric 12 and membrane 14 with water. Roll 22 is rotationally activated via the rotational drive mechanism (not shown) so as to excite membrane 14. Finally, paper stock 100 is provided via head box 86 to forming fabric 12 and initially distributed at forming board 88. As forming fabric 12 traverses past roll 22, protrusions 24 periodically excite membrane 14 causing excitation of paper stock 100 via water-filled cavity 20 resulting in the desired activity and dispersal of paper stock 100.
The activity generation of the apparatus 10 (i.e., the excitation of membrane 14 by the protrusions 24 on roll 22) will create an optimum formation through controlled activity.
Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims.
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The apparatus of the present invention is a papermaking machine with a forming fabric in a looped configuration. The forming fabric carries paper stock through the papermaking process. The forming fabric passes over a liquid-filled cavity which is bounded on its lower surface by a flexible non-permeable membrane. A roll with regular protrusions underneath the membrane is rotated to vertically excite the membrane, the liquid-filled cavity, and, subsequently, the paper stock in order to disperse the paper stock into a random orientation.
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BACKGROUND OF THE INVENTION
This invention relates to a power system and, more particularly, to a power system which achieves a maximum operating efficiency by independent manipulation of the power plant r.p.m. and flywheel input and output r.p.m. all in recognition of predetermined power requirements.
Various power systems have been proposed in an attempt to efficiently move vehicles with an accompanying reduction of fuel consumption and/or pollutant emission. One system known as a variomatic transmission utilized expanding pulleys directly geared to the rear wheels. However, such a system was admittedly inefficient in supplying suitable torque to drive large vehicles. Moreover, past power systems utilizing manual or automatic transmissions are inefficient. In conventional systems, much of the horsepower supplied by the engine is lost during its delivery from the engine to the drive wheels. The resistance of the drive wheels, as transferred to the power train, presents various junctions of mechanical disadvantage which are overcome by increasing the horsepower of the power plant.
Also, the power plant in a manual transmission equipped vehicle is not under a flywheel load when the clutch disc is disengaged from the flywheel. When first gear is selected the power plant is brought up to a sufficient r.p.m. to engage the clutch disc with the flywheel at a sufficient torque to put the vehicle in motion. Thus, the acceleration begins. The power plant must increase its r.p.m. to increase the vehicle speed. The point at which the engine operates most efficiently is reached when the engine r.p.m. and torque peak curves coincide. Ideally at this point the shift to the next higher gear is made.
As the clutch disc is disengaged from the flywheel to shift to second gear engine r.p.m. drops. At this point inefficiency occurs as the power plant r.p.m. drops during the gear change. Thus, the flywheels kinetic energy, inducing the vehicle's forward inertia, is lost. Thus, the conventional flywheel becomes a disadvantageous and unnecessary load on the power plant. Once the higher gear is engaged and the clutch disc re-engages the flywheel, the power plant must again produce the power necessary to propel both the flywheel and vehicle simultaneously, relying on the force produced by the combustion of the fuel/air mixture in the engine cylinders. Thus, piston/cylinder size is of importance.
This sequence of events is repeated with each gear change, road inclination (grade) change and vehicle acceleration.
Vehicles equipped with automatic transmissions never gain the advantage of increasing kinetic energy because of principles in hydraulics as applied to modern passenger vehicles. Although the constant drag on the power plant under idle conditions can be alleviated, the torque converter is a constant load on the power plant under all vehicle operating conditions. By the very nature of the automatic transmission equipped vehicle, the power plant and torque converter r.p.m. are always the same and the acceleration process begins at the low r.p.m. range of the power plant. No kinetic energy/inertia advantage is ever enjoyed. Thus, no advantage as to kinetic energy is ever ideally achieved in past vehicle power systems.
In response thereto I have invented a vehicle power system which utilizes an efficient power source preselected to move a vehicle at a range of preselected vehicle speeds with appropriate acceleration. The engine power is delivered to an input side of a flywheel at a precise r.p.m. by means of an intermediate, variable speed expansion pulley system as controlled by computer generated signals responsive to throttle depression and road grade. A second computer-controlled expansion pulley system is positioned intermediate the output side of the flywheel and transmission to deliver power to the downstream transmission. The control unit signals change the pitch of the expansion pulleys so as to efficiently and continuously transfer the power from the power source to the transmission without disengagement of the flywheel. In turn, the above problems are avoided as a plurality of ratios between the power plant and drive wheels are presented. Thus, small, high r.p.m. power plants can be utilized. The transmission is fluid controlled in coordination with selected vehicle speed ranges so that it will shift through efficient gears. Control of the input and output r.p.m.s, relative to the flywheel, enable one to pre-design an efficient power drive system. Also the accessories associated with the power system are driven at a constant functional r.p.m. Thus, no additional, unnecessary power need be delivered to power such accessories.
It is therefore a general object of this invention to provide a power system for a motor vehicle or the like.
Another object of this invention is to provide an efficient power plant which efficiently translates the energy of a power plant to the driven vehicle wheels.
A further object of this invention is to provide a system, as aforesaid, which provides a maximum safe power output for driving a selected vehicle load at preselected speeds.
A further object of this invention is to provide a system, as aforesaid, having an acceleration controlled by manipulation of the power plant r.p.m., flywheel r.p.m. and transmission so as to provide precise rates of acceleration and maximum top end speed.
Another object of this invention is to provide a system, as aforesaid, which provides an efficient rate of acceleration to the vehicle without the need to intermittently disengage the flywheel from the system.
Still a further object of the invention is to provide a system, as aforesaid, which allows for the preselection of an efficient power source so as to reduce the undesirable emissions emanating therefrom.
Another particular object of this invention is to provide a system, as aforesaid, which enables a preselection of efficient operating characteristics for a selected vehicle load.
A further particular object of this invention is to provide a system, as aforesaid, which provides for an efficient delivery of power for operating accessories associated with the system.
Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, a now preferred embodiment of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view showing the component parts of the power system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning more particularly to the drawings, FIG. 1 shows the components of the power system in a diagrammatic form. Power plant 100 , whether in the form of a gas or electric motor, is chosen to have a maximum r.p.m. for driving a selected vehicle load at a selected top speed.
Although various power plants may be selected, a rotary gas engine is a desirable power source as it has high r.p.m. and horsepower output, small size, light weight and fewer moving parts resulting in a greater reliability. Also, such engines, being adaptable to fit various horsepower needs, operate more efficiently at a higher r.p.m. than a reciprocating piston engine.
As part of development of my system a top desired speed is selected. As most vehicles need not exceed 75 m.p.h. in most driving conditions a motor 100 having a maximum output r.p.m. to efficiently achieve such a selected maximum speed is chosen. Thus, additional motor r.p.m.s to achieve a speed beyond this maximum speed need not be utilized provided that the acceleration of the vehicle efficiently achieves such maximum speed. The ability to provide such a maximum top vehicle speed without a significant loss in effective acceleration is a prime advantage of my system.
In connection with such speed the force necessary to put a vehicle of a selected weight in motion and maintain the vehicle at a top speed can also be determined. Thus, a chosen power plant 100 is desirable which will spin a conventional flywheel 900 at a maximum r.p.m. so as to supply the torque to transmission 1300 which is necessary for effective acceleration of the vehicle to such top speed. To spin the flywheel at greater r.p.m.s is a waste of energy. Also, to further achieve optimum efficiency the system flywheel should not be disengaged from the system during operation. As such the maximum flywheel weight, diameter and r.p.m. can be preselected and coordinated with the chosen power plant.
Transmission 1300 applies power to the drive wheels. The torque converter is eliminated with the transmission being controlled by means of an on/off fluid control valve 1400 which opens upon sensing 2060 a depression of a brake pedal 2050 and closes upon sensing 2060 a let off of a brake pedal 2050 and at preselected r.p.m. levels so as to shift the transmission 1300 into different gears at different preselected speeds, such as 25 m.p.h. and 50 m.p.h. This ratio presents three speed ranges which encompass the driving speeds for most vehicles.
The use of a power plant, flywheel and transmission is known. However, my novel delivery of power from the power plant 100 to the transmission via upstream and downstream expansion pulley systems 500 , 1000 , relative to the flywheel 900 , presents the ability to continuously adjust the r.p.m. ratio therebetween. This continuous flexibility allows for an efficient power plant to be selected which will efficiently accelerate the vehicle throughout the desired operating range of the vehicle.
As such I provide first 500 and second 1000 expansive pulley systems on the input and output sides of the flywheel 900 . A first expansion pulley system 500 controls the delivery of r.p.m.s to the input side of the flywheel 900 . This system 500 is positioned intermediate the power plant and input side of the flywheel 900 . The second pulley system 1000 ultimately controls the torque delivered to the input of transmission 1300 . These pulley systems are controlled by a computer unit 1900 so as to continuously change the mechanical advantages relative to the flywheel 900 . The two coordinated pulley systems 500 , 1000 ultimately provide the desired torque to the transmission 1300 so as to drive the wheels at a desired speed with a minimum of energy loss from the motor 100 . Thus, a small power plant 100 acting at a high r.p.m. can apply torque similar to a large power plant acting at a lower r.p.m.
As above, the chosen top vehicle speed is coordinated with the maximum r.p.m. of the chosen power source to drive a selected vehicle load. This maximum r.p.m. also is selected so as to also operate vehicle accessories connected to a pulley 1800 . The top end speed is thus controlled by limiting the maximum r.p.m. of the power source 100 and by the selection of the minimum/maximum gear ratios as supplied by the pulley systems 500 , 1000 . The vehicle acceleration rates to the top speed are controlled by the horsepower delivered from the power source at selected r.p.m.s and manipulation of these expansion pulley systems.
The accessories pulley system 1800 includes expansion pulley 600 which has a left movable plate attached to the movable right plate of the expansion pulley 500 . Belt 700 is attached to spring tensioned pulley 800 which in turn drives shaft 1750 connected to accessory pulley 1800 for a belt driven power of the system accessories. As such once the minimum r.p.m. is determined to insure the proper operation of accessory devices, e.g., water pump, alternator, power steering, etc., the proper r.p.m.s can be maintained at this level as movement of plate of pulley 500 will also move the plate of pulley 600 . Thus, the pitch of pulley 600 is adjustable so that no additional, unnecessary power need be delivered to pulley 800 by belt 700 as is in conventional systems as the accessories pulley is being driven at the engine r.p.m.s.
The system includes a computer control unit 1900 which receives information from signals corresponding to the degree of depression of the acceleration pedal 2000 as well as a grade level sensor 2100 . The control unit is preprogrammed with desired operating characteristics curves throughout the desired range of vehicle speeds and at the various possible road levels which support the vehicle. Thus, conventional programming techniques can be utilized to determine the desired operating characteristics and the fuel that needs to be delivered to the motor 100 by the fuel injection system 200 so as to achieve such characteristic, i.e., to power the vehicle at a selected speed on a selected grade. Such operating characteristic curves will include the desired ratios of the pulley systems needed to achieve this particular operating characteristic. Thus, the control unit 900 will generate output signals not only to control fuel delivery but also the servo motors 1600 , 1700 associated with the expansion pulleys 500 , 1200 . These motors will appropriately increase or decrease the effective radius of the same to achieve the desire ratios among the pulley systems.
To begin acceleration the power plant 100 is set at a preselected idle r.p.m. with the fluid control valve 1400 on the transmission 1300 being in the open position. Level sensor 2100 feeds grade information into the computer 1900 . Upon depression of throttle pedal 2000 the degree of depression is sent to the computer 1900 for translation into a signal corresponding to a desired vehicle speed. The computer 1900 utilizing the desired, preprogrammed operating characteristics then delivers signal information to the fuel injection system 200 to bring the output shaft of the power plant 100 to a desired r.p.m. to achieve such speed on the road level as sensed by sensor 2100 . At this time the computer sends signals to the servos 1700 which adjust the first expansion pulley 500 so as to transfer the desired r.p.m.s from motor 100 shaft to the flywheel 900 shaft at an optimum rate. The size of pulley 500 adjacent the input side of flywheel 900 approximates the size of the flywheel 900 . Thus a bigger gear ratio on the drive side of the flywheel 900 is presented. (It is understood that pulley 300 is a spring tensioned pulley on motor shaft.) Concurrently, the second expansion pulley 1000 is adjusted by servo 1600 so as to provide the proper torque on shaft which drives the transmission 1300 . (Pulley 1200 is a spring tension pulley of the system having a size approximating pulley 500 . Thus, a bigger gear ratio on the drive side of the transmission is presented)
Concurrently, the transmission 1300 , as fluid controlled by computer-controlled valve opening and closure, will shaft gears according to the range in which the desired vehicle speed is located. The desired vehicle speed is thus efficiently provided by a preselected power plant r.p.m., preselected expansion pulley ratios and transmission gear. As these factors can now all be preselected, predetermined operating characteristic curves can be stored in the computer which will vary according to power plant, vehicle weight, desired vehicle speeds, road levels and other desired parameters. My system enables the characteristics of such preselected optimal curves to be preselected, stored and thus achieved. Once the desired vehicle speed is achieved, the level sensor 2100 information to the computer can further adjust the power plant 100 r.p.m. and expansion pulleys 500 , 1000 . If vehicle speeds are needed outside a present gear range the computer will generate signals to accordingly open or close the fluid valve 1400 to allow the transmission to move to the gear enveloping the speed.
Accordingly, it can be seen that a continuous adjustment of the engine r.p.m.s, expansion pulleys and transmission corresponding to a desired vehicle speed is being achieved. As such adjustment is continuous there are no points of mechanical disadvantage in the system, as in past systems, which must be overcome by increasing engine horsepower. Thus, there is no waste in power delivery to the transmission and/or power system accessories, which contributes to an overall, effective power system.
It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto, except in so far as such limitations are included in the following claims.
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A power system for a vehicle includes a motor, a flywheel and a transmission. Intermediate the motor and flywheel and coupled thereto is a first expansion pulley system with a second expansion pulley system intermediate the flywheel and transmission and coupled thereto. A programmable computer receives information concerning a desired vehicle speed and road level and processes the information so as to vary the motor r.p.m.s in order to reach a desired vehicle speed. The pulley systems effectively transmit the power from the motor through the flywheel and to the transmission at preselected ratios so as to provide for an efficient power delivery and vehicle acceleration. An additional expansion pulley system drives accessories at a constant preselected r.p.m. to preclude the transfer of needless power from the motor to the accessories.
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BACKGROUND OF THE INVENTION
This invention relates to fluid flow control systems, such as surgical irrigation and aspiration systems, especially as used in ophthalmic surgery. In particular, this invention relates to the reduction or elimination of transient fluid waves at or near the pressure transducer apparatus in a surgical aspiration line. For purposes of this specification, the terms "fluid flow control," "fluid control" and "flow control" are used interchangeably.
Intraocular surgery, particularly cataract removal, has been greatly aided by the development of a procedure called phacoemulsification. The procedure involves the use of surgical instruments which include cutting or fragmenting means combined with means for irrigating the intraocular surgical site and aspirating therefrom the spent irrigating fluid, together with any tissue fragmented during the surgical procedure. See for example, U.S. Pat. No. 3,589,363 (Banko et al.). Improvements to that fluid control system are disclosed in U.S. Pat. Nos. 3,693,613 (Kelman); 3,902,495 (Weiss et al.); 4.041,947 (Weiss et al.); 4,496,342 (Banko); 4,832,685 (Haines); and 4,921,477 (Davis). The contents of each of the above-listed patents are hereby incorporated by reference in their entirety.
Phacoemulsification is accomplished by the use of an ultrasonic surgical tool capable of longitudinal vibrations such that, when the vibrating tool is applied to tissue (e.g., a cataractous lens), it is capable of fragmenting ocular tissue into small pieces. This tool is attached to a fluid system having means for supplying irrigation fluid to the surgical site and an aspiration means for removing the irrigation fluid and fragmented tissue from the surgical site. The aspiration means includes an axial bore through the ultrasonic tool which is connected to a source of fluid flow and vacuum, such as a pump, whereby the tissue fragments are evacuated form the surgical site along with the irrigation fluid.
Because the ultrasonic surgical tool fragments the excised tissue into tiny particles which are then removed from the surgical site along with the spent irrigation fluid, the incision in the eyeball need only be large enough to accommodate the tip of the tool therein and is therefore substantially smaller than the incision required to remove the lens in one piece. Thus, the surgical field is essentially a closed system and controlling the rate of fluid into and out of the eye becomes very important in order to prevent collapse of the anterior chamber of the eye. In particular, a blockage or occlusion may occur, for example, when a piece of fragmented tissue which is larger than the axial bore of the surgical tool is drawn against the entrance to the bore. When such a blockage occurs in the aspiration line, the negative pressure of the suction in the aspiration line between the surgical site and the pump increases. If the blockage is suddenly released, either by the mechanical action of the ultrasonic tool or by the increased value of the suction force, there is a tendency for the fluid within the surgical site to rush suddenly into the aspiration line, with possibly disastrous consequences. This is an especially important problem in ocular surgery because the total volume of the fluid in the surgical site is much smaller than the volume of fluid in the irrigation and aspiration lines.
Kelman (U.S. Pat. No. 3,693,613) was among the first to discuss the problems associated with maintaining a near-constant pressure within the fluid system. The system disclosed therein provides fluid control by the use of a relief valve located in the aspiration line upstream of the pump which opens the line to air when a change in the fluid pressure exceeds a pre-set level, as sensed by a transducer apparatus located in the aspiration line upstream of the relief valve. The Weiss et al. patents (U.S. Pat. No. 3,902,495 and U.S. Pat. No. 4,041,947) improve upon the flow control system of Kelman by limiting the flow rate of the irrigation fluid.
A second type of fluid flow control system is disclosed in Banko (U.S. Pat. No. 4,497,342). There, flow control is accomplished by the use of a second solution of infusion fluid (termed "surge fluid") which leads into the aspiration line. The valve which connects the surge fluid to the aspiration line is controlled by a transducer apparatus which is capable of sensing changes in the flow rate. In order to insure that the surge fluid, rather than the infusion fluid, is aspirated during a fluid surge, the surge fluid solution is placed at a higher level than the infusion fluid and therefore has a faster flow rate.
A third type of fluid flow control system, which improves upon the systems of both Kelman and Banko, is disclosed in Haines (U.S. Pat. No. 4,832,685). There, the fluid pressure is controlled by a line connecting the irrigation and aspiration lines. A valve located in the connecting line is normally closed, but is momentarily opened if there is an increased pressure in the aspiration line, as sensed by a pressure transducer apparatus located in the aspiration line. This fluid control system allows the excess vacuum in the aspiration line to be controllably and rapidly released after a partial or complete occlusion by venting to the irrigation line rather than to air. This liquid venting or pressure equalization system provides a faster rise time, reduces the chances of the occurrence of collapses of the enclosed surgical site (e.g. eye) and, further, requires only one irrigation bottle and the use of a check valve to prevent reversed irrigation flow towards the bottle when venting.
Davis (U.S. Pat. No. 4,921,477) improves upon the fluid flow control system of Haines by the inclusion of a dampening device. In Haines, due to the venting route, the non-compressible nature of liquids and the lack of air in the fluid system, the venting, or pressure equalization, causes an undesirable oscillating turbulence in the eye. The dampening device of Davis reduces or eliminates this undesirable oscillation. This dampening mechanism includes a membrane diaphragm along one side of a fluid chamber thereof which communicates directly with the aspiration line. The membrane absorbs the fluctuations caused by the displacement of fluid by the rollers of the peristaltic pump, thereby keeping the flow constant in the eye. A reflux shield of the dampening mechanism limits the outward movement of the diaphragm and a stop shield limits the inward movement of the diaphragm.
The fluid control systems of Haines and Davis utilize transducer apparatus to detect changes in pressure in the aspiration line, which, if the pressure change exceeds a pre-set limit, stops the pump and allows the surgeon to activate the venting mechanism. As used herein, the term "transducer apparatus" means the combination of one or more pressure-sensing means and the apparatus which connects said pressure-sensing means to the aspiration line. The transducer apparatus senses pressure changes in the aspiration line without impeding the flow of fluid and produces a corresponding electric signal which is transmitted to a control panel. If the change exceeds the pre-set limit, the control panel deactivates the and source, allowing the vacuum to remain relatively constant while the fluid flow stops. This permits the surgeon to activate the venting mechanism. The pre-set pressure level may be varied, according to a number of different factors, such as the mode or system function which a surgeon selects during the course of a surgical procedure.
When the fluid system is vented, fluid enters the aspiration line, often forming transient fluid waves (otherwise known as "water hammers") which enter the transducer apparatus and impact against the pressure-sensing means. Over time, or if a water hammer is of sufficient magnitude, these water hammers destroy the transducer apparatus, often also causing destruction of the surrounding circuitry.
There is therefore a need for a dampening device to prevent water hammers from destroying the transducer apparatus and surrounding circuitry in surgical irrigation and aspiration systems.
SUMMARY OF THE INVENTION
This invention is directed to a transducer apparatus for use in a surgical irrigation and aspiration system, wherein the transducer apparatus includes dampening means to prevent or reduce the destructive effect of water hammers on the delicate pressure-sensing means of the transducer apparatus. The dampening means acts as a "shock-absorber" by diverting the transient fluid wave away from the pressure-sensing means and allowing the residual air left in the transducer apparatus to compress and absorb a portion of the high levels of kinetic energy present in the transient fluid wave.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic illustration of a representative fluid circuit of a surgical irrigation and aspiration system.
FIG. 2 illustrates a prior art transducer apparatus.
FIG. 3 illustrates the preferred embodiment of the transducer apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a representative surgical irrigation and aspiration system of the present invention is illustrated schematically. The system 10 includes a bag or bottle 12 and a drip chamber 14 used to maintain a pressure in the eye 16 and to provide irrigation fluid. The bottle 12 is hung on a pole which, with the drip chamber 14, gives an even gravity flow or irrigation fluid through the irrigation line 18 to the handpiece 20 and then to the eye 16. A solenoid or valve 22 is positioned in the irrigation line 18 and is used to stop and start the irrigation fluid when needed and is operated by a footswitch controllable by the surgeon. A schematic or an electrical circuit including this footswitch which can be adapted and used to control this fluid flow control system is shown for example in U.S. Pat. No. 4,832,685. A one-way check valve 24 in the irrigation line 18 between the irrigation solenoid 22 and the handpiece 20 prevents the fluid from returning up or back flowing in the irrigation line 18 during venting, as will be described below.
A pump 26, or other vacuum source, provides a vacuum to evacuate spent irrigation fluid from the surgical site 16 through the handpiece 20, through the aspiration line 28 and then through drainage line 31 into a waste material drainage container or bag 30. When there is an occlusion in the aspiration line 28, such as at the tip 29 of the handpiece 20, a vacuum results in the aspiration line 28 as the pump 26 continues to exert a suction force thereto. This vacuum is relieved or vented by the influx of irrigation fluid along the pressure equalization or vent line 32 which directly communicates between the irrigation line 18 and the aspiration line 28. The vacuum is thereby quickly relieved by the head pressure of the bottle 12 via the vent solenoid or valve 34. This process is called "venting" the system.
The valve 34 is normally closed when the handpiece 20 is being used to aspirate fluid and tissue from a surgical site 16. When a blockage occurs in the aspiration line 28, such as when a tissue fragment occludes the axial bore in the ultrasonic tool of the handpiece 20, the increased suction in the aspiration line 28 is sensed by the pressure sensitive transducer apparatus 36, which in turn sends a signal to shut off the pump 26. The surgeon can then release the vacuum in the aspiration line 28 by momentarily opening the valve 34 to admit irrigation fluid from bottle 12 to the aspiration line 28 via the vent line 32 and through a special fitting 38 such as is shown and described in detail in U.S. Pat. No. 4,832,685. As soon as the pressure has been equalized, the transducer apparatus 36 detects the lower level of suction or vacuum and allows the surgeon to restart the pump 26. When the valve 34 is closed and the surgeon restarts the system, the pump 26 will again draw fluid from the aspiration line 28 and suction will thereby be reapplied to the surgical site. The check valve 24 prevents a backward surge of fluid in the irrigation line 18 when the valve 34 is open to permit irrigation fluid to flow into the aspiration line 28. A filter 37 is provided just upstream of the transducer apparatus 36 to prevent bacteria or ocular tissue from getting into the transducer apparatus.
In fluid control systems which vent to air rather than to fluid, such as described in the Kelman and Weiss patents, when a blockage occurs in the aspiration line and the increased suction is sensed by the pressure-sensitive transducer apparatus, the transducer signals the vent to flutter (to open and close rapidly), but the pump is not deactivated. The surgeon can then deactivate the pump and fully vent the system.
Referring now to FIG. 2, a prior art transducer apparatus 136 is illustrated. Fluid from the aspiration line 28 enters through fluid connector 110 and is divided between fluid lines 112 and 114, which each lead to pressure-sensing means 150. When the fluid system is operational, the fluid connector 110 and fluid lines 112 and 114 are filled with air and fluid, unlike the aspiration line, which is essentially filled with fluid only. This is because fluid lines 112 and 114 dead-end at pressure-sensing means 150; therefore, there is some residual air left in the transducer apparatus 136.
When the fluid system 10 vents, the irrigation fluid flowing through the vent line 32 and then through the aspiration line 28, creates a transient fluid wave. When the wave reaches the transducer apparatus 136, it impacts with full force on the delicate pressure-sensing means 150 (thus creating a "water hammer"). Due to the high levels of kinetic energy present in such transient fluid waves, this repeated hammering on the transducer apparatus 136 usually results in the destruction of the pressure-sensing means 150, as well as the surrounding circuitry. In fact, one water hammer of sufficient magnitude may cause the destruction of the pressure-sensing means 150.
Referring now to FIG. 3, the preferred embodiment of the invention is illustrated. The delicate pressure-sensing means 250 are now configured such that transient fluid waves will not impact with full force upon the pressure-sensing means 250; rather, the fluid enters fluid connector 210 and splits at the Y-junction to flow into fluid lines 212 and 214 which connect to dampening means 216, where the water hammer expends a portion of the kinetic energy contained therein by impacting against itself. Although fluid lines 212 and 214 also connect to fluid lines 218 and 220, which are in turn connected to the pressure-sensing means 250, the transient fluid waves coming from fluid lines 212 and 214 will flow into the dampening means 216 rather than into fluid lines 218 and 220, since fluid has a tendency to maintain a constant flow direction.
The invention has been described by reference to certain preferred embodiments; however, it should be understood that it may be embodied in other specific forms or variations thereof without departing from its spirit or essential characteristics. The embodiments described above are therefore considered to be illustrative in all respects and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description.
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An improvement to a flow control system is disclosed which comprises a transducer apparatus having dampening means to prevent or reduce the destructive effect of water hammers in such fluid control systems. This is especially useful in surgical irrigation and aspiration systems. The dampening means functions by diverting the transient fluid waves away from the delicate pressure-sensing means until a portion of the kinetic energy contained therein is dispersed.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to filters and more particularly to radio frequency RF filter arrangements formed using printed circuit board techniques.
BACKGROUND OF THE INVENTION
[0002] Radio frequency (RF) filter apparatus incorporating one or more radio frequency radiator elements, for example, constructed from helical wire or rod conductors to produce frequency dependent filter arrangements are known in the art. Typically, filter arrangements employing conductive rod and machined rod conductive elements form a frequency dependent resonator circuit to condition radio frequency signals passing through the filter. A general description of the construction and tuning of certain types of RF radiator resonant filter assemblies is given our issued U.S. Pat. No. 6,064,285.
[0003] Heretofore, construction of rod type RF radiator resonant filters required the supply and production of one or more rod elements machined into the form required to provide the desired filter characteristics of a resonator filter. Supply and production of the rod elements employ construction methods that have several disadvantages in the context of a printed circuit board production facility including the need to produce metal conductors of the required structural dimensions to construct and mount the rods of the filter.
[0004] Construction of RF filters in this manner has several disadvantages. The complexity and cost of producing printed circuit board assemblies could be reduced if the need for machined rods and the mounting steps consequent on use of such rods in producing an RF is eliminated. Furthermore, the cost of producing printed circuit board assemblies that include RF filters could be reduced if the need for rod forming and mounting equipment could be eliminated. Accordingly, there exists a need for implementation of resonator filters which do not require the supply of conductor rods to form the structure of an RF filter.
SUMMARY OF THE INVENTION
[0005] The present invention provides an RF filter apparatus constructed using printed circuit board techniques and materials. In accordance with the invention, an RF filter is fabricated using the equipment, materials and production methods as used to produce a printed circuit board assembly. In accordance with the manner of construction of an RF filter using the principles of the present invention, the need to provide conductive rods to construct a resonator filter is eliminated. Moreover, with the present invention, radiator type RF filters can be produced without the need to provide equipment to form rod conductors.
[0006] The invention is characterised by an RF filter arrangement constructed from radiators fabricated from printed circuit board materials in accordance with the invention and has a radio frequency (RF) shielding enclosure bounding a volume enclosing the filter assembly. The shielding enclosure forms a single cavity eliminating the need or requirement for inner walls to form apertures to control the RF coupling between adjacent radiators.
[0007] Other characteristics of the invention include at least one elongate conductive element that is coupled to the shielding enclosure and extends inwardly into the volume bounded by the shielding enclosure. The free end of the elongate conductive element is disposed proximal to a radiator or between adjacent radiators to control the RF signal filtering effected by the radiator and the RF coupling between adjacent radiators. The shape, length, mass and positioning of the conductive elements are selected to obtain the operation of the RF filter in accordance with the characteristics desired for requirements of the application in which the filter will be incorporated.
[0008] In one of its aspects, the invention provides a radio frequency (RF) filter assembly having a conductive RF shielding means bounding a volume. At least two spacedly disposed elongate radiator elements are disposed within the volume bounded by the conductive RF shielding means. Each elongate radiator element is oriented in a common plane and is substantially parallel to another and one end of each elongate radiator element being is attached to the shielding means. An input tap line is connected at a predetermined input location to a first radiator element disposed proximal to said conductive RF shielding means. The input tap line extends outwardly through to the exterior of the conductive RF shielding means. An output tap line is connected at a predetermined output location to a second radiator element disposed proximal to the conductive RF shielding means and remote from the first radiator element. The output tap line extends through to the exterior of the conductive RF shielding means.
[0009] In another of its aspects, the invention provides, a radio frequency (RF) filter assembly comprising at least two spacedly disposed elongate radiator elements formed from double sided PCB material and includes means to electrically interconnect each side of said radiator double sided PCB material. Shielding means bounding a volume containing all said elongate radiator elements. Spacing means maintain the spaced disposition of each elongate radiator element to the other and to said shielding means. Conductor means interconnects an end of each elongate radiator element to the conductive RF shielding means. An input tap line is connected to a first radiator element at a predetermined input location and extends outwardly through to the exterior of the conductive RF shielding means. An output tap line is connected to a second radiator element remote from the first radiator element at a predetermined output location. The output tap line extends through to the exterior of the conductive RF shielding means.
[0010] These and other objects and advantages of the present invention will become apparent to those skilled in the art in the context of the present invention as described in the specification, drawings and claims herein. Referring to the drawings, like reference numerals identify like features of the invention in the several figures throughout. The preferred embodiments of the invention will now be described with reference to the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a bottom plan view of a filter and shielding apparatus constructed in accordance with the principles invention;
[0012] [0012]FIG. 2 is a top plan view of a mounted shielding can of FIG. 1;
[0013] [0013]FIG. 3 is a cross-section of the mounted shielding can of FIG. 2 taken along cutting line 3 - 3 including a cross section through one of the filter radiator elements;
[0014] [0014]FIG. 4 is a plan view of an alternate embodiment of a filter apparatus of the invention;
[0015] [0015]FIG. 5 is a cross-section of the radiator structure of FIG. 2 including mounted shielding apparatus and showing a filter radiator element in cross-section;
[0016] [0016]FIG. 6 is a top plan view of an alternate embodiment of a filter apparatus constructed in accordance with the principles of the invention;
[0017] [0017]FIG. 7 is a bottom plan view of the embodiment of FIG. 6;
[0018] [0018]FIG. 8 is a top plan view of the embodiment of the filter apparatus of FIG. 6 including an overlay printed circuit board;
[0019] [0019]FIG. 9 is a cross-section of the filter arrangement of FIG. 8, further including mounted shielding cans;
[0020] [0020]FIG. 10 is a graph showing representative insertion loss and return loss characteristics of an RF filter constructed in accordance with the principles of the invention.
[0021] [0021]FIG. 11 is a bottom plan view of an alternate embodiment of a filter and shielding apparatus constructed in accordance with the principles invention;
[0022] [0022]FIG. 12 is a graph showing representative insertion loss and return loss characteristics of an RF filter constructed using the alternate embodiment of FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] [0023]FIG. 1 shows a bottom plan view of an RF filter, designated generally by reference numeral 10 , that is constructed in accordance with the principles of present invention. In the embodiment depicted in FIG. 1, the filter 10 is constructed with five radiator elements 12 . It is not necessary for the structural features of each of the radiators to be identical. The radiator elements 12 are constructed from a printed circuit board (PCB) 14 material, where each side of the PCB is printed with a surface conductor 24 . A printed circuit board with surface conductors on both sides is typically referred to as a double sided printed circuit board. The surface conductors 24 of the PCB 14 are configured to form an elongate conductor for each of the radiator elements 12 . Preferably, a web 15 of the nonconductive PCB substrate material provides a structure to link and orient each radiator element 12 to the other. Generally, each of the radiator elements 12 will extend in a substantially parallel orientation or configuration to the other. A shielding enclosure, for example shielding can 16 , encloses the radiator elements 12 to confine the RF electromagnetic radiation emanating from them to remain within the volume of the cavity formed by shielding can 16 . In each radiator element 12 , the surface conductor 24 on each side of the PCB is electrically coupled to the surface conductor on the other opposed side, for example, by a plurality of plated-through apertures 26 . To couple each surface conductor to the other in this fashion, the apertures 26 are drilled through the PCB substrate 14 and a conductive material is deposited in each aperture to interconnect the surface conductors on each side of the PCB board.
[0024] For RF filter assemblies, it is necessary for each of the radiator elements 12 to couple radio frequency energy to the next adjacent radiator to pass the RF signal to be filtered from the signal input lead 28 to the signal output lead 30 . In the RF filter depicted in FIG. 1, a plurality of radiator elements, namely five radiator elements 12 are depicted. Other radiator element counts may be used, for example, five or some other efficacious count. The signal from the input lead 28 is supplied to a first radiator element by means of an input tap line 32 . An input tap line 32 connects the input lead 28 to a first radiator element 12 a at a predetermined location along the length of the first radiator element 12 a . The location of the input tap line relative to the base end 34 of the radiator element 12 a affects the input impedance presented by input tap line 32 . The input tap line location is selected in the filter design to provide a desired impedance match to the circuitry supplying the input signal to input lead 28 . The base end 34 of each of the radiator elements 12 is grounded, for example, to shielding can 16 , to complete the signal supply circuit of the filter that provides an input signal to the radiator element 12 a on the input tap line 32 . The presence of an input radio frequency signal on input supply line 28 causes an electromagnetic (EM) field to radiate from the radiator element 12 a and extend into the space surrounding the radiator in accordance with principles of EM fields. The EM field emanating from each radiator will couple to the next adjacent radiator, that is, RF coupling is provided in the filter between radiators 12 a , 12 b , 12 c , 12 d and 12 e . A shielding can 16 is connected to a ground plane conductor 18 to form a shielding enclosure, that is a conductive enclosure surrounding all of the radiators 12 .
[0025] [0025]FIG. 2 shows a plan view of the filter apparatus of FIG. 1 from the opposite side to that shown in FIG. 1. The filter apparatus 10 is mounted on a ground plane 18 . The signal to be filtered is supplied into the RF filter on input lead 28 . The filtered output signal is provided on output lead 30 . Shielding can 16 is affixed to a ground plane 18 , preferably by soldering which provides both mechanical and electrical coupling. A skirt 40 may be provided to provide an ample structure to assist in affixing and coupling the shielding can 16 to the ground plane 18 .
[0026] [0026]FIG. 3 is a cross-section of the RF filter of FIGS. 1 and 2 taken along the cutting line 3 - 3 of FIG. 2. The filter assembly includes a surrounding electrically conductive structure that is maintained at ground potential. In this embodiment of the RF filter, the surrounding shielding enclosure, is a conductive structure is comprised of a shielding can 16 and a ground plane 18 to which the shielding can 16 is mounted. Ground plane 18 is the conductive material on a surface of the PCB substrate 36 . A radiator element 12 is shown in cross section in the figure and comprises a PCB structure having a surface conductor 24 on each of the opposed sides of the PCB as described previously with reference to FIG. 1. A plurality of apertures 26 are plated through to interconnect electrically the surface conductors 24 disposed on each side of the PCB formed into the radiator element. Each radiator element 12 is in spaced relation to the surrounding ground potential surfaces, which is achieved by attaching the radiator elements 12 to the shielding can 16 such that each radiator element is oriented substantially parallel to the planar surface of can 16 and the ground plane 18 . Suitable means of attachment include soldering the conductive surface 24 of the radiator element to the shielding can 16 . Soldering also provides the electrical connection to maintain one end of each of the radiator elements 12 at ground potential as well as providing the mechanical structure to maintain the orientation of the radiator elements 12 with respect to shielding can 16 and ground plane 18 . For additional means to control filter tuning, conductive leads 20 , 21 and 22 may be used. When such conductive leads are used, each extends from either ground surface 18 or shielding can 16 inwardly toward the central portion of the enclosure proximal to radiator elements 12 .
[0027] Tuning of the filter is effected by variation of the filter elements, for example, by selection of a radiator shape and by the spacing configuration of the radiators to each other and to the surrounding grounded surfaces, most clearly shown in FIG. 3, namely, ground plane 18 and shielding can 16 . Also, filter tuning is affected by the dimension and the placement of conductive leads 20 , 21 and 22 . When conductive leads are used, the conductive leads are connected at one end to ground potential, that is, connected either to the shielding can 16 or to the ground plane conductor 18 . The other end of the conductive leads, the end opposed to the grounded end, extends inwardly toward the radiator elements 12 in the central portion of the cavity or volume of the grounded enclosure.
[0028] Each conductive lead element 20 , 21 or 22 is preferably in the form of a wire to allow and the design specification of the items that affect EM coupling and filter behaviour by parameters such as: wire material, wire gauge, wire length and wire location. Also, these conductive lead elements may be constructed from a ferromagnetic material.
[0029] Thus, from the foregoing, the following factors can be varied to affect the tuning of the filter, that is:
[0030] (1) the dimension of the radiator elements 12 ,
[0031] (2) the spacing of the radiator elements from each other,
[0032] (3) the spacing of the radiator elements from the ground potential surfaces, that is, from the shielding can 16 and the opposed ground plane 18 , and
[0033] (4) the presence, dimension and location of tuning element conductive leads 20 , 21 and 22 .
[0034] Examples of the conductive elements 20 , 21 and 22 show locations where such conductive elements may be mounted in the shielding enclosure of this embodiment of the invention. The conductive elements may be of a fixed length and location, such as conductive elements 20 and 21 and the conductive elements may be attached to the shielding enclosure by soldering. The conductive elements may also be adjustable by providing suitable adjustment means. An example of a tuneable tuning element is conductive element 22 which is provided with a threaded body threaded into a nut 23 . Naturally, a screw type threaded body of conductive element 22 threadingly engaging the passage through PCB 36 and ground plane 18 would eliminate the need to provide a separate nut. Tuning adjustment is effected by rotation of the exterior portion 25 of the conductive element which changes the length of conductive element 22 disposed in the interior volume of the shielding enclosure.
[0035] [0035]FIG. 4 is a plan view of an alternate embodiment of construction of a PCB RF filter apparatus in accordance with the principles of the invention. A double sided printed circuit board 42 is formed into each of the radiator elements 12 of the filter. In this embodiment of the RF filter, the surface conductor 24 of each radiator element 12 extends from the ground plane conductor 18 as, in this embodiment, the radiator elements and the ground plane 16 are constructed from a single piece of printed circuit board material. An input tap line 32 and an output tap line 33 extend from the outside radiator elements 12 a and 12 e . The footprint of the mounted shielding can is shown in ghost outline form 42 in the figure.
[0036] [0036]FIG. 5 is a cross-section of the embodiment of the RF filter construction of FIG. 4 showing the mounted shielding cans 16 . One shielding can 16 a is mounted on one side of the apparatus and the other shielding can 16 b is mounted on the other side of the PCB 42 from which the radiator elements 12 are constructed. The PCB 42 has a plated surface conductor on both sides, which provides the ground surfaces 18 to which the shielding cans 16 are mounted. In this manner, the volume enclosed by the shielding cans 16 a and 16 b surrounds the radiator elements 12 and, consequently, the shielding cans enclose and contain the RF radiation emitted from the radiator elements 12 . The shielding cans 16 a and 16 b are preferably solder mounted to the ground plane 18 on each respective side of the PCB 42 to provide electrical contact and a mechanical attachment of each shielding can 16 to the PCB board.
[0037] A variation of construction of a tuneable conductive element and 22 is shown in this embodiment. In this arrangement, the threaded nut 23 is shown mounted on the exterior of shielding can 16 b.
[0038] [0038]FIG. 6 shows a top plan view of an alternate embodiment of the RF filter apparatus of the present invention which employs a two board construction. In this embodiment, the radiator elements 12 are fabricated from a first double sided printed circuit board 14 by fabricating the printed circuit board material to form each of the radiators 12 a , 12 b , 12 c , 12 d and 12 e . Similar to other embodiments, each radiator element has plated through apertures 26 interconnecting the conductors on each opposed side of the PCB forming the radiators 12 . Also in this embodiment, the radiator elements 12 are formed from a single PCB board which also forms a surrounding ground plane 18 . Consequently, the inter-radiator web 15 of FIG. 1 is not required in this embodiment. The input tap line 32 and output tap line 33 are etched into the printed circuit board at a predetermined distance from the base area 44 of the respective radiator 12 a and 12 e and one end of each tap line 32 , 33 is connected to a corresponding radiator element. The other ends of the tap lines 32 and 33 extend outside of the shielding can mount footprint 42 . That is, an end of each of input tap line 32 and output tap line 33 will extend outside of the mounted shielding can 16 . Extension of the input tap line and output tap line 32 and 33 respectively to the exterior of the shielding can permits interconnection of the tap lines with the input and output leads exterior to the shielding can, as shown in FIGS. 8 and 9.
[0039] Construction of the radiator elements in accordance with the embodiment of the invention shown in FIGS. 6 and 7 uses a two board, or multi-layer PCB, arrangement to provide an input lead trace 28 exterior to the shielding can 16 . Similarly, an output lead trace 30 is provided exterior to the shielding can 16 . As will be describe in more detail subsequently, this embodiment of the invention permits installation of signal lead wires exterior to the shielding can and, consequently, enables the signal lead wires to be mounted before or after the shielding can is mounted.
[0040] [0040]FIG. 7 shows a bottom plan view of the structure of FIG. 6.
[0041] [0041]FIG. 8 shows an upper plan view corresponding to that of FIG. 6 and further includes a second PCB 46 mounted to the PCB of FIGS. 6 and 7.
[0042] As most clearly depicted in FIG. 9, the second PCB 46 is coupled to the upper surface of the PCB board 14 from which the radiator elements 12 , shown in FIGS. 6 and 7, are constructed. The filter input lead 28 is interconnected with input tap line 32 to provide a signal path to radiator element 12 a . The filtered signal arriving at radiator element 12 e is carried by output tap line 33 to output lead 30 . An upper shielding can 16 a and a lower shielding can 16 b are attached to the printed circuit boards 14 and 46 to provide an enclosure surrounding radiator elements 12 of the resonant filter structure. Ground leads 20 , 22 , may be attached to the shielding cans 16 a or 16 b to facilitate tuning of the filter.
[0043] [0043]FIG. 10 is a graph showing the electrical characteristics of an RF filter constructed in accordance with the principles of the invention. The RF filter provides a bandpass region centred around the 2.34 GHz frequency. Signal frequencies below the lower cut-off frequency at approximately 2.32 GHz roll off to approximately a 45 dB insertion loss at 2.28 GHz. The filter transmission frequency response characteristics or insertion loss above the upper cut-off frequency at approximately 2.35 GHz falls off more to −50 dB by approximately 2.4 GHz as depicted in the drawings.
[0044] Another filter characteristic shown in the graph is a trace of the filter signal reflection performance for given frequencies which is also known as the filter return loss. Return loss is a measure of the power transfer of a filter and the filter return loss trace in the figure shows peaks on either side of the filter bandpass, at approximately 2.33 GHz and 2.35 GHz. The graph of FIG. 10 is shown by way of illustration only of the characteristics of a filter constructed in accordance with the principles of the invention. Naturally, the frequency response characteristics of a filter constructed in accordance with the principles of the invention can be altered by changing the shape of the radiator elements and their location relative to each other and to the shielding can. As well, the shape, location and orientation of tuning conductive leads can be employed as previously described with reference to FIGS. 3 and 5 of the drawings.
[0045] [0045]FIG. 11 shows a bottom plan view of an alternate embodiment of an RF filter, designated generally by reference numeral 10 , that is constructed in accordance with the principles of present invention. In the embodiment depicted in FIG. 11, the filter 10 is constructed with three radiator elements 12 . It is not necessary for the structural features of each of the radiators to be identical. The radiator elements 12 are constructed from a printed circuit board (PCB) 14 material, where each side of the PCB is printed with a surface conductor 24 . A printed circuit board with surface conductors on both sides is typically referred to as a double sided printed circuit board. The surface conductors 24 of the PCB 14 are configured to form an elongate conductor for each of the radiator elements 12 . Preferably, a web 15 of the non-conductive PCB substrate material provides a structure to link and orient each radiator element 12 to the other. Generally, each of the radiator elements 12 will extend in a substantially parallel orientation or configuration to the other. A shielding enclosure, for example shielding can 16 , encloses the radiator elements 12 to confine the RF electromagnetic radiation emanating from them to remain within the volume of the cavity formed by shielding can 16 . In each radiator element 12 , the surface conductor 24 on each side of the PCB is electrically coupled to the surface conductor on the other opposed side, for example, by a plurality of plated-through apertures 26 . To couple each surface conductor to the other in this fashion, the apertures 26 are drilled through the PCB substrate 14 and a conductive material is deposited in each aperture to interconnect the surface conductors on each side of the PCB board.
[0046] [0046]FIG. 12 is a graph showing the electrical characteristics of an RF filter constructed in accordance with the principles of the invention. The RF filter provides a bandpass region centred around the 2.3 GHz frequency. Signal frequencies below 2.3 GHz roll off to approximately a 15 dB insertion loss at 2.05 GHz. The insertion loss or frequency response above 2.3 GHz falls off more dramatically to a trough located at approximately 2.45 GHz as depicted in the drawings.
[0047] While the invention has been disclosed with reference to the particular embodiments disclosed in the description and drawings hereof, it will be apparent to those skilled in the art that many modifications and substitutions may be made to the specific embodiments herein described without departing from the spirit and scope of the invention as defined in the claims appended hereto.
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An RF filter includes elongate radiator elements constructed from printed circuit board (PCB) materials and using PCB fabrication techniques. The radiator elements are spacedly disposed and contained within a shielded enclosure. The filter apparatus has input and output leads exterior to the filter to pass a signal to be filtered. The filter is tuned by the shape and of the elongate radiator elements and shielded enclose and by conductive leads extending from the shielded enclosure toward the elongate radiator elements. The shape and number of the conductive lead elements may be varied to control RF coupling between radiator elements and the tuning of the filter.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to optical information processing and, more particularly, to the sorting and classification of radio frequency signals and the excision of interference.
2. Discussion of the Prior Art
A given signal waveform usually consists of the signal of interest and interference. The signal and interference composite is a current or voltage waveform which is a function of time. Usually, only the signal without interference is of concern, and more specifically, only certain frequencies of the given signal are of concern; therefore, it is necessary to extract the useful information and isolate the desired frequencies from the composite signal.
A receiver has the job of extracting source information from a received modulated signal which has in some form been corrupted by interference. A modulated signal is originally a bandpass signal with a given carrier frequency that has been encoded with source information by the process of modulation. Standard receivers employ the superheterodyne receiving technique. This technique consists of either up-converting or down-converting the input signal to some convenient frequency band, and then extracting the encoded information by using the appropriate detector. Filtering in the superheterodyne receiver is done at the original radio frequency and at the up or down converted frequency.
It has been shown that maximum probability of detection of a signal occurs when it is processed with a matched filter. Basically, the purpose of a matched filter is to characterize an incoming waveform based on a predetermined signal waveshape as determined by the transfer function of the matched filter. In other words, a matched filter is used to detect the presence of a particular signal based on the characteristics of that particular signal. The objective of a matched filter system is to weight the input signal waveform and filter the interference so that at the sampling time the output signal level will be as large as possible with respect to the Root Mean Square (RMS) of the output noise level. A matched filter is therefore a linear filter that minimizes the noise level while maximizing the signal level. In applications employing matched filter filtering systems, the signal may or may not be present, but if it is present, its waveshape must be completely or nearly completely characterized. When the waveshape is not known, or not completely characterized, a search for a signal generally means that conditions for intercept will be less than ideal. That is, the filter pass band must be large enough to pass all frequencies of all possible signals with the most generalized response, clearly not a matched filter.
Broadband receivers often have to function in dense signal and noise environments. The job of a filtering system or receiver is to sort, classify and remove interference, such as noise, from signals of interest (SOI). The interference may be characterized as noise from the outside world and disturbances from the electronic components as well as mechanical components of the system itself. To enhance the filtering function it would be highly desirable to perform real-time parallel signal processing to effectively channelize and remove unwanted spectra from the SOI's. This would in effect transform a single channel that is corrupted with unwanted signals, interference and noise to a specific number of discrete channels where each is tailored to selected SOI's.
The accepted practice has been to electronically filter the given signals. It has been found, however, that electronic filtering means have a number of distinct disadvantages. Inherent in electronic filters is the problem of phase distortion and non-linear effects. In addition, electronic filters are also susceptable to noise corruption; therefore, other techniques such as optical filtering of signals have increasingly become of interest.
The prior art shows a number of examples of optical systems for the detection and/or removal of interference and unwanted frequencies from given SOI's. U.S. Pat. No. 4,645,300, assigned to the same assignee as the present invention, discloses a Fourier Plane Recursive Optical Filter which is used to recursively pass a given signal beam a multiplicity of times through a single optical spatial filter such that the attenuation of unwanted signal frequencies is multiplied. However, the aforementioned invention does not exploit the advantages of parallel processing.
U.S. Pat. No. 3,671,106, discloses an Optical Multiplex Filter System which is used for optical data processing. The object of the invention is to distribute data over a large number of parallel transmission channels in which the data passes through optical filters that process the data in a described manner. However, the aforementioned invention does not provide the filtered signals at their original radio frequencies.
U.S. Pat. No. 4,699,466, assigned to the same assignee as the present invention, discloses an Optical RF Filtering System which is used as an optical notching filter in which a band of radio frequencies such as the RF input of a radio receiver is an input signal. This invention provides adaptive programmable spatial filtering techniques in which an optical filter is programmed to notch out spikes. However, the aforementioned patent does not provide matched filter capabilities.
SUMMARY OF THE INVENTION
The present invention is directed to a multi-channel receiver system for processing large numbers of signals in real time by modulating a coherent optical radiation beam with incoming RF signals, channelizing the signals and providing adaptive real-time filtering. The adaptive real-time filtering is accomplished through the use of an electronic controller which has the capability to automatically or interactively control various parameters of the filters. The incoming RF signals are modulated onto a carrier laser beam by means of an acousto-optic modulator. The resulting modulated RF signals are Fourier transformed and channelized to produce nxm number of discrete channels of the RF spectra. The nxm channels of the RF spectra are then passed through a beam splitting means in order to produce two identical arrays of the RF spectra. Each array is then passed through an identical programmable spatial filter (PSF). Each PSF is used to adaptively filter the incoming signal array by physically blocking unwanted frequencies. The filtered signal arrays are then down converted to their original radio frequencies by means of optical heterodyning. One down converted signal array is available for further processing such as in signal detection networks or for archival recording of the filtering signal for dissementation to other systems, while the other array is used by an operator or automatic controller. The operator or automatic controller can structure each channel of the programmable spatial filter with any desired strategy to maximize detection of the signal in real-time. The particular strategy can be preprogrammed to try frequency scans over a specific frequency range, or real time operator instructions can be utilized to try different filter frequencies or shapes. The electronic controller configures the programmable spatial filters in order to achieve matched filter operation at the receiver.
The multi-channel receiver system of the present invention provides for the detection and classification of an incoming band of signals by dedicating an optical channel for each specific SOI intercept. The multi-channel receiver of the present invention approaches 100 percent SOI intercept probability by providing a selected number of responses throughout an operating band where matching the response to the signal would come closer to an ideal matched filter.
The multi-channel receiver can be used for intelligence gathering and recording and for sorting and filtering through radio frequency spectra to reduce bottlenecks in downstream serial processing.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings the forms which are presently preferred; however, it should be understood that the invention is not necessarily limited to the precise arrangements and instrumentalities here shown.
FIG. 1 is a block diagram of the multi-channel receiver system of the present invention.
FIG. 2 is a schematic diagram of a programmable spatial filter embodied in the invention.
FIG. 3 is a schematic diagram showing the liquid crystal filter elements of the filter of FIG. 2 in greater detail.
FIG. 4 is a block diagram of the control system employed by the multi-channel receiver system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The multi-channel receiver system of the present invention optically filters and classifies incoming radio frequency (RF) signals by dedicating a channel for each specific signal of interest (SOI) and selectively rejecting unwanted frequencies and noise. In the multi-channel receiver system, a beam of substantially coherent light is modulated by a spectrum of RF SOI's and transformed into the Fourier domain. The modulated light beam is channelized into a plurality of channels, each corresponding to a preselected RF spectral component of the spectrum of interest. The resulting channelized signals are then divided into two identical arrays of the RF spectra. Each array is then passed through identical programmable spatial filters. The programmable spatial filters are used to selectively reject unwanted frequencies and interference. The two arrays of filtered RF spectra are then down converted to their original radio frequencies by means of optical heterodyning. One array of down converted signals is available for further signal processing systems or archival recording, while the other array is directed a to control system that can structure each channel of the programmable spatial filters with a particular strategy to maximize detection of the signal of interest.
Referring now to FIG. 1, there is shown a schematic diagram illustrating the multi-channel receiver 10 architecture. An electromagnetic radiation source 12 produces a substantially coherent electromagnetic radiation wave or light beam 14 with a given wave length. The electromagnetic radiation source 12 can be a gas laser such as a helium neon gas laser or a semiconductor laser such as a laser diode. Operating efficiency is greater with single-frequency laser operation which can be obtained with most semiconductor lasers, or if a gas laser is used that does not provide acceptable single-frequency laser operation, an intra or extra cavity Farby Perot interferometer structure can be added.
The substantially coherent electromagnetic radiation light beam 14 is passed through a first beam splitter 16 in order to produce two beams 18 and 20 from the one incoming beam. Beam 18 is used as the carrier beam in the filtering system and beam 20 is used as a local oscillator beam in the down conversion process. Alternatively, the zero order term of acousto-optic modulator (AOM) 30 can be extracted at the output of the AOM 30 and used as the local oscillator beam 20. The principles of operation of the AOM 30 will be described below. The carrier beam 18 is then passed through a wave plate 22 in order to adjust the polarization of the incoming beam 18. It should be noted that the various components of the multi-channel receiver system affect the polarization of the radiation; therefore, it is necessary to maintain the equivalent polarization throughout the device in order to ensure proper down conversion. The properly polarized light beam 24 is then brought incident onto a cylindrical lens 26 in order to develop a one-dimensional sheet beam 28 for entrance into the AOM 30.
The AOM 30 is a complex light modulator which transforms a radio frequency signal to an acoustic wave which modulates the refractive index of the optical material, thereby producing a phase modulated medium manifested periodic with the radio frequency signal. The modulated medium appears to the incident laser beam as a dynamic phase grating which produces a zero order signal, a first order signal, and depending upon operating regions sometimes higher orders, emerging as an exciting beam where angular deflection is proportional to the radio frequency signal. When light from a radiation source is transmitted at an appropriate angle through a medium which is transparent to light and through which an ultrasonic wave is propagated and the refractive index of the medium is varied periodically with time, the light is diffracted. At this time, the frequency of the light beam is shifted by the number of vibrations of the ultrasonic wave. This is accomplished when an incoming RF signal produces an electric field across a transducer (i.e. piezoelectric crystal transducer) which creates a strain proportional to the incoming RF signal. This strain is the aforementioned ultrasonic wave. The result most closely resembles a narrow band phase modulated signal. A Bragg Cell may be used for imposing the RF signal spectral intellegence on the carrier beam 26 in the form of narrow beam phase modulation. If a Bragg Cell is used for the AOM 30, it typically comprises an optical medium such as a crystal element driven by an appropriate transducer. A further description of the AOM 30 is given in U.S. Pat. No. 4,699,466 assigned to the same assignee as the present invention and incorporated herein by reference.
In the receiver system of the invention, an RF signal is brought into the AOM 30 by an RF amplifier 32. The output of the AOM 30 is a narrow band phase modulated beam 34 that is the first order signal. The modulated beam 34 is then input to a second cylindrical lens 36 in order to develop a two-dimensional sheet beam 38. The two-dimensional sheet beam 38 is directed to a multiple holographic lens (MHL) 40. The MHL 40 is fabricated in a known manner such as that described in U.S. Pat. No. 4,421,379 assigned to the same assignee as the present invention. The MHL 40 divides the modulated sheet beam 38 into a plurality of distinct channels in the form of an array 42. In addition, the MHL 40 performs an optical Fourier transform of the incident modulated beam 38, so that the array of channels contain the spectra of the original incoming RF signal.
The array of transformed beams or RF spectra 42, now in the spatial frequency domain, are then directed into a beam splitter/combiner 44, which is an optical cube, where it is summed with the local oscillator beam 20 and split into two identical arrays 46 and 48 for further processing. The beam 20 is directed to the beam splitter/combiner 44 by reflective elements, such as mirrors 21 and 23 respectively. The composite arrays 46 and 48 each pass through programmable spatial filters 50 and 52 respectively.
In one embodiment, each of the PSF's 50 and 52 is essentially a comb filter (see FIGS. 2 and 3) having liquid crystal teeth like columns or segments 53 arranged linearly on a suitable transparent plate 54 having a transparent backplane 55 in the path of the transformed radiation passing through the beam splitter/combiner 44. Each liquid crystal segment or element 53 is connected by means of conductors 56 and 57 to terminals 58 and 59 on the edges 60 and 61 respectively of plate 54 such that connections can be made thereto for passing an electric current selectively through the segments. Terminals 58 and 59 are suitably plugged into terminating means (not shown) in electrical conduit 60 such that the PSF's 50 and 52 are in circuit with the electronic controller 70. Different types of liquid crystal materials are available to obtain a variety of effects. The elements can be activated to block a signal or deactivated to pass the signal. Each channel of the PSF 50 and 52 is specifically tailored for each incoming signal of interest. Specifically, the pass characteristics of each PSF can be formed for narrowband, broadband, discontinuous and disjoint spectra as well as for notching or passing spectral bands. The PSF's 50 and 52 can be reconfigured or re-programmed in near real-time (as fast as the photoconductive surfaces's permit) either remotely or on site.
In the PSF, each segment or element corresponds to a narrow RF frequency band. In a practical embodiment of the invention, 256 segments which can be selectively activated, as required, in any combination, are provided. It will be appreciated that a number of segments greater or fewer than 256 can be provided if the application so dictates. When not activated, the PSF is highly transmissive optically and passes incident radiation substantially unchanged to the photomixer arrays. However, when a segment is activated by an electrical signal from the filter activation system, the change in alignment of the constituent crystals in the liquid crystal due to the imposed electrical field renders the element opaque. This blocks the passage of light therethrough to thus notch out radiation of a narrow frequency band of the signal spectrum. In liquid crystals, as is well known, optical attenuation is achieved by cross-polarization, or scattering, or the like. To simplify the explanation of the invention, however, the liquid crystal segments will be said to have been rendered opaque by the imposition of an electrical field thereon irrespective of the phenomenon, whether it be scattering or the like, that is actually involved in the optical attenuation. U.S. Pat. No. 4,699,466 assigned to the same assignee as the present invention contains a description of the use and operation of a PSF as an optical notching filter.
Referring again to FIG. 1, the filtered composite beam arrays 46 and 48 are down converted at detectors 62 and 64, which are mated with the respective PSF 50 and 52. The actual down conversion is done optically and is well known in the art. The local oscillator (LO) beam 20 is summed with the modulated radiation beam 42 at the beam combiner 44. The filtered version of this composite beam is now down converted at the detectors 62 and 64, which may be photomixer arrays that respond as an intensity detector, squaring the sum of the light amplitude. The detectors 62 and 64, must be operatively associated preferably with a specific one of the linear liquid crystal segments or elements of the PSF's 50 and 52. The output arrays 66 and 68 of the detectors 62 and 64 contain a dc term proportional to each light intensity (LO and signal) and a RF term which corresponds to the difference in frequency of the LO beam 20 and the modulated radiation signal beam 42. The various channelized output signals 66 and 68 are available at the original radio frequencies with only the pass characteristics altered.
In another embodiment the detectors 62 and 64 are photo charged-coupled device (CCD) arrays. The CCD arrays 62 and 64 are composed of a linear arrangement of photosensitive CCD elements, the outputs of which are fed into a suitable sample and hold register in controller 70. As in the case with the photomixer arrays, each CCD element is operatively associated preferably with a specific one of the linear liquid crystal segments of the PSF's 50 and 52. Each CCD element will represent some specific frequency band of the spread frequency spectrum to the RF signal imposed by the AOM on the radiation beam and will be associated with a liquid crystal segment representing the same frequency band in the PSF.
The array of output signals 66 are in the form of responses that are available for further information processing by various detection and capture devices as well as many types of recording devices. The impulse responses of output array 68 are used by a controller 70 to adjust the programming of the PSF 50 and 52 to maximize the probability of signal detection.
The controller 70 can operate in an automatic mode or an interactive mode. In the interactive mode, an operator alters the characteristics of both PSF's 50 and 52 via the controller 70. Through the controller 70, the operator can display the filtered array of signals 48 in the frequency domain. In addition, the operator can annotate the various, parameters of the given signals. In other words, the operator has available quantitative as well as qualitative data available to him. Basically, the operator is viewing the power spectrum information of the given signals.
Based on the given data, the operator can alter the pass characteristics of both PSF's 50 and 52 through the controller 70 and then view the results through the display of the controller 70. The controller 70 can change both the frequency and amplitude of all signals in the arrays 46 and 48. By continuously monitoring the display, the operator can in real time adjust the PSF's 50 and 52 for basically any type of pass structure since the PSF's 50 and 52 are in an electronically addressable architecture as mentioned previously.
In an automatic mode of operation, a computer or microprocessor can be programmed to sequentially try different filter patterns. The controller 70 would interface the PSF's 50 and 52 in an identical manner; however, instead of an operator dictating the filter patterns, they are preprogrammed into the computer or microprocessor. In addition to the sequential pattern, the controller 70 can be programmed to remove selected interferers above predetermined thresholds.
Referring now to FIG. 4, controller 70 is shown in detail. A computer terminal 72 displays the location and status of each receiver channel and provides information on bandwidth, response and notches within that bandpass. By placing an index marker 71 and a cross-hair cursor 73 at a particular location on the screen, the particular PSF 52 channel and segment can be manipulated by an operator to control the above mentioned displayed parameters. The computer or microprocessor associated with terminal 72 and keyboard 74 contains a program that allows this type of manipulation. Basically, the computer program forms a matrix of the channels of the PSF 52 and forms specific commands based on entries into the keyboard 74. The generated commands which are based on operator instructions, contain an address and data word for each multi-channel receiver channel. For the purpose of explaining the operation of the controller 70, a command word is chosen to be 8 bits in length with 3 bits allocated for the address, and 5 bits for data. The number of bits chosen is dictated by the number of channels and the number of segments or fingers in each PSF 50 and 52. For example, a 3 bit address field would accomodate 9 channels whereas 6 bits would accomodate 64 channels, and a 5 bit data field would accomodate a 32 segment PSF whereas a 10 bit data field would accomodate a 1024 segment PSF.
The composite word or command is then separated into its component parts wherein the 5 data bits are routed to a 5 bit counter 76 and a 3 bit address decoder 78. The output of the 5 bit counter 76 and the output of the 3 bit address decoder 78 are then routed to a pair of data transfer devices 80, which are multiplexer circuits or holding registers. Basically, the output of the address decoder 78 is used to direct the data to the designated channel. The data is then transferred from the data transfer devices 80 into a pair of counters and latches 82. The data is used to set a counter whose output is latched to drive the segments of both PSF's 50 and 52 in accordance with the keyboard entry. The output of the counters and latches 82 are connected to the channels of both PSF's 50 and 52. It should be noted that in this embodiment of the controller of the multi-channel receiver, two PSF's are used; however, the controller can be configured to control more than two PSF's.
Although shown and described in what are believed to be the most practical and preferred embodiments, it is apparent that departures from specific methods and designs decribed and shown will suggest themselves to those skilled in the art and may be used without departing from the spirit and scope of the invention. The present invention in not restricted to the particular constructions described and illustrated, but should be constructed to cohere of all modifications that may fall within the scope of the appended claims.
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A multi-channel receiver which exploites the parallel processing advantages of an optical signal processor is used to facilitate 100 percent intercept of an incomming RF signal in a dense RF environment. The receiver performs real time parallel signal processing to effectively capture a given signal of interest. The receiver modulates a laser beam with incoming RF signals. The modulated laser beam is then Fourier transformed, channelized into an array of signals of varying frequencies, optically filtered and then down converted into their original radio frequencies with only the pass characteristics altered so that the captured signal can be readily identified. An electronic controller is used to control the pass structure of the optical filter which can be reconfigured in real time to selectively pass signals having the desired characteristics.
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BACKGROUND
1. Technical Field of this Invention
The present Invention relates to novel devices and methods to minimize the production of sand in subterranean environments. In particular, in poorly consolidated formations, for instance, sand is co-produced along with the desired fluid (e.g., oil); sand production is undesirable, hence in the present Invention, elliptically shaped perforations of a particular orientation (in preferred embodiments) are created through the casing that lines the wellbore (as well as created in an uncased formation) and that penetrate the formation rock, to improve the stability of the perforation tunnel, and therefore minimizing sand intrusion (or the intrusion of disaggregated formation particles generally, in the case of, e.g., carbonate formations).
2. Prior Art
In the production of oil and gas from a subterranean reservoir, one persistent problem in certain types of reservoirs is that sand is also produced along with the hydrocarbon. The present Invention is directed to novel techniques to control the coproduction of sand with hydrocarbons (i.e., “sand control”). Obviously, the goal in oil and gas production is to move the hydrocarbon from the underground formation where it resides, to a wellbore drilled in the earth, and eventually to the surface, for transportation and eventual refining. Many hydrocarbon-bearing formations are sandstone, and many of those are poorly consolidated sandstone, which means that the sand grains that comprise the geologic formation are loosely held together. In certain formations, sand flows from the formation along with the oil—this may occur initially, or later in the life of the well. This “sand production” is highly undesirable. For one thing, sand is a harsh abrasive and so abrades just about everything it comes in contact with—production string (generally steel tubing) lining the wellbore, aboveground pipelines, and so forth. If enough sand is co-produced with the oil then it is not even suitable for processing, or only at substantial additional expense.
Therefore, numerous techniques have evolved to deal with the problem; they are roughly divisible into two categories: mechanical and non-mechanical. The primary mechanical technique is known as “gravel packing.” A particularly sophisticated type of gravel packing is AllPAC, a patented technology jointly developed by Mobil and Schlumberger and exclusively licensed to Schlumberger. (See, e.g., L. G. Jones, Alternate-Path Gravel Packing , SPE 22796 (1991)). The idea behind gravel packing is to place a permeable screen inside the wellbore between the casing (if there is one) and the wellbore, next the annulus formed by the screen and casing/wellbore is filled with gravel. (Alternatively, a screen without gravel is sometimes used; also, sometimes “pre-packed” screens are used, in which the gravel is placed in the screen before it is placed in the wellbore). The purpose of the screen is to hold the gravel in place, and the purpose of the gravel (and screen) is to remove the sand, yet allow the oil (or gas) to migrate through the gravel pack, into the wellbore and eventually to the surface.
Although gravel packing is a venerable sand control technique, still widely relied upon, it has numerous very substantial disadvantages. First, screens are very expensive; this expense is naturally exacerbated in horizontal wells, where the amount of screen needed frequently exceeds a thousand feet. Moreover, placing a screen in a horizontal section is time-consuming and expensive. Second, a rig or mast must be used to place screen in a wellbore; rig rates are quite often very high, particularly offshore (e.g., in the North Sea, they can exceed $100,000/day). Third, whatever benefit—in reduced sand production—is derived from the gravel pack, the fact remains that it is a choke on production, often substantially reducing potential production rates. Related to this, screens can become plugged—e.g., by fines (very small grain sands) may become affixed to the screen face where they form a “filter cake,” which can severely inhibit, or even halt production.
The second major category of sand control techniques relates not to impeding the flow of sand via a filter (gravel pack) but instead relates to improving the near-wellbore integrity of the formation so that less sand flows into the wellbore. For the most part, these techniques involve somehow consolidating the sandstone around the wellbore—i.e., cementing the sand grains together so that they do not flow along with the oil, into the wellbore. To do this requires some sort of cementing material, such as a furan resin or epoxy resin. For instance, U.S. Pat. No. 5,551,514, assigned to Schlumberger, discloses and claims, e.g., a method of controlling sand production by consolidating the near-wellbore formation by injecting a resin into that region of the formation. Next, that portion of the formation is hydraulically fractured—i.e., sufficient fluid is pumped into the formation to cause it to split. The idea is that formation consolidation is achieved (via the resin) but not at the expense of reduced hydrocarbon production (since the formation is actually stimulated by the fracture).
These non-mechanical (or chemical) sand control techniques suffer predictably, from reduced permeability in the region of the formation where the consolidation is placed. In other words, while the idea behind these types of treatments is to cement the contiguous sand grains together, but not leave the resin in the pore spaces (where the oil must flow), most treatments rarely approach this ideal. Indeed, to remove the resin from the pore spaces requires that still more chemicals be pumped into the reservoir to “flush” the resin from the pore spaces; still more chemicals are required in some cases, to “pre-treat” the sand grains so that the resin sticks to the sand grains preferentially (hence resists the flushing step) but is readily removable from the (un-pre-treated) pore spaces.
The present Invention is also directed to sand control, but fits in neither of these categories. That is, it is neither mechanical nor chemical. The present Invention shall be explained below with reference to certain prior art.
One of the first steps in oil and gas production is drilling a wellbore into the hydrocarbon-bearing formation. Next, a casing (liner), generally steel, is inserted into the wellbore, and forms a gap between the casing and wellbore, typically referred to as the annulus. Once the casing is inserted into the wellbore, it is then cemented in place, by pumping cement into the annulus. The reasons for doing this are many, but essentially, a liner helps ensure the integrity of the wellbore, i.e., so that it does not collapse; another reason for the wellbore liner is to isolate different geologic zones, e.g., an oil-bearing zone from an (undesirable water-bearing zone). By placing a liner in the wellbore and cementing the liner to the wellbore, then selectively placing holes in a liner cemented to the wellbore, one can effectively isolate certain portions of the subsurface, for instance to avoid the co-production of water along with oil.
That process of selectively placing holes in the liner and cement so that oil and gas can flow from the formation into the wellbore and eventually to the surface is generally known as “perforating.” One common way to do this is to lower a perforating gun into the wellbore using a wireline or slickline, to the desired depth, then detonate a shaped charge within the gun. The shaped charge creates a hole in the adjacent wellbore liner and formation behind the liner. This hole is known as a “perforation.” Perforating guns are comprised of a shaped charge mounted on a base. U.S. Pat. No. 5,816,343, assigned to Schlumberger Technology Corporation, incorporated by reference in its entirety, discusses prior art perforating systems (e.g., col. 1., 1. 17).
We are aware of one group that has examined the role of perforation stability on sand production. See, N. Morita, Fracturing, Frac Packing, and Formation Failure Control: Can Screenless Completions Prevent Sand Production ? SPE 36457 (1998). For instance, these investigators note that “Perforation stability significantly improves if the perforations are shot in the maximum horizontal in-situ stress direction, if the two principal horizontal stresses are significantly different, or the perforations can be shot in the well azimuth direction if the well is highly inclined.” Id. at 395. Yet this articles neither discloses nor suggests a particular perforation geometry (other than circular) and particular orientation (since that only has meaning if the perforations are non-circular)
In addition, U.S. Pat. No. 5,386,875, Method for Controlling Sand Production of Relatively Unconsolidated Formations (assigned to Halliburton) is directed to a method for controlling sand production by optimizing perforation orientation. This patent differs from the present Invention in part because the '875 patent neither claims, discloses, nor suggests optimizing the geometry of the perforations (i.e., their shape), but instead is directed solely to their orientation around the well casing.
The present Invention relates to a method of controlling the production of sand, based on optimizing the geometry and the orientation of perforations. Hence, this method suffers from none of the difficulties which plague conventional sand control techniques—e.g., cost (screens) and diminished permeability (resin consolidation).
SUMMARY OF THE INVENTION
We have found that perforations having a particular geometry and orientation, impart greater stability to the formation surrounding the perforation tunnel. Greater stability in turn means less disaggregation of the individual particles that comprise the formation (i.e., sand in the case of a sandstone formation). By “geometry” we mean that the perforations are ideally elliptically shaped—when viewed in cross section perpendicular to an axis defined by the direction of the perforation tunnel. By “orientation” we mean that the perforation (again defined as the roughly largest cross section perpendicular to an axis defined by the perforation tunnel): (1) has its major(long) axis substantially parallel to a plane perpendicular to an axis defined by the perforation tunnel; and (2) that major axis is substantially aligned in the direction of maximum compressive stress in that plane. In other words, item (1) fixes the perforation's orientation somewhere in a given plane; item (2) fixes the perforation's long axis within that plane.
What we have found is that a particular shape and orientation of the perforation minimizes this destabilization, hence also minimizes sand production. In particular, and in the specific case of a vertical wellbore, for instance, elliptically shaped perforations, having the major axis aligned in the direction of maximum principal in situ, or compressive stress, improve the stability of the formation in the region near the wellbore, hence minimizing sand intrusion. Particularly preferred embodiments of this aspect of the Invention are perforations with an aspect ratio of about 5:1, and having their principal axis substantially aligned (± about 10°) with the direction of maximum compressive stress.
Having shown that the benefit of producing such unusually shaped perforations, another aspect of the present Invention relates to perforating guns (or the shaped charges deployed within the guns) modified to produce such perforations. In preferred embodiments, the shaped charge is modified by making the case exterior more oval-shaped. In particularly preferred embodiments, the shaped charge is modified by modifying the case exterior and interior in accordance with the disclosure below.
As evidenced by our preceding remarks, the present Invention has numerous advantages over the state-of-the-art sand control techniques. For one thing, all of the significant disadvantages associated with screen placement are avoided, and for another, no chemicals are pumped in the formation, which inevitably lead to a loss in permeability. In addition, the sand control measures of the present Invention are not exclusive—that is, they can be used to supplement existing techniques, e.g., a screen-only completion. Put another way, all cased wellbores must be perforated—regardless of whether they are later gravel packed or resin consolidated, etc.
We wish also to note that the present Invention is applicable not just in poorly consolidated formations, but rather is a more general system for imparting greater in stability on well consolidated formations. For one thing, some of these may not produce sand initially, but may much later. In addition, the present Invention can be relied upon to stabilize formations other than sandstones, for instance carbonate formations as well; however, for convenience sake, we shall use the shorthand “sand” to refer to particles that disaggregate from the formation, whether sandstone or carbonate, etc. Indeed, not only is the present Invention also suitable for other than poorly consolidated sandstone formations (subject to immediate sanding) in fact it is best suited to other than totally unconsolidated formations. By “totally unconsolidated formations” we mean formations subject to perforation tunnel collapse shortly after the perforation was shot. Obviously, if the formation will not support a perforation tunnel, then the present Invention is essentially inoperable.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 a depicts stress concentration (σ) as a function of the angle θ from the x-axis for a circular shaped perforation as well as elliptically shaped perforations of different orientations with respect to the principal axis.
FIGS. 1 b , 1 c , and 1 d define what we mean by “perforation orientation” (and related terms) as well as illustrate the requirement for preferred embodiments that the perforations be orientated in a particular way.
FIG. 2 shows a discretized domain in a stress field for a quarter section of a circular perforation.
FIG. 3 shows contours of shear plastic strain after localization of deformation.
FIG. 4 shows a displacement field in the vicinity of a circular perforation.
FIG. 5 shows a deformed mesh in the vicinity of a circular perforation.
FIG. 6 shows a discretized domain in a stress field surrounding a quarter section of an elliptical perforation.
FIG. 7 shows the change of cross-sectional area with applied stress for elliptical and circular perforations having the same cross-sectional area.
FIG. 8 shows contours of shear plastic strain after localization of deformation for an elliptically shaped perforation.
FIG. 9 shows a displacement field in the vicinity of an elliptically shaped perforation.
FIG. 10 shows a deformed mesh in the vicinity of an elliptically shaped perforation.
FIG. 11 shows contours of shear plastic strain after localization of deformation for an elliptically shaped perforation having an aspect ratio a/b=3, and applied stresses σ 1 /σ 2 =1.5.
FIG. 12 is a three-dimensional computer-drawn picture of a conventional shaped charge (22 g HMX deep-penetrating charge used in a 3 ⅜′ perforating gun) modified by a small change to the case exterior (made more elliptical). FIG. 12 a is a side view from the widest portion of the charge; FIG. 12 b is a view of the narrow side.
FIG. 13 is a three-dimensional computer-drawn picture of a conventional shaped charge (22 g HMX deep-penetrating charge used in a 3 ⅜′ perforating gun) modified by a substantial change to the case interior (made more elliptical).
FIG. 13 a is a side view from the widest portion of the charge;
FIG. 13 b is a view of the narrow side.
FIG. 14 is a three-dimensional computer-drawn picture of a conventional shaped charge (22 g HMX deep-penetrating charge used in a 3 ⅜′ perforating gun) modified by small changes to the case exterior and interior (made more elliptical).
FIG. 14 a is a side view from the widest portion of the charge;
FIG. 14 b is a view of the narrow side.
FIG. 15 is a computer-simulated picture of the collapsing liner and jet, viewed parallel with the trajectory. This Figure shows the jet produced (at 12.5 microseconds) from the modified shaped charge in FIG. 12 .
FIG. 15 a (left) shows the jet midsection, and
15 b shows the jet tip.
FIG. 16 is a computer-simulated picture of the collapsing liner and jet, viewed parallel with the trajectory. This Figure shows the jet produced (at 12.5 microseconds) from the modified shaped charge in FIG. 13 .
FIG. 16 a (left) shows the jet midsection, and 16 b shows the jet tip.
FIG. 17 is a computer-simulated picture of the collapsing liner and jet, viewed parallel with the trajectory. This Figure shows the jet produced (at 12.5 microseconds) from the modified shaped charge in FIG. 14 .
FIG. 17 a (left) shows the jet midsection, and 17 b shows the jet tip.
FIG. 18 is a side-view schematic of a conventional shaped charge (for convenient comparison with FIG. 19 below) showing the primary features of the charge: case, explosive, and liner.
FIG. 19 is a schematic of a shape charge modified in accordance with the present Invention; 19 a is a side-view; 19 b the corresponding view from the rear of the charge;
FIGS. 19 b and 19 c show the identical shaped charge, except that the charge has been rotated 90°; 19 d shows the back view corresponding to FIG. 19 c.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
We have found that perforations having a particular geometry and orientation, impart greater stability to the formation surrounding the perforation tunnel. The term “greater stability” means that as oil flows from the formation, through the perforation and into the wellbore, it has an obvious destabilizing effect on the geologic formation near the perforation—i.e., it tends to cause it to break down, or to cause the individual sand grains to slough off from the formation and migrate towards the wellbore, carried by the oil. In other words, breakdown of the formation in the region near the wellbore (and hence the perforation) leads to sand production (assume that the formation is a loosely consolidated sandstone formation, hence as it weakens, loose sand grains disaggregate from the formation).
Before going further, we wish to define several additional terms which are critical to properly understand the present Invention. One concept crucial to the present Invention is “orientation,” another is “perforation.” As used here, orientation can refer either to the orientation of the perforation tunnel axis or the orientation of the major axis of the elliptically shaped perforation. The difference between these two meanings of the same term needs to be understood; in each instance here, the meaning intended by us is either expressly stated or is clear from context.
To best understand these terms, refer to FIGS. 1 b , 1 c , and 1 d . FIG. 1 c shows an axis 10 defined by the direction of the perforation tunnel (the direction in which the jet traveled to create the perforation). That is one of the two crucial axes. The other is shown in FIG. 1 b . Again, in preferred embodiments of the present Invention the perforation is an ellipse; that ellipse is defined by a cross-section (cross-section with respect to the axis shown at 10 . Hence, as shown in FIG. 1 b , the term “ellipse,” “perforation orientation,” and in particular “perforation,” refer to the perforation's cross-section: The orientation of that perforation has a major (or long) axis 20 and a minor (or short) axis 30 .
FIG. 1 d shows a perforation shot in a deviated wellbore 40 . (This discussion subsumes the vertical and horizontal wellbore cases as well.) As we shall discuss in far more detail below, particularly preferred embodiments of the present Invention require that the perforation (again defined as a cross-section, as shown in FIG. 1 b ): (1) have its major axis 20 substantially aligned (“substantially” in this context shall be more precisely defined later) in the direction of a plane perpendicular to the axis formed by the perforation tunnel (shown at 10 ); this plane is shown at 50 ; and (2) this major axis is substantially aligned in the direction of the formation's maximum compressive stress.
Having defined crucial terms, we now turn to a discussion of the preferred embodiments of the present Invention. We wish to note that for clarity's sake, the discussion that follows is directed to a vertical wellbore, a perforation tunnel shot 90° from that wellbore, and the direction of maximum compressive stress is vertical.
Again, conventional methods of sand control are roughly classifiable into either (1) screens, or (2) chemical consolidation. Chemical consolidation, even if performed properly, can lead to diminished permeability of the formation. The disadvantages of screens are numerous. See, for instance, N. Morita, Fracturing, Frac Packing, and Formation Failure Control: Can Screenless Completions Prevent Sand Production ? SPE 36457 (1998). This article is hereby incorporated by reference in its entirety. (This article also discusses other types of “screenless completions, or means of controlling sand production without the use of a screen, not discussed here.)
The present Invention is premised upon the insight that elliptically shaped perforations, having their major axis substantially parallel to the direction of major principal compressive stress, is much more stable, than a perforation of circular cross-section area having identical flow capacity. By “stable” we mean that the perforation, or the formation around the perforation, can experience greater drawdown and depletion before the production of sand occurs. In other words, one particularly preferred set of embodiments of this invention relates to methods for controlling sand production, comprising shooting elliptically shaped perforations.
The enabling support for the present Invention is based in part upon three separate detailed studies: (1) an elastic stress analysis to show enhanced nearwellbore formation stability of elliptically shaped perforations; (2) finite element analysis to corroborate the (1); and (3) numerical modeling to design a shaped charge in a perforating gun that will create elliptically shaped perforations.
EXAMPLE 1
Elastic Stress Analysis
Persons familiar with the teachings in petroleum engineering, and in particular drilling, know that wellbores drilled parallel to the maximum compressive stress are more stable—i.e., they resist collapse—because the difference between the other two stresses acting on a plane perpendicular to the wellbore axis is minimized—resulting in reduced stress concentrated near the borehole wall.
And yet in the case of perforations, the situation is far more complicated. Perforations are generally shot in a stress field of unequal compressive stresses—since the vertical stress is normally higher than the horizontal stresses. Although the differential among all stresses is not large, the ratio between effective compressive stresses is generally much higher. In cases where the orientation of perforations to the direction of maximum stability is not possible due to technical considerations (e.g., perforations are shot perpendicular to the borehole wall), the risk of perforation failure can be minimized if the shear stress around the perforation wall is distributed uniformly. According to the present Invention, this is accomplished—i.e., uniformly distribute the shear stress thus avoiding excessive stress concentration in the direction of breakouts—by shooting elliptically shaped perforations instead of cylindrical shaped ones. The study that follows, as well as the one presented in Example 2, provides exhaustive support for that conclusion.
The purpose of this study is to investigate the ideal orientation and geometry of perforations—to permit the highest drawdown and depletion before sanding.
First, consider an ellipse with aspect ratio (a/b) embedded in a stress field of two principal stresses at infinite σ 1 and σ 2 . The stress σ 2 is inclined at angle β to the x axis. The stress σ 1 is inclined at an angle 90°+β. The tangential surface stress, σ t around the elliptical hole is given by: σ t = 2 ab ( σ 1 + σ 2 ) + ( σ 1 + σ 2 ) [ ( a + b ) 2 cos 2 ( β - η ) - ( a 2 - b 2 ) cos 2 β a 2 + b 2 - ( a 2 - b 2 ) cos 2 η ( 1 )
where η is the eccentric angle borrowed from the theory of conic sections. This angle η is related to the polar angle θ via tanθ=(b/a)tan η. Model calculations are based on a stress field ratio of σ 1 /σ 2 =2σ/σ; and a perforation aspect ratio of a/b=2.
FIG. 1 shows the variation of the tangential surface stress σ t with polar angle σ for different orientations of the stress field with respect to the ellipse (i.e., the orientation of the ellipse). In particular, FIG. 1 presents modeling results for a circular shaped perforation as well as elliptically shaped perforations of different orientations with respect to the principal axis.
Thus, according to FIG. 1, for a circular perforation, hole collapse is expected to occur at σ=0 where the stress concentration is σ t =3σ 1 −σ 2 =5σ. Hydraulic fracture will initiate at σ=90, where the stress concentration is minimum: σ t =3σ 2 −σ 1 =σ.
In an elliptical hole with the major axis a parallel to the minimum compressive stress (hence β=0), the stress concentration at θ=0 or 180° is σ t =9σ which is much higher compared to the stress concentration of the circular hole. In other words, an elliptical perforation is expected to be less stable than the circular perforation, at β=0. Now, imagine that the elliptical perforation is rotated 90° (i.e., β=90); i.e., now the major axis of the ellipse is aligned with the direction of maximum stress, σ 1 . In this case, the stress concentration is uniformly distributed around the surface of the hole with a value σ t =3σ. Again, the ratio of the ellipse axis is the same as the ratio of principal stresses at infinity. Hence, as evidenced by
FIG. 1, a particularly stable type of perforation geometry is an ellipse, provided that its major axis is parallel to the maximum compressive stress.
In most applications, the vertical compressive stress is the major principal stress. In these instances, the elliptical shaped perforations will be shot such that the major axis is vertical. As we have discussed, that is the ideal situation; nevertheless, the risk of misalignment is no doubt present. FIG. 1 also presents data showing the effect of different misalignment on stress concentration. As evidenced by these data, as long as the major axis is within about 23° of the ideal case (β=90) then an elliptical hole is more stable than a circular one.
EXAMPLE 2
Finite Element Analysis
The Example just presented, shows that according to elastic stress analysis, an elliptical hole suffers less stress concentration than a circular hole when its major axis is aligned with the direction of the major principal stress. That analysis does not account for imperfectly elastic properties of the rock (i.e., formation rock has a narrow elastic domain).
Put another way, the prior analysis does not guarantee that the elliptical perforation will be more stable than the circular perforation, since the curvature of the elliptical hole is different than the curvature of the circular hole. For instance, based on previous modeling studies performed by us, an increase of tangential stress may cause surface buckling. This may result in surface buckling, which in turn results in localization of deformation in shear bands, leading ultimately to failure in the form of breakouts. We have found that surface buckling of a borehole depends on its curvature.
Therefore, in order to examine the stability of elliptically shaped perforations and the corresponding jet, or penetration profile into the formation, we have developed a finite element-based model to predict surface buckling and localization of deformation. The model is based on bifurcation theory in addition to a modified flow theory for a Mohr-Coulomb material with Cosserat microstructure. This model is capable of predicting the existing scale effect in small-sized holes, such as perforations (small holes are more stable than larger ones). Material input parameters were obtained by triaxial tests on Castlegate sandstone. An extra calibration constant is used to define the material softening required for triggering localization. In addition, the grain size is a required model input parameter—e.g., for Castlegate sandstone, the grain diameter is 0.2 mm.
First, we performed computations for a circular perforation with radius r=0.01—this served as the benchmark for later comparison. Due to the complete symmetry of a circle, only a quarter section was discretized (FIG. 2 ). The external boundary was defined to be at least 10 times the radius of the hole in order to eliminate boundary effects. The stresses were applied incrementally with constant ratio σ y /σ x =2. The solution was controlled by decreasing the cross-sectional area while the stress level was determined indirectly (displacement control). Localization of deformation has occurred after the applied stress reached σ x =24 MPa and σ y =48 MPa. FIG. 3 shows the contours of plastic strain after localization of deformation. FIG. 4 shows the total displacement field; FIG. 5 shows the deformed mesh in the vicinity of the hole. Again, the results presented in these Figures are valid for circular perforations.
Next, the model was applied to evaluate elliptically shaped perforations. As with the circular perforations, a quarter section of the perforation is shown in the relevant Figures. As evidenced from the results presented in Example 1 (the elastic strain analysis) the best ellipse orientation is alignment of the ellipse's major axis parallel to the axis of major principal stress, σ y . As in the circular case, the same stress ratio σ y /σ x =2 was incrementally applied. The aspect ratio was, however, varied. Some modeling runs were performed using an aspect ratio of a/b=2; other modeling runs were performed using an aspect ratio of a/b=3. A typical mesh showing the discretization of the domain surrounding the ellipse is shown in FIG. 6 . FIG. 7 shows the closure curve versus applied minimum stress, σ x (σ y =2σ x ). The point at which the curve ends denotes failure. FIG. 7 indicates, for instance, that an elliptically shaped perforation with a larger aspect ratio fails at a higher minimum stress.
Finally, as evidenced by the above discussion, a poorly oriented elliptically shaped perforation may impart less stability to the contiguous formation than a round perforation. Indeed, due to the overburden stress, a perforation that “begins” as round may become elliptical due to overburden (with the principal axis aligned perpendicular to the maximum stress). The significance of this is that an even modestly elliptically shaped perforation may improve formation stability (compared with a perforation that is initially round), though it later becomes more round due to overburden stress.
EXAMPLE 3
Deviated and Horizontal Wells
We wish now to expand our discussion above to include deviated and pure horizontal wells. Above, we stated that the major axis of the ellipse should be orientated in the direction of maximum compressive stress for improved stability. This is generally true for vertical wells (the paradigm case upon which the preceding discussion was directed) in which the vertical stress is the maximum stress.
Obviously, in many cases, the vertical stress is not the maximum stress. In the case of horizontal wells, perforations shot vertically (up or down but not sideways) will be stabilized if the major axis of the ellipse is oriented in the direction of maximum horizontal stress; in horizontal wells, vertical stress does not influence perforation stability—in the specific case where the perforations are placed up or down (rather than sideways). Third, in the case of deviated wells, the particularly preferred embodiments of the present Invention require that one orient the major axis of the ellipse in the direction of maximum stress in the plane perpendicular to the perforation tunnel.
To generalize—that is, to cover all three cases, vertical, horizontal and deviated, (referring to FIGS. 1 b , 1 c , and 1 d ) the particularly preferred embodiments of the present Invention are satisfied by creating perforations having a particular orientation. Again, by “orientation” we mean the orientation of the major (largest) axis of the perforation cross-section, as shown in FIG. 1 b . What is important (for preferred embodiments) is that this cross-section be aligned in a particular way. To understand that, we have chosen a particular reference point—an axis defined by the perforation tunnel, as shown in FIG. 1 c . So, the most preferred embodiments of the present Invention are satisfied by creating perforations (again, a cross-section) substantially parallel to a plane drawn perpendicular to the axis defined by the perforation tunnel. This is shown in FIG. 1 d.
EXAMPLE 4
Design of the Perforating Apparatus
Again, conventional practice in the art is to shoot circular perforations, not irregularly shaped perforations. In order to shoot elliptically shaped perforations, the perforating apparatus will need to be redesigned. That is the focus of this section.
This Example reports a series of three-dimensional numerical simulations to demonstrate the feasibility of creating elliptically shaped perforations using perforating shaped charges.
The software used to generate the simulations is commercially available—OTI*HULL (1). (See, e.g., HULL Documentation, Version 4 (1997), D. Matsuka, et al., Orlando Technology, Inc.) This (as well as other) hydrocode has been used since about the late 60's to solve ordinance-related problems, included detonation, explosive/metal interaction, shaped charge functioning, and hypervelocity impact. HULL solves the conservation equations of continuum mechanics, coupled with descriptive material models (equations of state & strength models). These equations are solved on a finite difference grid, and the solution is advanced explicitly in time. In an Eulerian framework, the grid points (cells) are fixed in space, and material flows through the cell boundaries.
In a particularly preferred embodiment of the present Invention, the perforating device used to create the desired elliptically shaped perforations is based closely upon a conventional gun design—that way, the cost associated with performing the methods of the present Invention is lowest. In other words, we sought a particular shaped charge design that would involve only a modest reconfiguration of an existing or conventional shaped charge.
We begin with a baseline charge of 22 g HMX deep-penetrating charge, used in Schlumberger's 3 ⅜′ HSD gun system. The shaped charge consists of three primary components: the case, the explosive, and the liner. By modifying the liner one could create non-circular jets, such a modified shaped charge is less desirable since fabrication of such a liner is more difficult. By contrast, modifications to the case are comparatively easy to make, hence the design iterations were directed there. Naturally though, changes to the case will also change the explosive geometry.
FIG. 12 is a computer-simulated picture of a modified shaped charge. The case geometry is clearly shown (both the interior and exterior portions). The case exterior was modified slightly. In FIG. 13, the case interior was modified; and in FIG. 14, both the case interior and exterior were substantially modified. The jets produced by these three case designs are shown in FIGS. 15-17. These figures are a view of a simulated firing of each of the three shaped charges in FIGS. 12-14. Specially, each is a view of the collapsing liner and jet, viewed along the axis in which jet propagates; the tip is shown at right (FIGS. 15 a , 16 a , and 17 a ) and the jet midsection is shown on the left (FIGS. 15 b , 16 b , and 17 b ).
As evidenced by FIG. 15, a shaped charge having a slightly modified case exterior (shown in FIG. 15) is sufficient to produce an elliptically shaped jet (and therefore an elliptically perforation) in a wellbore liner. The jet tip is shown in FIG. 15 a ; the midsection at 15 b —both are 12.5 microseconds after detonation. The modified shaped charge shown in FIG. 13 (case interior changed slightly compared with a conventional case) produces an even more elliptically shaped jet, as shown in FIG. 16 —both in the tip region (FIG. 16 b ) and the midsection (FIG. 16 a ). Finally, as evidenced by FIG. 17, more substantial modifications to both the interior and exterior of the case results in more highly elliptically shaped jets. Indeed, the case configuration of FIG. 14 produces a jet having an aspect ratio of greater than about 5:1. This jet will produce a perforation in a wellbore casing having an aspect ratio of less than 5:1, but still substantially elliptical in the vast majority of instances—depending upon the casing material, and most strongly upon the formation geology.
The shaped charges shown in FIGS. 12-14 can be further explained by reference to FIGS. 18 and 19. FIG. 18 is a side view schematic of a conventional shaped charge. A shaped charge's three primary components are clearly shown: the case 110 , the liner 130 , and the explosive juxtaposed between the case and liner, show at 120 . This shaped charge is axi-symmetric.
By comparison, a shaped charge modified in accordance with the present Invention is shown in FIG. 19 . This shaped charge is non axi-symmetric. Since it is non axi-symmetric, two side views need to be shown ( 19 a and 19 c ); the corresponding front views are shown in 19 b and 19 d , respectively. As evidenced by FIGS. 19 a and 19 c (again, two different side views of the same shaped charge) when viewed in comparison with FIG. 18, clearly show the shape of the charge case, modified in accordance with (preferred embodiments of) the present Invention. In particular, FIG. 19 a shows the case exterior, and FIG. 19 b , the case interior, both of which are modified in preferred embodiments of the present Invention.
We wish also to note that the present Invention is not limited to the manner in which the perforations are “shot.” In particularly preferred embodiment, they are shot with a conventional perforation apparatus, modified as discussed in Example 4, above. In other embodiments, the perforations may be shot using, for instance, the “BRIDGEBlASTER™” apparatus, a proprietary service developed and sold by Schlumberger, and originally intended for removal of scale from wellbores.
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The present Invention relates to novel devices and methods to minimize the production of sand in subterranean environments; in particular, in poorly consolidated formations, sand is often co-produced along with the desired fluid (e.g., oil); sand production is undesirable, hence in the present Invention, elliptically shaped perforations of a particular orientation are created in the casing (or directly into the formation in the case of an uncased wellbore) that lines wellbore drilled through the formation, to improve near-wellbore stability of the formation, hence minimizing sand intrusion.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made with Government support under Prime Contract No. DE-FC36-93CH10580 awarded by the Department of Energy. The Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0002] The field of the invention is superconducting electric motors, specifically those that require that the superconducting material of the rotor be cooled, requiring the use of a cryogenic coolant supply system and a vacuum chamber.
[0003] Superconducting motors provide increases in power and efficiency over motors of a conventional, non-superconducting design. However, the use of superconducting materials presents obstacles that increase the complexity of the motor. The most significant impediment to the use of superconducting materials is temperature.
[0004] The current state of the art in superconductor motor technology is the use of what are referred to as high temperature superconductors (HTS) in the rotor of an electric motor. Despite their nomenclature, high temperature superconductors require an operating temperature in the range of 30K to 70K. This requires the use of a coolant system to deliver a low temperature coolant, such as liquid neon or gaseous helium, to the superconducting material. It also requires that the superconducting material be enclosed in a vacuum chamber to provide thermal insulation.
[0005] The fact that the superconducting material is contained in the rotor, which must be allowed to rotate, poses a significant problem for the creation and maintenance of a vacuum chamber. One way to obtain a vacuum in the rotor is to manufacture it as a sealed vacuum chamber. This approach does not require that the rotor be connected to an external vacuum pump during operation. However, it does require that the welds and joints be of a very high quality. In addition, the composite materials commonly used in high temperature superconductors have inherently high outgassing rates that rapidly compromise the vacuum level. This requires that the motor be stopped and the rotor vacuum chamber be pumped out periodically to maintain a sufficient level of vacuum.
[0006] The second way to obtain a vacuum surrounding the superconducting material is to enclose the entire rotor (and sometimes the stator) in a stationary vacuum chamber. This allows that vacuum space to be constantly pumped by an external vacuum pump to maintain the requisite level of vacuum. The major disadvantage to this approach is that it requires rotating vacuum seals for the rotor shaft. The cost and complexity of rotating vacuum seals increases as the size of the shaft increases. Therefore, for very large motors, the use of rotating vacuum seals becomes prohibitively expensive.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention overcomes the cost and complexity associated with creating and maintaining a vacuum insulation about the superconducting rotor coils in electric motors with large rotor shafts by continually pumping out the vacuum space through a rotating vacuum seal that is smaller in diameter than the rotor shaft. By using seals that are much smaller than the size of the shaft support bearings, and that do not have to support high radial loads, seal life is improved, seal cost is reduced, and leakage is reduced. The vacuum chamber is attached to the rotor to rotate therewith. Because the diameter of the coupling is not dependent on the diameter of the rotor shaft, the shaft can be made as large as desired without incurring the cost and complexity of large vacuum couplings.
[0008] Specifically, then, the present invention provides a rotor for use with a superconducting electric motor. The rotor includes a rotor support shaft having an outer surface having a first diameter for receiving a support bearing and having an inner axial bore and a vacuum seal with an interface dividing stationary and rotating portion of the vacuum seal, the interface having a second diameter smaller than the first diameter. A superconducting rotor winding communicates with the rotor support shaft to rotate therewith and a vacuum jacket is attached to the rotor support shaft to surround the superconducting rotor winding thereby providing thermal insulation. The inner bore of the rotor support shaft communicates with an interior of the vacuum jacket and a non-rotating vacuum line communicates with the inner bore so as to provide a path of evacuation of the interior of the vacuum jacket through the inner bore into the vacuum line. The vacuum seal fits between the vacuum line and the inner bore with one of the stationary and rotating portions of the vacuum seal fitting against the vacuum line and one of the stationary and rotating portions of the vacuum seal fitting against the inner bore.
[0009] Thus it is one object of the invention to provide a means for continuously evacuating a running motor. The use of a vacuum seal with a smaller diameter than the motor shaft makes a continuous coupling between the rotor and an external vacuum pump more robust and less expensive.
[0010] The vacuum seal may fit against the inner surface of the inner bore and an inner periphery of the vacuum seal fits against an outer periphery of the vacuum line.
[0011] Thus it is another object of the invention to provide a coupling that fits unobtrusively within one motor shaft.
[0012] The inner bore may include a concentric partitioning tube having a central lumen leading to the superconducting rotor windings and the vacuum line may include an inner concentric cryogen supply line positioned so that when the vacuum line communicates with the inner bore, the cryogen supply line engages the central lumen of the partitioning tube and the vacuum line communicates with the space between the partitioning tube and the inner bore.
[0013] Thus it is another object of the invention to provide a continuous cryogen supply to a rotating rotor.
[0014] The cryogen supply tube overlaps with the partitioning tube to minimize conduction between the vacuum seal and the cryogen of the cryogen supply line. Both the vacuum line and the inner concentric cryogen supply line extend beyond the second seal and are joined at their edges to provide an extended thermal path between the cryogenic temperatures of the cryogen supply line and the second seal.
[0015] Thus it is another object of the invention to permit the use of vacuum seals that cannot function at cryogenic temperatures.
[0016] The foregoing and other objects and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings that form a part hereof, and in which there is shown by way of illustration, a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention, however, and reference must be made to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a perspective side view of the rotor and shaft assembly of the present invention showing the position of the rotating coupling and its size relative to the size of the rotor and rotor shaft and support bearings;
[0018] [0018]FIG. 2 is a cross-sectional view along lines 2 - 2 of FIG. 1 of the rotor and shaft showing the concentric cryogen supply line and vacuum line interfitting with seals within a bore of one rotor shaft; and
[0019] [0019]FIG. 3 is a detailed view of FIG. 2 showing the dual cryogen and vacuum pathways provided by the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring now to FIG. 1, the present invention provides a superconducting rotor 10 for an electric motor. The rotor 10 includes a generally cylindrical vacuum jacket 12 having closed bases 14 and 16 . Axial drive shaft 20 extends from base 16 , and axial support shaft 22 extends from base 14 . The shafts 22 and 20 are aligned with the central axis of the cylindrical vacuum jacket 12 . The drive shaft 20 may be solid for increased torque and flexibility in coupling.
[0021] Drive shaft 20 and support shaft 22 may be supported by conventional ball bearings 24 in a manner well known in the art and extend through the ball bearings 24 to provide outer end 26 of drive shaft 20 , that may be coupled to a machine receiving torque from the rotor 10 and to provide outer end 28 , of support shaft 22 , that may receive a combined cryogen/vacuum line 30 . Referring now to FIGS. 2 and 3, the combined cryogen/vacuum line 30 provides a cryogen pipe 32 concentrically located within a larger vacuum pipe 34 . Referring now principally to FIG. 2, the bearings 24 in turn may be supported by a housing 58 of a type well known in the art containing the armature and other features of the motor.
[0022] Continuing to refer to FIGS. 2 and 3, the support shaft 22 includes an axial bore 36 and fitted within the axial bore 36 at the end 28 is a ferrofluidic seal and bearing 38 abutting at its outer periphery the inner surface of the bore 36 and supporting at its inner periphery the outer surface of the combined cryogen/vacuum line 30 . As is well understood in the art, the ferrofluidic seal and bearing provides both a conventional radial ball bearing and by means of a ferrofluidic liquid, a vacuum seal between the sliding surfaces which define an interface between the moving a stationary portions of the ferrofluidic seal and bearing 38 . The interface is of a significantly smaller diameter than the diameter of the support shaft 22 . Such ferrofluidic seal and bearings are well known in the art and may be obtained from a number of commercial manufacturers including Ferrofluidics Corporation of New Hampshire.
[0023] After passage into the bore 36 and past the ferrofluidic seal and bearing 38 , the vacuum pipe 34 necks inward to a reduced diameter 40 to fit within a second ferrofluidic seal and bearing 42 having an inner periphery of smaller diameter than the inner periphery of ferrofluidic seal and bearing 38 . The second ferrofluidic seal and bearing 42 supports the outer surface of the necked portion of the vacuum pipe 34 . The outer periphery of the second ferrofluidic seal and bearing 42 fits within a spacer ring 44 spanning the distance between the outer periphery of the second ferrofluidic seal and bearing 42 and the inner surface of the bore 36 and forming part of a stationary portion of the second ferrofluidic seal and bearing 42 . The ring 44 is fixed to the support shaft 22 to rotate therewith.
[0024] Attached to the inner radial face of ring 44 (removed from the outer end 28 of the support shaft 22 ) is a radially outwardly flared lip of a partition tube 48 fitted coaxially within bore 36 . The partition tube 48 loosely surrounds the necked down portion of the vacuum pipe 34 and cryogen pipe 32 and extends through the vacuum jacket 12 into its inner volume.
[0025] Ring 44 includes a plurality of axial ports 46 aligning with an axial bore in the flared lip of partition tube 48 to provide communication between a space 49 defined within the ferrofluidic seal and bearing 38 , the ring 44 , the bore 36 of the support shaft 22 and outer surface of the vacuum pipe 34 , and a space 50 defined within the bore 36 of the support shaft 22 and the outer surface of the partition tube 48 . A port 53 cut in the outer surface of the vacuum pipe 34 provides a path 54 for drawing air from space 50 , through the ring 44 to space 49 and then into the vacuum pipe 34 which is connected externally to a vacuum pump (not shown).
[0026] Cryogen may pass along path 56 within the inner cryogen pipe 32 to a volume 52 inside the wall of the partition tube 48 . The vacuum pipe 34 and cryogen pipe 32 extend an arbitrary distance past the ferrofluidic seal and bearing 42 so as to provide a high thermal resistance between the cryogen and the ferrofluidic seal and bearing 42 and are joined together by stopper ring 51 which connects the outer surface of the inner cryogen pipe 32 to the inner surface of the vacuum pipe 34 , It will be understood that the cryogen pipe 32 will thus be more thermally isolated from the support shaft 22 as is connected by the ferrofluidic seal and bearing 42 and ring 44 by a relatively thin cross-section of an appropriately long thermal path. The loose fit between the vacuum pipe 34 within the partition tube 48 provides a gas passage from the end of vacuum pipe 34 and cryogen pipe 32 back to the ferrofluidic seal and bearing 42 but this is a relatively narrow cross section and dead-ended so there is little thermal conduction through gas trapped therein.
[0027] Referring now principally to FIG. 2, the support shaft 22 abuts the vacuum jacket 12 of the rotor 10 to sandwich a base of the vacuum jacket 12 between itself and a composite torque tube 60 axially aligned with the support shaft 22 inside the vacuum jacket 12 . The torque tube 60 provides a continuation of the support function of the support shaft 22 , however, with lower thermal conductivity provided both by material selection and its being hollow. The partition tube 48 extends from the bore 36 of the support shaft 22 into the torque tube 60 and then by means of a second outwardly flared lip expands radially to attach to the inner surface of the torque tube assembly 60 . An orifice 62 cut in the torque tube 60 to communication between space 50 and the interior of the vacuum jacket 12 so that the latter may be evacuated through vacuum pipe 34 .
[0028] The torque tube assembly 60 connects also to a coil support 64 which includes an internal cryogen distribution structure 66 allowing cryogen in volume 52 to pass through the cryogen distribution structure 66 to high temperature superconducting field windings 68 attached at the outer periphery of the support structure 64 . An AC flux shield 72 may be positioned outside of the high temperature superconductor windings 68 between the high temperature superconductor windings 68 and the armature 74 .
[0029] The cryogen introduced into volume 52 may thus communicate with an inner surface of the high temperature superconducting winding 68 without release to the general inner volume of the vacuum jacket 12 surrounding the high temperature superconducting windings 68 . In this manner, both vacuum and cryogen may be separately contained with the rotor 10 .
[0030] Axially, on the opposite side of the support structure 64 from the torque tube 60 , a similar torque tube 70 connects to the base 16 of the vacuum jacket 12 which is sandwiched between torque tube 70 and drive shaft 20 as described with respect to FIG. 1.
[0031] Importantly, it will be noted that the size of the ferrofluidic seal and bearings 38 and 42 is substantially smaller than the size of the bearing 24 thus reducing the potential leakage area significantly decreasing the cost of the seals which also are not required to support any substantial radial loads which are handled by the bearing 24 . In this embodiment, vacuum vessel rotates with the shaft thus eliminating any further seal that would be required between the vacuum vessel and the shaft.
[0032] The rotor 10 thus formed may be surrounded by armature 74 of conventional design having standard conductors which are thus isolated from the high temperature superconductor windings 68 which are within the vacuum jacket 12 . An exciter of conventional design (not shown) may be fit either to the drive shaft 20 or to the support shaft 22 .
[0033] During operation, a vacuum pump is attached to the vacuum line and cryogen is inserted into the cryogen pipe 32 without the need for complex couplings and both lines are nonrotating.
[0034] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but that modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments also be included as come within the scope of the following claims.
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A rotating coupling allows a vacuum chamber in the rotor of a superconducting electric motor to be continually pumped out. The coupling consists of at least two concentric portions, one of which is allowed to rotate and the other of which is stationary. The coupling is located on the non-drive end of the rotor and is connected to a coolant supply and a vacuum pump. The coupling is smaller in diameter than the shaft of the rotor so that the shaft can be increased in diameter without having to increase the size of the vacuum seal.
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[0001] This application claims priority to prior Japanese patent application JP 2005-309416, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a semiconductor device, and more particularly to a ZQ calibration circuit for adjusting impedance of an output circuit and a semiconductor device having such a ZQ calibration circuit.
[0004] 2. Description of the Related Art
[0005] The speed of recent electronic systems has been enhanced, and an extremely high data transfer rate has been achieved between semiconductor devices forming a system. In order to achieve such an ultrafast data transfer, the amplitude of data signals is reduced. Further, impedance of a transmission line between semiconductor devices and an output impedance of an output circuit of the semiconductor device are matched with each other. The matched impedance provides transmission without causing distortion to data signals having a small amplitude, thereby enhancing a data transfer rate. If the impedance of the transmission lines between the semiconductor devices and the output impedance of the semiconductor device are not matched with each other, then a data waveform is dulled during transmission so as to cause an overshoot or an undershoot, so that a high speed data transfer cannot be performed.
[0006] In order to match impedance of a transmission line and output impedance of an output circuit with each other, it is necessary to adjust the output impedance of the semiconductor device so as to match the impedance of the transmission line. Generally, a calibration circuit is used to adjust output impedance of a semiconductor device. For example, a ZQ pin is provided as a ZQ calibration terminal in a semiconductor device, and an external ZQ calibration command (ZQCS or ZQCL) is inputted into the ZQ pin. When the external ZQ calibration command (ZQCS or ZQCL) is inputted, a ZQ calibration operation is performed within a period defined by the command. During the ZQ calibration operation, the output circuit cannot be used. Accordingly, access to chips is prohibited, and a next command is not inputted. Thus, the period defined by the ZQ calibration command is for ZQ calibration. The ZQ calibration should be completed within this period.
[0007] The period for ZQ calibration is defined as follows:
tZQ init=512 *tCK
tZQCS= 64 *tCK
tZQ oper=256 *tCK
Here, tCK represents a cycle of a clock. These specifications are defined by the number of clocks. Specifically, in the AC specifications, a ZQ calibration period (tZQinit) for ZQ calibration performed during an initial stage after power is turned on is defined as tZQinit=512*tCK. Further, ZQ calibration periods for ZQ calibration performed after the initial stage are defined according to inputted commands. A ZQ calibration period (tZQCS) for ZQ calibration performed when an external ZQ calibration command of ZQCS is inputted is defined as tZQCS=64*tCK. A ZQ calibration period (tZQoper) for ZQ calibration performed when an external ZQ calibration command of ZQCL is inputted is defined as tZQoper=256*tCK.
[0008] When power is turned on, impedance adjustment can be performed for a long period of time. The ZQ calibration periods after the initial stage are short (64*tCK, 256*tCK). This is because the impedance adjusted by the intitial ZQ calibration is used for the subsequent ZQ calibrations and thereby the subsequent ZQ calibrations can be completed within a shorter period of time. Further, since the subsequent ZQ calibration periods are short, it is possible to shorten a period during which chip access is prohibited. It is assumed that the short-time ZQ calibrations (tZQCS, tZQoper) are performed at a certain frequency. When a short-time ZQ calibration is performed in a state in which device variation is small, specifically in cooperation with refresh cycles, it is possible to perform the ZQ calibration (tZQCS) without lowering the performance of the semiconductor device.
[0009] However, the impedance varies according to conditions under which the device is placed, such as an operation mode, a power source voltage, and temperature. That is, in a case where a self-refresh operation or the like is performed for a long period of time, even if a short-time ZQ calibration (tZQCS or tZQoper) is performed after the self-refresh operation, there is no guarantee that the impedance can be adjusted. As shown in FIG. 1 , even if a DLL lock period (tDLLK=512*tCK) after completion of a self-refresh operation is employed for a ZQ calibration, there is no guarantee that the impedance can be adjusted. In accordance with the AC specifications, i.e., when a short-time ZQ calibration (tZQCS or tZQoper) is performed after a ZQ calibration command has been inputted, there is little possibility that the impedance can be adjusted.
[0010] A ZQ calibration operation is completed in a short period of time if the ZQ calibration result is close (or equal) to an output impedance at the time when a ZQ calibration command was inputted. If there is a difference between the impedance and the ZQ calibration result, then the ZQ calibration operation may not be completed within the defined ZQ calibration period. If the impedance matching is not completed successfully, the impedance of the transmission line does not match the output impedance of the semiconductor device. In this case, a data waveform is dulled during transmission so as to cause an overshoot or an undershoot, so that a high speed data transfer cannot be performed.
[0011] The following references relate to a ZQ calibration operation and a refresh operation of a semiconductor memory. Patent Document 1 (Japanese laid-open patent publication No. 2002-026712) discloses that a slew rate of an output circuit is adjusted by matching an external terminator. Patent Document 2 (Japanese laid-open patent publication No. 08-335871) discloses that a switching transistor is turned on and off by an external control signal so as to adjust the impedance. Patent Document 3 (Japanese laid-open patent publication No. 2005-065249) discloses that a terminating resistance of an input terminal and an impedance of an output circuit are adjusted by using one external resistance. Patent Document 4 (published Japanese translation No. 2005-506647) discloses that an input buffer is set in a disable state during an automatic refresh operation and in a low-power pre-charged state after the automatic refresh operation to thereby reduce a power of a semiconductor memory.
[0012] If there is a difference between a ZQ calibration result and an output impedance at the time when a ZQ calibration command was inputted, then the ZQ calibration operation may not be completed within the defined ZQ calibration period. In this case, the impedance of the transmission line does not match the output impedance of the semiconductor device. As a result, a data waveform is dulled during transmission so as to cause an overshoot or an undershoot, so that a high speed data transfer cannot be performed. The aforementioned references do not consider these problems and are silent on these problems.
SUMMARY OF THE INVENTION
[0013] The present invention has been made in view of the above drawbacks. A ZQ calibration operation is automatically added during operation of a semiconductor device so as to increase the number of impedance adjustments for more accurate impedance adjustment. Specifically, when a self-refresh operation is completed, a ZQ calibration command is generated to add a ZQ calibration operation for more accurate impedance adjustment. Thus, it is an object of the present invention to provide a ZQ calibration circuit capable of matching an impedance of a transmission line and an output impedance of a semiconductor device more accurately by automatically adding a ZQ calibration operation. Further, it is another object of the present invention to provide a semiconductor device which has such a ZQ calibration circuit and can perform a high speed data transfer.
[0014] In order to resolve the above problems, the present invention basically adopts the following technology. As a matter of course, the present invention covers applied technology in which various changes and modifications are made therein without departing from the spirit of the present invention.
[0015] According to a first aspect of the present invention, there is provided a ZQ calibration circuit capable of matching impedance of a transmission line and output impedance of a semiconductor device more accurately. A control signal for ZQ calibration is issued from a command different from an external ZQ calibration command so as to perform a ZQ calibration operation.
[0016] The control signal may be inputted into a counter so as to perform the ZQ calibration operation. In this case, the control signal may be inputted into the counter so as to perform a pull-up ZQ calibration operation. An additional control signal may be issued after completion of the pull-up ZQ calibration operation so as to perform a pull-down calibration operation. Further, the ZQ calibration operation performed by the control signal may be the same as a ZQ calibration operation performed when an external ZQ calibration command is inputted.
[0017] The command different from an external ZQ calibration command may be a command for a self-refresh operation. In this case, the ZQ calibration operation may be concurrently performed during a DLL lock period defined by the command for a self-refresh operation.
[0018] According to a second aspect of the present invention, there is provided a ZQ calibration circuit capable of matching an impedance of a transmission line and an output impedance of a semiconductor device more accurately. The ZQ calibration circuit includes a first pull-up circuit connected to a ZQ calibration terminal, a replica buffer having a second pull-up circuit and a pull-down circuit, and a first counter to which a first control signal and a second control signal are inputted. The ZQ calibration circuit also includes a second counter to which a third control signal and a fourth control signal are inputted, a first comparator operable to compare a potential of the ZQ calibration terminal with a reference potential, and a second comparator operable to compare a potential of a contact between the second pull-up circuit and the pull-down circuit with the reference potential. A first ZQ calibration operation is performed in response to the first control signal and the third control signal which are generated according to a ZQ calibration command. A second ZQ calibration operation is performed in response to the second control signal and the forth control signal which are generated according to a self-refresh command.
[0019] The first pull-up circuit, the first counter, and the first comparator may be configured to perform a pull-up ZQ calibration operation. The replica buffer, the second counter, and the second comparator may be configured to perform a pull-down ZQ calibration operation after the pull-up ZQ calibration operation.
[0020] According to a third aspect of the present invention, there is provided a semiconductor device which has the aforementioned ZQ calibration circuit and can perform a high speed data transfer.
[0021] According to a ZQ calibration circuit of the present invention, a ZQ calibration command is generated from a command different from an externally inputted ZQ calibration command so as to additionally perform a ZQ calibration operation. By additionally performing a ZQ calibration operation, the number of the ZQ calibration operations is increased so that the matching of the impedance can be conducted more accurately in a shorter period of time. The command different from the externally inputted ZQ calibration command is preferably a self-refresh command. In this case, it is possible to obtain a ZQ calibration circuit which automatically performs a ZQ calibration operation after a self-refresh operation. Further, it is possible to obtain a semiconductor device which has such a ZQ calibration circuit and can perform a high speed data transfer.
[0022] The above and other objects, features, and advantages of the present invention will be apparent from the following description when taken in conjunction with the accompanying drawings which illustrate preferred embodiments of the present invention by way of example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a timing chart of a conventional ZQ calibration operation;
[0024] FIG. 2 is a timing chart of a ZQ calibration operation according to the present invention;
[0025] FIG. 3 is a circuit diagram of a ZQ calibration circuit according to the present invention;
[0026] FIG. 4 is a circuit diagram of a pull-up circuit in the ZQ calibration circuit shown in FIG. 3 ;
[0027] FIG. 5 is a circuit diagram of a pull-down circuit in the ZQ calibration circuit shown in FIG. 3 ; and
[0028] FIG. 6 is a timing chart of a ZQ calibration operation according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] A preferred embodiment of the present invention will be described below with reference to FIGS. 2 through 6 . FIG. 2 is a timing chart of a ZQ calibration operation according to the present invention. FIG. 3 is a circuit diagram of a ZQ calibration circuit, FIG. 4 is a circuit diagram of a pull-up circuit, and FIG. 5 is a circuit diagram of a pull-down circuit. FIG. 6 is a timing chart of a ZQ calibration operation. As shown in FIG. 2 , the ZQ calibration circuit according to the present invention automatically performs a ZQ calibration operation after completion of a self-refresh operation. Even if no external ZQ calibration command is inputted, the ZQ calibration circuit automatically performs a ZQ calibration operation after completion of the self-refresh operation. Specifically, the ZQ calibration circuit concurrently performs a ZQ calibration operation (tDQoper=256*tCK) within a DLL clock cycle (tDLLK=512*tCK) after completion of the self-refresh operation.
[0030] The ZQ calibration circuit shown in FIG. 3 is incorporated in a semiconductor device. The ZQ calibration circuit includes a first pull-up circuit 301 , a second pull-up circuit 302 , a pull-down circuit 303 , a first counter 304 , a second counter 305 , a first comparator 306 , a second comparator 307 , and resistances 308 and 309 . Impedance control signals DRZQ from the ZQ calibration circuit are supplied to an output circuit. An impedance control signal DRZQP (DRZQP 1 to DRZQP 5 ) is outputted as a gate control signal for transistors forming a load at a final stage of the output circuit. An impedance control signal DRZQN (DRZQN 1 to DRZQN 5 ) is outputted as a gate control signal for transistors forming a driver at a final stage of the output circuit. The impedances of the load and the driver of the output circuit are set to optimal values.
[0031] The basic structure of the ZQ calibration circuit according to the present invention is the same as that of the inventors'prior Japanese patent application No. 2005-011272, the disclosure of which is incorporated herein by reference in its entirety. The ZQ calibration circuit according to the present invention differs from the prior Japanese patent application in that additional counter control signals SELFEX 1 and SELFEX 2 are inputted to the counters 304 and 305 , respectively. The counter control signals SELFEX 1 and SELFEX 2 have the same functions as control signals ACT 1 and ACT 2 , respectively. When the control signal SELFEX 1 is inputted, the first counter 304 also starts a count operation for performing a ZQ calibration operation of the load. Similarly, when the control signal SELFEX 2 is inputted, the second counter 305 also starts a count operation for performing a ZQ calibration operation of the driver. Other arrangements are the same as those of the prior Japanese patent application. Each of the first pull-up circuit 301 , the second pull-up circuit 302 , and the pull-down circuit 303 is formed by five impedance adjustment transistors connected in parallel. Each of the counters 304 and 305 has a 5-bit arrangement.
[0032] The semiconductor device has a pin ZQ for ZQ calibration. The pin ZQ is connected to a ground potential GND via an external resistance R. The first pull-up circuit 301 is provided between the pin ZQ for ZQ calibration and a power source potential VDD. Thus, the pin ZQ for ZQ calibration is connected to the power source potential VDD via the first pull-up circuit 301 and is connected to the ground potential GND via the external resistance R. The impedance of the pull-up circuit is made equal to the external resistance R by adjusting a potential of the pin ZQ for ZQ calibration so as to be a half of the power source potential VDD. The resistance 308 and the resistance 309 are connected in series between the power source potential VDD and the ground potential GND. The resistances 308 and 309 serve as a reference potential generation circuit for outputting a reference potential Vref from a contact between the two resistances 308 and 309 . For example, the resistances 308 and 309 generate a potential of VDD/2 as a reference potential Vref.
[0033] The first comparator 306 is operable to compare an inputted potential of the pin ZQ for ZQ calibration with the reference potential Vref and generate an output COMP 1 . The first counter 304 starts a count operation in accordance with the output COMP 1 of the first comparator 306 when the control signal ACT 1 or the control signal SELFEX 1 is activated. The transistors in the pull-up circuits are brought into conduction or out of conduction by the impedance control signal DRZQP (DRZQP 1 to DRZQP 5 ) outputted from the first counter 304 , thereby adjusting the impedance.
[0034] The first counter 304 is initially set so that all bits have a high level (11111). When the control signal ACT 1 or the control signal SELFEX 1 is activated, the first counter 304 performs a count-down operation if the output COMP 1 has a low level and performs a count-up operation if the output COMP 1 has a high level. The first counter 304 outputs a 5-bit signal DRZQP (DRZQP 1 to DRZQP 5 ). Each of the pull-up circuits 301 and 302 is supplied with the impedance control signals DRZQP 1 to DRZQP 5 , which bring the corresponding transistors into conduction or out of conduction so as to adjust the impedance. Further, the impedance control signals DRZQP 1 to DRZQP 5 are outputted as control signals for transistors forming a load at the final stage of the output circuit.
[0035] Further, the second pull-up circuit 302 is provided between the power source potential VDD and a contact A. The pull-down circuit 303 is provided between the contact A and the ground potential GND. Thus, the second pull-up circuit 302 and the pull-down circuit 303 form a replica buffer. A potential of the contact A and the reference potential Vref are inputted into the second comparator 307 , which compares these potentials with each other to generate an output COMP 2 . The second counter 305 starts a count operation when the control signal ACT 2 or the control signal SELFEX 2 is activated. For example, the second counter 305 is initially set so that all bits have a low level (00000). The second counter 305 performs a count-down operation if the output COMP 2 has a low level and performs a count-up operation if the output COMP 2 has a high level.
[0036] The second counter 305 outputs a 5-bit impedance control signal DRZQN (DRZQIN 1 to DRZQIN 5 ). The pull-down circuit 303 is supplied with the impedance control signals DRZQN 1 to DRZQN 5 , which bring the corresponding transistors into conduction or out of conduction so as to adjust the impedance. Further, the impedance control signals DRZQN 1 to DRZQN 5 are outputted as control signals for transistors forming a driver at the final stage of the output circuit.
[0037] The pull-up circuits 301 and 302 will be described in detail with reference to FIG. 4 . Since the first pull-up circuit 301 and the second pull-up circuit 302 have the same structure, the following description concerns only the first pull-up circuit 301 . FIG. 4 is a circuit diagram of the pull-up circuit 301 (or 302 ). As shown in FIG. 4 , the pull-up circuit 301 includes a plurality of P-channel transistors 311 to 315 (five transistors in FIG. 4 ) and a resistance 331 . Sources of the P-channel transistors 311 to 315 are jointly connected to the power source potential VDD, and drains of the P-channel transistors 311 to 315 are jointly connected to a first end of the resistance 331 . Further, a second end of the resistance 331 is connected to the pin ZQ for ZQ calibration. The impedance control signals DRZQP 1 to DRZQP 5 are inputted into corresponding gates of the P-channel transistors 311 to 315 . The impedance control signals DRZQP 1 to DRZQP 5 have a binary bit arrangement. The size of the corresponding transistors is based on the binary system.
[0038] For example, assuming that the transistor 311 has a size of W/L, the transistor 312 has a size of 2 W/L. The transistor 313 has a size of 4 W/L, the transistor 314 a size of 8 W/L, and the transistor 315 a size of 16 W/L. Thus, the transistors have a size of 2 (n−1) W/L. Each of the transistors is set to have an impedance ratio of 2 (n−1) , The second end of the resistance 331 is connected to the pin ZQ for ZQ calibration. The pull-up circuit 301 serves to pull up a potential of the pin ZQ for ZQ calibration toward the power source potential.
[0039] The pull-up circuits 301 and 302 have the same arrangement as the load at the final stage of the output circuit. Thus, the pull-up circuits 301 and 302 are replica circuits for the load at the final stage of the output circuit. Further, the pull-down circuit 303 , which will be described later, has the same arrangement as the driver at the final stage of the output circuit. Thus, the pull-down circuit 303 is a replica circuit for the driver at the final stage of the output circuit. Accordingly, each of the pull-up circuits 301 , 302 , and the pull-down circuit 303 is simply referred to as a replica circuit. The buffer formed by the second pull-up circuit 302 and the pull-down circuit 303 is referred to as a replica buffer of the output circuit. Here, it is desirable that each of the pull-up circuits 301 , 302 , and the pull-down circuit 303 is a replica circuit for the output circuit and has the same arrangement as the output circuit. However, each of the pull-up circuits 301 , 302 , and the pull-down circuit 303 may not have strictly the same arrangement and may have substantially the same arrangement as the output circuit. The size of the pull-up circuits 301 , 302 , and the pull-down circuit 303 may be shrunken as long as the pull-up circuits 301 , 302 , and the pull-down circuit 303 have volt-ampere characteristics equivalent to those of the output circuit.
[0040] The pull-down circuit 303 will be described in detail with reference to FIG. 5 . FIG. 5 is a circuit diagram of the pull-down circuit 303 . As shown in FIG. 5 , the pull-down circuit 303 includes a plurality of N-channel transistors 321 to 325 (five transistors in FIG. 5 ) and a resistance 332 . Sources of the N-channel transistors 321 to 325 are jointly connected to the ground potential GND, and drains of the N-channel transistors 321 to 325 are jointly connected to a first end of the resistance 332 . Further, a second end of the resistance 332 is connected to the contact A. The impedance control signals DRZQN 1 to DRZQN 5 are inputted into corresponding gates of the N-channel transistors 321 to 325 . The impedance control signals DRZQN 1 to DRZQN 5 have a binary bit arrangement. Thus, the size of the corresponding transistors is based on the binary system.
[0041] For example, assuming that the transistor 321 has a size of W/L, the transistor 322 has a size of 2 W/L. The transistor 323 has a size of 4 W/L, the transistor 324 a size of 8 W/L, and the transistor 325 a size of 16 W/L. Thus, the transistors have a size of 2 (n−1) W/L. Each of the transistors is set to have an impedance ratio of 2 (n−1) . The second end of the resistance 332 is connected to the contact A. The pull-down circuit 303 serves to pull down a potential of the contact A toward the ground potential.
[0042] The ZQ calibration operation according to the present invention will be described below. The calibration operation is an operation to generate a control signal for optimizing the impedance of the replica circuit of the output circuit. The impedance of the output circuit is adjusted by the optimized control signal. When power is turned on, an initial ZQ calibration operation (ZQinit) is performed for setting the output circuit. Further, in order to set the output circuit more accurately, ZQ calibration operations (ZQCS, ZQoper) are periodically performed during an actual operation of the semiconductor device. Furthermore, according to the present invention, an additional calibration operation is also performed after completion of a self-refresh operation.
[0043] As shown in FIG. 3 , a ZQ calibration operation is performed in a state in which the external resistance R is externally attached to the pin ZQ for ZQ calibration. The external resistance R should have a resistance value that meets requirements for the output circuit. In the ZQ calibration operation, the impedance control signals DRZQP 1 to DRZQP 5 are determined so that the external resistance R and the impedance of the pull-up circuits 301 and 302 are equal to each other. Further, the impedance control signals DRZQN 1 to DRZQN 5 are determined so that the impedance of the second pull-up circuit 302 and the impedance of the pull-down circuit 303 are equal to each other. The impedance control signals DRZQP 1 to DRZQP 5 and the impedance control signals DRZQN 1 to DRZQN 5 thus obtained are used as gate control signals for the transistors of the output circuit to thereby adjust the impedance of the output circuit to an optimal value.
[0044] First, the control signal ACT 1 (or the control signal SELFEX 1 ) is activated so as to perform impedance adjustment of the pull-up circuit connected to the pin ZQ for ZQ calibration. The impedance of the first pull-up circuit 301 is adjusted so as to be equal to the external resistance R connected to the pin ZQ for ZQ calibration. After the adjustment is completed, the impedance control signals at that time are fixed and supplied to the pull-up circuits 301 and 302 and to the gates of the transistors forming the load at the final stage of the output circuit. Then, the control signal ACT 2 (or the control signal SELFEX 2 ) is activated so as to perform impedance adjustment of the pull-down circuit connected to the contact A.
[0045] The ZQ calibration operation is started when ZQ calibration is commanded by an external command or when a self-refresh command (SELFEXIT in the present embodiment) is inputted. Then, the control signal ACT 1 (or the control signal SELFEX 1 ) is activated to start a count operation of the first counter 304 . At that time, the control signal ACT 2 and the control signal SELFEX 2 are in an inactive state. It is assumed that the first counter 304 is initially set so that all impedance control signals DRZQP 1 to DRZQP 5 have a high level (11111) while all transistors of the first pull-up circuit 301 are in an off-state, Because the potential of the pin ZQ for ZQ calibration is a ground potential GND and is lower than the reference potential Vref, the first comparator 306 generates an output COMP 1 having a low level. The first counter 304 performs a count-down operation so as to output an impedance control signal DRZQP of (11110).
[0046] The impedance control signal DRZQP of (11110) brings the transistor 311 of the pull-up circuits 301 and 302 into an on-state and the transistors 312 , 313 , 314 , and 315 of the pull-up circuits 301 and 302 into an off-state. The transistor 311 has a minimum size of W/L and a low drive capability. Accordingly, the potential of the pin ZQ for ZQ calibration becomes slightly higher than the ground potential GND but is still lower than the reference potential Vref. Accordingly, the output COMP 1 of the first comparator 306 still has a low level. Thus, the first counter 304 further performs a count-down operation so as to output an impedance control signal DRZQP of (11101).
[0047] When the impedance control signal DRZQP of (11101) is inputted into the pull-up circuits 301 and 302 , the impedance control signal DRZQP brings the transistor 312 into an on-state and the transistors 311 , 313 , 314 , and 315 into an off-state. The transistor 312 has a size of 2 W/L. Accordingly, the potential of the pin ZQ for ZQ calibration becomes higher than that in a case of the impedance control signal DRZQP of (11110). However, the potential of the pin ZQ for ZQ calibration is still lower than the reference potential Vref. Accordingly, the output COMP 1 of the first comparator 306 still has a low level. Thus, the first counter 304 further performs a count-down operation so as to output an impedance control signal DRZQP of (11100).
[0048] These steps are sequentially repeated so that the first counter 304 performs a count-down operation to bring the transistors having a larger size in the first pull-up circuit 301 into an on-state. As the count operation is repeated, the impedance of the first pull-up circuit 301 is gradually lowered while the potential of the pin ZQ for ZQ calibration is gradually increased. When the potential of the pin ZQ for ZQ calibration becomes higher than the reference potential Vref by repetition of the count operation, the output COMP 1 of the first comparator 306 becomes a high level. Then, the first counter 304 inversely performs a count-up operation. Thus, the output of the comparator 306 becomes a low level or a high level according to the magnitude of the potential of the pin ZQ for ZQ calibration and the reference potential Vref, so that the first counter 304 accordingly performs a count-down operation or a count-up operation. As a result, the potential of the pin ZQ for ZQ calibration is stabilized near the reference potential Vref (=VDD/2).
[0049] When the potential of the pin ZQ for ZQ calibration is stabilized near the reference potential Vref (=VDD/2), the control signal ACT 1 (or the control signal SELFEX 1 ) is inactivated. The inactivation of the control signal ACT 1 (or the control signal SELFEX 1 ) stops the count operation of the first counter 304 and fixes the count value. Further, the impedance adjustment of the pull-up circuits is completed and fixed by the fact that levels of the impedance control signals DRZQP 1 to DRZQP 5 are fixed. At that time, the impedance of the pull-up circuits 301 and 302 is fixed so as to be equal to the external resistance R. While the pull-up circuits are thus fixed, the control signal ACT 2 (or the control signal SELFEX 2 ) is activated to perform impedance adjustment of the pull-down circuit.
[0050] When the ZQ calibration operation of the first pull-up circuit 301 is completed, the control signal ACT 2 (or the control signal SELFEX 2 ) is activated so as to start a count operation of the second counter 305 . It is assumed that the second counter 305 is initially set so that all impedance control signals DRZQN 1 to DRZQN 5 have a low level (00000) while all transistors of the pull-down circuit 303 are in an off-state. Because the potential of the contact A is a power source potential VDD, the second comparator 307 generates an output COMP 2 having a high level. The second counter 305 performs a count-up operation so as to output an impedance control signal DRZQN of (00001).
[0051] The impedance control signal DRZQN of (00001) from the second counter 305 brings the transistor 321 of the pull-down circuit 303 into an on-state and the transistors 322 , 323 , 324 , and 325 of the pull-down circuit 303 into an off-state. The transistor 321 has a minimum size of W/L and a low drive capability. Accordingly, the potential of the contact A becomes slightly lower than the power source potential VDD but is still higher than the reference potential Vref. Accordingly, the output COMP 2 of the second comparator 307 still has a high level. Thus, the second counter 305 further performs a count-up operation so as to output an impedance control signal DRZQN of (00010).
[0052] When the impedance control signal DRZQN of (00010) is inputted into the pull-down circuit 303 , the impedance control signal DRZQN brings the transistor 322 into an on-state and the transistors 321 , 323 , 324 , and 325 into an off-state. The transistor 322 has a size of 2 W/L. Accordingly, the potential of the contact A becomes lower than that in a case of the bit signal DRZQN of (00001). However, the potential of the contact A is still higher than the reference potential Vref. Accordingly, the output COMP 2 of the second comparator 307 still has a high level. Thus, the second counter 305 further performs a count-up operation so as to output an impedance control signal DRZQN of (00011).
[0053] These steps are sequentially repeated so that the second counter 305 performs a count-up operation to bring the transistors having a larger size in the pull-down circuit 303 into an on-state. As the count operation is repeated, the impedance of the pull-down circuit 303 is gradually lowered while the potential of the contact A is gradually lowered. When the potential of the contact A becomes lower than the reference potential Vref by repetition of the count operation, the output COMP 2 of the second comparator 307 becomes a low level. Then, the second counter 305 inversely performs a count-down operation. Thus, the output of the comparator 307 becomes a high level or a low level according to the magnitude of the potential of the contact A and the reference potential Vref, so that the second counter 305 accordingly performs a count-up operation or a count-down operation. As a result, the potential of the contact A is stabilized near the reference potential Vref (=VDD/2).
[0054] When the potential of the contact A is stabilized near the reference potential Vref (=VDD/2), the control signal ACT 2 (or the control signal SELFEX 2 ) is inactivated. The inactivation of the control signal ACT 2 (or the control signal SELFEX 2 ) stops the count operation of the second counter 305 and fixes the count value. Further, the impedance adjustment of the pull-down circuit is completed by the fact that levels of the impedance control signals DRZQN 1 to DRZQN 5 are fixed. Thus, when the control signal ACT 2 (or the control signal SELFEX 2 ) is inactivated, all of states are fixed.
[0055] The impedance of the pull-up circuits 301 and 302 is fixed so as to be equal to the external resistance R when the control signal ACT 1 (or the control signal SELFEX 1 ) is activated. Further, the impedance of the pull-down circuit 303 is fixed so as to be equal to the impedance of the second pull-up circuit 302 when the control signal ACT 2 (or the control signal SELFEX 2 ) is activated. As a result, all of the pull-up circuits 301 , 302 , and the pull-down circuit 303 are set to have an impedance equal to the external resistance R. The impedance of the output circuit is adjusted by using the impedance control signals DRZQP and DRZQN as control signals of the output circuit. Thus, it is possible to obtain a semiconductor device which includes an output circuit having matched impedance and can perform a high speed data transfer.
[0056] As described above, a pull-up ZQ calibration operation is started not only by the control signal ACT 1 but also by the control signal SELFEX 1 . Further, a pull-down ZQ calibration operation is also performed by the control signal SELFEX 2 . Thus, the ZQ calibration circuit according to the present invention can perform a ZQ calibration operation by the control signals SELFEX 1 and SELFEX 2 , which are different from the control signals ACT 1 and ACT 2 . The control signal SELFEX 1 is automatically issued from an internal circuit after a self-refresh command SELFEXIT has been issued. Further, the control signal SELFEX 2 is automatically issued so as to perform a pull-down ZQ calibration operation when a pull-up ZQ calibration operation is completed. Thus, the ZQ calibration operation is automatically added after the self-refresh operation.
[0057] Operation of a ZQ calibration circuit according to the present invention will be described below with reference to FIG. 6 . FIG. 6 is a timing chart of a ZQ calibration operation according to the present invention. Usually, when an external ZQ calibration command is issued, the control signal ACT 1 is activated so as to start a ZQ calibration operation. According to the present invention, the control signal SELFEX 1 is further inputted as a signal for performing the same control process as the control signal ACT 1 . An external command SELFENTRY for self-refresh is inputted to start a self-refresh operation. The self-refresh period is ended by an external command SELFEXIT.
[0058] When the external command SELFEXIT is issued, the control signal SELFEXI is activated (with a high level in the example shown in FIG. 6 ) so as to start a pull-up ZQ calibration operation. The pull-up ZQ calibration operation is performed as described above. Thus, the pull-up ZQ calibration is first performed by the control signal SELFEX 1 . The level of the pin ZQ for ZQ calibration is gradually increased by the counter operation of the first counter 304 and stabilized near a level of VDD/2. Then, the control signal SELFEX 1 is inactivated (with a low level in the example shown in FIG. 6 ) so as to fix the impedance control signal DRZQP.
[0059] When the control signal SELFEX 1 is inactivated, the control signal SELFEX 2 is activated (with a high level in the example shown in FIG. 6 ) so as to start a pull-down ZQ calibration operation. The pull-down ZQ calibration operation is performed as described above. The level of the contact A is gradually lowered by the counter operation of the second counter 305 and stabilized near a level of VDD/2. Then, the control signal SELFEX 2 is inactivated (with a low level in the example shown in FIG. 6 ) so as to fix the impedance control signal DRZQN. Thus, the ZQ calibration operation is completed.
[0060] According to the present invention, the ZQ calibration operation is automatically started by the external command SELFEXIT for a self-refresh operation. After the completion of the pull-up ZQ calibration, the pull-down ZQ calibration is automatically started. No external commands are inputted during a DLL lock period (TDLLK=512*tCK) of 512 clocks after the self-refresh operation. The ZQ calibration operation is concurrently performed with use of the DLL lock period. Accordingly, the ZQ calibration operation has no influence on an external access prohibition period. Further, commands can be inputted after completion of the DLL lock period (tDLLK=512*tCK). The ZQ calibration can be completed until the completion of the DLL lock period. Accordingly, in a case where a ZQ calibration command is inputted during the calibration operation, even if the calibration operation is performed while the ZQ calibration command is ignored, the specifications (tZQoper=256*TCK, tZQCS=64*tCK) can be met. Thus, the ZQ calibration operation according to the present invention is consistent with the conventional specifications.
[0061] As described above, the ZQ calibration operation is automatically performed after the completion of the self-refresh operation, The DLL lock period has 512 cycles, which are sufficient for a ZQ calibration period. Accordingly, the ZQ calibration operation can be performed accurately. Further, an additional ZQ calibration operation is performed in addition to a ZQ calibration operation performed by an external ZQ calibration command. Therefore, the number of the ZQ calibration operations is increased. Intervals of the ZQ calibration operations can be made shorter so as to perform the ZQ calibration operations more accurately. Thus, it is possible to obtain a ZQ calibration circuit which automatically performs a ZQ calibration operation after a self-refresh operation. Further, it is possible to obtain a semiconductor device which has such a ZQ calibration circuit and can perform a high speed data transfer.
[0062] While the present invention has been described in detail with reference to the preferred embodiment thereof, it would be apparent to those skilled in the art that many modifications and variations may be made therein without departing from the spirit and scope of the present invention. As a matter of course, the present invention covers such modifications and variations.
[0063] For example, in the above embodiment, the ZQ calibration operation is automatically performed with use of a self-refresh command. However, a ZQ command may be issued from a self-refresh command by an internal operation and used to perform a ZQ calibration operation. Further, such a command is not limited to a self-refresh command. The present invention is applicable to a case in which an operation period specified by an external command is long and has a large number of clocks until a next command is inputted.
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AZQ calibration command internally generated from an external command different from a ZQ calbration command so as to automatically perform an additional ZQ calibration operation. A command interval between an imputted command and a next command is effectively employed to obtain a ZQ calibration period. The external command different from the ZQ calibration command is preferably a self-refreshed command. The addition of the ZQ calibration operation shortens intervals between ZQ calibration operations. Thus, it is possible to obtain a ZQ calibration circuit capable of performing a ZQ calibration operation more accurately.
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DESCRIPTION
OBJECTIVE OF THE INVENTION
The present invention refers to a household lighter, more specifically a lighter with a piezoelectric ignition mechanism, of the type equipped with a fuel tank with a corresponding valve whose exit is connected to a burner via an elastic tube, which is situated inside one end of a decorative tube that also serves as a combustion chamber and has a push-button that allows both the opening of the valve and the operation of the piezoelectric mechanism to ignite the gas.
The objective of the invention is to obtain a household lighter equipped with a mechanism simple in conception and which guarantees safety, obstructing the manoeuvres necessary to ignite the lighter if used by young children, more specifically children younger than five years of age.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,697,775 sets out safety mechanisms whose operation depends on jamming the push-button; this mechanism is incorporated into the push-button itself or is attached in the form of a second push-button. The different solutions claimed in this document have as an objective the obstruction of the movement of the push-button, with the result that it cannot act either on the piezoelectric or on the valve's opening mechanism.
The abovementioned embodiments holder the safety element on jamming the push-button. The various mechanisms claimed offer solutions, which are complex to a greater or lesser degree as far as the execution is concerned but when used as a jamming mechanism introduce a certain degree of uncertainty as far as the reliability of the system is concerned, whether this be due to the deterioration or even breakage of its components.
U.S. Pat. No. 6,135,763 sets out safety mechanisms whose operation depends on obstructing the opening of the valve unless a specific sequence of movements is carried out on the push-button. The various solutions claimed in this document have as an objective the obstruction of the action carried out on the valve's opening mechanism.
The abovementioned embodiment holders the operation on the absence of the application of an active force on the valve's opening mechanism, a situation obtained by means of an element incorporated into the push-button itself. Despite the fact that the solution claimed here is economical and simple to execute, one inconvenient aspect is the need to execute a two-fold operating manoeuvre on the double functional nature of the push-button when the latter moves freely on two perpendicular axes.
DESCRIPTION OF THE INVENTION
This invention's premise is to overcome the inconvenient aspects mentioned by means of mechanisms that block or obstruct its use by children.
The invention provides a lighter of the type described at the beginning, which is characterised in that it has an additional mechanism that acts as a safety element. The system is reliable, incapable of constant use without intervention from the user.
The invention holders its operation on a mechanism capable of creating a reaction force on the valve's opening mechanism.
The invention supposes that said force is created or eliminated according to the arming or disabling of the point of support on the lever defined by the tilting that is part of the maneuver necessary to open the valve.
One advantage of the invention is that this mechanism can be adapted to the majority of lighters currently available on the market; its manufacture would not involve any great modifications to lighters that lack a safety system and the investment that would be required is not very high.
In an initial preferred embodiment of the invention said mechanism is formed by an array of new elements that are actually part of the lighter. These elements are set up in their basic form through a secondary element that acts as a track mechanism perpendicularly to the main push-button and operated by a second push-button, this mechanism forming part of the actual push-button; the push-button can be moved by a finger pressing it, going from a dormant, resting position to a position where it acts as a point of support for the lever set up by the tilting; the push-button is equipped with a spring that forces the push-button to stand in a dormant support position once the operating force on the push-button has disappeared. The push-button can be made of metal or plastic independent of the structural characteristics of the design. This push-button is situated on the upper face of the holder of the lighter that houses all the elements of the latter.
In a second preferred embodiment of the invention said mechanism is formed by the same elements described in the preceding paragraph with the secondary push-button situated in either of the two side faces of the holder of the lighter.
In a third preferred embodiment of the invention said mechanism is formed by the same elements described in the first form outlined above, the difference being that the track mechanism is operated by a push-button that moves on a perpendicular axis to the former and acts on the mechanism by means of a cam with a contact surface of defined dimensions. This secondary push-button is located on the upper face of the holder of the lighter housing all the elements.
In a fourth preferred embodiment of the invention said mechanism is formed by the same elements described in the third form outlined above with the secondary push-button being situated on either of the two side faces of the holder of the lighter.
DESCRIPTION OF THE DRAWINGS
Other advantages and characteristics of the invention can be appreciated in the following description, which gives details of different embodiments of the invention, mention being made of the drawings attached that show the following:
FIGS. 1 and 1A show two schematic views in cross section of a lighter made according to the objective of the present invention, and shown in symmetry.
FIGS. 2 and 2A show two schematic views of the invention perpendicular to the one above.
FIGS. 3 and 3A show simplified representations of the operating mechanism with the arming safety mechanism in its dormant position without a finger pressing the main push-button.
FIGS. 4 and 4A show simplified representation of the operating mechanism with the arming safety mechanism in its dormant position with a finger pressing the main push-button.
FIGS. 5 and 5A show simplified representations of the operating mechanism with the disabling safety mechanism in its dormant position without a finger pressing the main push-button.
FIGS. 6 and 6A show simplified representations of the operating mechanism with the disabling safety mechanism in its dormant position and a finger pressing the main push-button. In this situation ignition occurs.
PREFERRED EMBODIMENT OF THE INVENTION
The lighter in this invention is made up of a tank ( 1 ) for fuel and a valve ( 2 ) that regulates the opening and closing of the tank ( 1 ). This valve ( 2 ) is equipped with an exit mouth ( 3 ) that is joined by an elastic tube ( 5 ) to the burner ( 6 ) that fixes an exit level ( 4 ), which will be referred to further on.
In the embodiment laid out, the valve ( 2 ) is operated, as is customary, by means of a tilting ( 17 ) that also is operated by the push-button ( 15 ), which carries out the functions of transmitting force and movement between the finger and the tilting ( 17 ). Similarly, the push-button ( 15 ) acts as an element that transmits force and movement between the finger and the piezoelectric ( 7 ). There is also a metal tube ( 8 ) that is there for aesthetic reasons and to fasten the elements ( 10 ) that support the burner ( 9 ); likewise, this tube establishes the shape of the fuel tank and acts as a circuit and electrode in the piezoelectric lighting mechanism. As elements conducting electric current between the piezoelectric ( 7 ), the tube ( 8 ) has an electric conductor ( 18 ). There is also a second element ( 19 ) conducting electric current from the piezoelectric ( 7 ) and the burner ( 6 ), which also acts as a second electrode in the generation of the voltage arc.
In the lighter outlined in this invention, as well as the elements described above there is a novel element ( 14 ) that fulfils the role of a second push-button arming and disabling the safety mechanism of the lighter and is based on a track mechanism ( 16 ), which is dependent on the steady, armed position (A) thanks to a spring ( 20 ). When the finger is not pressing this push-button ( 14 ), FIGS. 3 and 3A and FIGS. 4 and 4A, the point of support of the lever mechanism formed by the tilting ( 17 ) does not come into contact with the push-button itself ( 14 ) and so does not exert any force on the tilting ( 17 ) and as a consequence no power is transmitted between the push-button ( 15 ) and the valve ( 2 ), with the result that the valve stays closed despite the fact that the actual tilting can still move. Under such circumstances the push-button acts as a piezoelectric generator ( 7 ) creating a voltage arc between the electrodes; the absence of gas in the combustion chamber means that ignition is impossible. When the finger exerts pressure on the push-button ( 14 ) the safety mechanism is disabled, position (B), FIGS. 5 and 5A and FIGS. 6 and 6A, the point of support of the lever mechanism formed by the tilting ( 17 ) comes into contact with the push-button itself ( 14 ), thereby generating reaction force on the tilting ( 17 ) and as a consequence force and movement are transmitted between the push-button ( 15 ) and the valve ( 2 ), with the result that the valve remains open. Under these circumstances the fuel in the combustion chamber is ignited, generating a flame whose characteristics are regulated by the geometry of the combustion chamber, the burner ( 6 ) and the regulating valve ( 2 ).
A second spring ( 21 ) positions the tilting element ( 17 ) in such a way that the latter's fulcrum is kept separate from the sliding mechanism ( 16 ) to avoid any interference with it.
In the lighter outlined in this invention the operating force of the secondary push-button ( 14 ) can be adjusted to the pressure necessities of the finger so that the track mechanism ( 16 ) moves when operated by an adult and does not move when operated by a child, whose force is limited by its physiological characteristics; moreover, to operate the system a series of movements is required in which the secondary push-button ( 14 ) must be operated before the main push-button ( 15 ). As a consequence the invention is original in that it requires a certain force and a specific sequence of movements to operate it.
Furthermore, and unlike other safety systems currently available on the market, which are based on mechanisms mechanically more complex, this mechanism is reliable thanks to the simple nature of its operation.
In a variation of the embodiment of the device, the switch ( 14 ) which moves parallel to the track mechanism ( 16 ) is replaced by a switch ( 24 ) which moves substantially perpendicular to the track mechanism ( 16 ), as shown in FIGS. 1 a , 2 a , 3 a , 4 a , 5 a , 6 a , in which a spring ( 22 ) is provided to bias the switch ( 24 ) into a state in which the lighter is inactive. The inside end of the switch ( 24 ) terminates in a triangular cam which, together with the other triangular cam at the end of the upper end of the track mechanism ( 16 ), coverts the longitudinal movement switch ( 24 ) into movement of the track mechanism ( 16 ) substantially perpendicular to that of switch ( 24 ).
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Of the type of lighters that have a gas tank ( 1 ) equipped with an exit valve ( 2 ) leading to a burner ( 6 ), where a push-button ( 15 ) simultaneously determines the opening of the valve ( 2 ) and the operation of a piezoelectric ignition generator ( 7 ), whose central characteristic is the incorporation of a track mechanism ( 16 ), operated by a second push-button ( 14 ) using the tension of a spring ( 20 ), so that said track mechanism can stop the functioning of the valve ( 2 ), in turn obstructing ignition, even though it acts on the push-button ( 15 ), which is necessary for the functioning of the lighter and simultaneously act on the push-buttons ( 14 ) and ( 15 ), thus producing ignition. The lighter has been designed to obstruct the manoeuvres necessary to produce ignition when in the hands of a child.
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This application claims priority to U.S. patent application Ser. No. 10/342,992, filed Jan. 14, 2003 entitled “Pneumatic Cot for Use with Emergency Vehicles.”
BACKGROUND
1. Field of the Invention
The present invention is a wheeled cot, and in particular an emergency vehicle cot is provided having a wheeled carriage, a frame for mounting the wheels, a horizontally oriented patient litter supported from the wheeled carriage by a scissors mechanism and a pneumatic ram to vary the height of the litter.
2. Background
Early ambulance cots were cloth stretched between two long poles. Adding four wheels made cots easier to move to ambulances or fire and rescue trucks. Two additional wheels not in contact with the ground were eventually added to the loading end to make it possible to wheel the cot to the vehicle and engage the extra wheels with the floor of the vehicle before taking the weight off of the ground wheels. However, this wheel assembly, although providing for added mobility on flat surfaces, is not well suited for stairs. In addition, as the cot is wheeled down the stairs, the patient is inclined and the vibration of the wheels bouncing down each stair not only causes pain, but may also result in further injury if the patient is inadvertently allowed to slide off of the cot, particularly if not properly restrained.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 a illustrates an embodiment of the present invention wherein a litter is attached to and placed on top of a cot litter support;
FIG. 1 b illustrates the tubular construction of the cot litter support and an air connection of the present invention;
FIG. 1 c illustrates a vehicle entry assembly of the present invention;
FIG. 2 is an illustration of the built in air reservoir, and some of the pneumatic pistons and related mechanics which elevate the litter;
FIG. 3 shows the movement of the cot from a retracted to an extended position;
FIG. 4 shows the intermediate steps between extraction and extension of the cot;
FIG. 5 illustrates the pivoting of the litter bed;
FIG. 6 illustrates an embodiment of the present invention utilizing tracks applied over the wheels for ascending and descending stairwells; and
FIG. 7 illustrates an embodiment of the present invention utilizing a descending and ascending trolley or stair glider configuration.
OBJECT AND SUMMARY OF THE INVENTION
It is an object of some embodiments of the present invention to provide a pivoting litter.
It is an object of some embodiments of the present invention to provide an ambulance cot which does not lock in the upright position, but instead provides an air-cushioned ride.
It is a further object of some embodiments of the present invention to provide a scissors frame in which the pneumatic system is powered by air which is stored in a reservoir built into the cot litter support frame.
Another object of some embodiments of the present invention is to provide a wheeled cot capable of accepting tracks for use when ascending and/or descending uneven terrain such as stairwells.
The emergency vehicle cot has a tubular frame made of a light-weight material to which is attached a litter. One unique aspect of the present invention is that the tubular frame also serves as the reservoir for the pneumatic system, thereby eliminating the need for an additional tank which can limit the travel of the cot. The incorporated reservoir also reduces the weight of the overall cot.
The wheeled cot is designed to be transported in a retracted position in an ambulance and then extended when removed from the ambulance and when transporting a patient on the ground. When the cot is desired to be placed back into the ambulance, the wheeled portion is retracted so as to reduce the amount of space occupied in the ambulance. The retraction and extension and the height of the cot is controlled by a pneumatic system utilizing a ram attached to a scissors frame.
Unlike some cots, however, when this cot is in a fully extended position, it does not lock in that position, but instead is maintained in that position by pneumatic pressure. The advantage to this arrangement is that the pneumatic pressure acts as a shock absorber to reduce the impact on the patient from vibrations and bumps encountered by the ambulance or when transporting the patient on the ground.
Once the cot is placed in the ambulance, helicopter, or other emergency vehicle, an electric compressor within that vehicle recharges the pneumatic reservoir and maintains the pneumatic pressure within the cot through the ram so that the cushioned ride is maintained while the cot is in the emergency vehicle. This also allows the cart to be recharged periodically if needed.
One of the embodiments of the cot anticipates a set of tracks which are applied over the wheels of the cot. These tracks smooth the transitions between the steps and other obstacles thereby allowing the patient to be transported more comfortably over uneven terrain. To assist in steering the cot when it is in the tank track mode, a hand brake is utilized.
In addition, when the cot is inclined and encountering these unwieldy conditions, the litter bed may be pivoted so the patient may remain horizontal even though the cot is on an incline.
Another embodiment features a descending and ascending trolley configuration, in which the trolley configuration is positioned between a front and rear wheel assembly of the cot. The trolley configuration comprises a plurality of wheel assemblies adjacent one another with preferably a track or belt placed around the wheels to provide a smooth, uniform surface, by which the cot can be maneuvered over uneven terrain. The trolley configuration can be selectively lowered and raised as desired using any known means in the art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to FIG. 1 , two plan views and one elevational view of the present invention are provided. A litter 12 is shown in the lower plan view labeled 1 A attached to and placed on top of a cot litter support 14 . Litter 12 is attached to cot litter support 14 at a central section 16 . Central section 16 has at either side a pivoting attachment for the reminder of litter 12 . As a result, both the left and right sides of litter 12 may be inclined to aid a patient in remaining on the litter when the litter is being transported down a stairwell or over inclined terrain. There are also medical reasons why litter 12 may be inclined and the present invention allows either side to be partially inclined to meet the needs of the patient.
As can be seen in FIG. 1C , a vehicle entry assembly 18 is provided having a pivot arm 20 , a wheel 22 , and a retracting arm 24 . The entire vehicle entry assembly can be retracted into the bottom of the cot to lower the profile of the cot, but may then be extended to engage the floor of the rescue vehicle as the cot is being pushed into the vehicle. This aids in the transition from ground transportation into some emergency vehicles.
As can be seen in FIG. 1B , cot litter support 14 employs a tubular construction which is hollow and which serves as an air reservoir for the pneumatic system to be discussed later. An air connection 26 allows for the introduction of a gas into the air reservoir under pressure which is then utilized to activate the pneumatic lifting mechanism. As used in this application, the term air will also apply to any other gas which can safely be compressed and utilized to drive the pneumatic system.
Also shown in FIG. 1B is a pivoting entry assembly 28 which is utilized in tight spaces to help direct the cot when only one person is guiding the cot. In addition to the ability of the litter to be inclined in two directions, another aspect of the present invention is that the entire cot litter support 14 may also be inclined and pivoted about a point on the scissor structure which raises and lowers the support to provide additional adaptability in maintaining the patient in a horizontal position when the cot is traveling on an incline. Since the inclinable cot litter support also serves as the air reservoir for the pneumatic system, there is no need for an additional tank which could impeded the movement of the scissors lifting system. The present invention also operates at a reduced weight because of the lack of any additional reservoir in the system. Since weight is an important factor in the fatigue of emergency personnel, this is an important advancement in the art. Back injuries are also reduced by using a lighter weight cot.
Turning now to FIGS. 2 through 5 , the operation of the extension and retraction system is illustrated. FIG. 2 shows a pneumatic ram 32 which receives pressure through a pressure line attached to litter support 14 and operates to push against cot litter support 14 . Ram 32 is attached to a portion of the scissors mechanism that contacts the center of cot litter support 14 so that the cot will be raised in a horizontal manner as pressure is applied. A scissors frame 52 is connected to a wheeled undercarriage 37 . A part of the wheeled undercarriage 37 is a support bar 39 that provides stability and support. The geometry of the scissors frame 52 also assures that the litter is maintained in a horizontal position as the cot is raised and lowered. Controls to release and increase pressure within pneumatic cylinder 34 are placed on the cot litter support 14 for easy access. By releasing pressure within cylinder 34 , gravity will force cot litter support 14 downward thereby retracting the scissors mechanism and lowering the cot to the retracted position and lowering the litter near the ground. A separate control on cot litter support 14 allows air from the air reservoir within the cot litter support 14 to enter cylinder 34 thereby forcing ram 32 to place pressure against the bottom of cot litter support 14 thereby elevating cot litter support 14 above the ground into an extended position. The intermediate positions between fully extended and fully retracted are shown in FIGS. 3 , 4 , and 5 .
The embodiments of the present invention do not lock the cot in a fully extended position. As a result, the weight of the patient is exerted on ram 32 and cylinder 34 acts as a shock absorber to reduce the vibration and shocks to which the patient will be exposed. When the cot is placed in an emergency vehicle, an alternative air source will be connected which will maintain the air cushioned ride during transport. Connection to the air system will also replenish the air supply within the air reservoir in cot litter support 14 . If no compressed air supply is available in the emergency vehicle, then some other compressed gases may be utilized on a temporary basis. Care should be taken to select gasses which are not overly corrosive or flammable. Cot litter support frame 14 should be constructed of a light-weight material which resists corrosion.
Turning now to some of the details of the scissors mechanism, the mechanism is designed to minimize the height of the overall cot when the scissors frame is in its retracted position. While it is desirable to maintain the scissors frame in its lowest position, care must be taken in the placement of ram 32 so that sufficient pressure may be exerted on the scissors frame to elevate the frame from its fully retracted position. As can be seen in FIG. 3 , the pneumatic ram is at an approximate twenty-five degree angle, even when the scissors frame is fully retracted. Positioning of the pneumatic ram at other angles is also contemplated to optimize the function of the cart and the pneumatic ram.
However, the present invention pneumatic ram is preferably positioned at an angle between 20 and 45 degrees. As a result of this positioning, pneumatic ram 32 may still elevate the scissors frame, even in its fully reclined position. To further assist in the elevation from the fully retracted position, the height between the cot pivot connection of the scissors frame and the ram are maximized to provide the ram with the highest angle from horizontal. The scissors configuration is also designed to make the loading force in the lifting cylinder increase as the cot is raised. Since this force increases as the scissors mechanism is extended, the lifting force stabilizes the cot in the extended position. The scissors lift has bearing joints and cam followers to smoothly rotate and translate horizontally as the litter moves up and down. This arrangement reduces friction and vibration. Ram 32 in some embodiments is attached to a yoke between the two jointed upper sections of the scissors frame. As ram 32 pushes on the yoke connected to the side frames of the cot at mid-span, as the cot raises, the pressure within the piston increases for additional height. At the fully extended position, this pressure is sufficient to provide a shock absorbing pressure discussed earlier. As the wheels of the cot move up and down when encountering obstacles, the cylinder allows the movement of the cot frame to dampened providing extra comfort for the patient.
As can be seen in FIGS. 2 through 5 , pneumatic cylinder 34 is mounted as low as possible to the body to provide a sufficient angle for pneumatic ram 32 to raise the scissors mechanism.
Turning now to FIG. 6 , to enable the cot to negotiate stairs, stair gliders or tracks 36 are mounted on the wheels of this embodiment of a cot. This belt or track arrangement allows the weight of the cot to be on two or more stair tread nosings at the same time so that there is no undulating movement as wheels travel across the tread then down the riser and then onto the next tread. Instead, an even incline is created so that the bumps are removed from the experience of the patient. The belt is equipped with a simple hand brake control that allows the servicing attendant to control the rotational velocity of the wheels, and the speed of the cot, such as the cot's descent down a flight of stairs.
FIG. 6 illustrates an additional embodiment that enables the cot to negotiate stairs. In this embodiment, stair gliders or tracks 36 are mounted below the support bar 39 . Wheels 50 are attached to the attachment ends 38 of the support bar 39 . This embodiment facilitates the smooth transition from negotiating stairs to travel along a flat surface.
With reference to FIG. 7 , shown is the cot equipped with a translational (ascending and descending) trolley configuration 40 . The trolley configuration 40 is preferably placed between the front and rear wheel assemblies of the cart, and operates on a translational system designed to allow the trolley configuration to move bi-directionally in a vertical manner, or ascend and descend, when uneven terrain is experienced or as otherwise needed. The trolley configuration comprises a plurality of wheels 44 positioned adjacent one another as shown, with a track or belt member 48 surrounding the perimeter portion of the wheels of the trolley configuration in order to provide a uniform, even or flat engagement surface on which the cart may be rolled or maneuvered. This track or belt system is similar to that shown and described in FIG. 6 , but is strategically positioned between the wheel assembly of the cart. In addition, the cot further comprises means for actuating and deactuating the trolley configuration, wherein the actuation position is defined as the position where the trolley configuration is active and in its lowered position ready to engage various terrain and support the weight of the cot. The deactuated position is defined as the position where the trolley configuration is inactive and in its uppermost extended and stored position. Preferably, means for actuating allows the trolley configuration to move bi-directionally in an up and down, or vertical, manner relative to the terrain and is comprised of a mechanical, electromechanical, hydraulic, or pneumatic device coupled to the cot that is capable of actuating (lowering) or deactuating (raising) the trolley configuration as needed. As in other embodiments, the trolley configuration provides support to the cot on uneven surfaces where the wheels of the cot are insufficient.
When descending steep steps, the litter may be pivoted into a horizontal position so that the patient does not slide off of the litter when the patient is traveling down the incline. This pivoting further aids in maintaining the patient in a position which does not compromise patient care. In one embodiment, arm supports rotatable around the patient's shoulder socket are provided which can be attached to the cot to support a patient's limbs as an attendant performs medical procedures. These rails rotate in a one-hundred eighty degree motion towards the emergency personnel to make an IV arm board and to stabilize the patient's arm while starting an intravenous flow.
The present invention may be embodied in other specific forms without departing from its spirit of essential characteristics. The described embodiments are to be considered in all respects only al illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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An ambulance cot is provided having a wheeled carriage, a frame for mounting the wheels, a horizontally oriented patient litter supported from the wheeled carriage and variable, pneumatically powered height scissors frame. The pneumatic actuator is designed to give a patient air-ride transportation and an adjustable height litter for lifting a patient from the ground. The patient litter has a pivoting hinge for transporting a patient down stairs. This pivot will allow the stretcher to pivot to a horizontal angle while going down stairs, for patient support and ease of transportation for said operator below. One embodiment has tracks attached over the wheels to provide a more stable and smooth ride as the cot is moved down stairs. Another embodiment comprises a translational trolley configuration. A hand brake is mounted on the patient litter for braking the tank-like motion of the tracks.
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